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Composite Structures
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Article history:
Available online 14 April 2009
Keywords:
PVC-polyester fabric
Biaxial tensile tests
Finite element analysis
Non-linear material model
a b s t r a c t
A simple model based on experimental observations of the yarn-parallel biaxial extension of PVC-coated
polyester fabric cruciform specimens is proposed. In situ loading conditions are considered. The material
behaviour is assumed to be plane stress orthotropic for a particular load ratio, while the elastic properties
can vary with the load ratio in order to represent the complex interaction between warp and ll yarns. A
linear relationship is experimentally found between elastic moduli and normalized load ratios for a wide
range of PVC-coated polyester (Type I to Type IV). Two new parameters corresponding to the moduli variations are introduced to complement the existing plane stress orthotropic model. Theoretical results
show that only ve biaxial tests are required to accurately describe the material response with the proposed material model. Finally, the model was integrated in a commercial nite element software. It is
shown that the proposed material model signicantly increases the accuracy of the nite element predictions compared to the standard orthotropic linear material model with almost identical computation
times.
2009 Elsevier Ltd. All rights reserved.
1. Introduction
Coated fabrics are widely used in structural engineering for
fabric or inated structures. New developments as the recently
introduced Tensairity-technology broaden the spectrum of
applications of fabrics in civil engineering. Tensairity combines
inated structures with cables and struts leading to a tremendous
increase of the load bearing behaviour of inated beams [1,2]. First
permanent applications of this new class of fabric structure are a
roof for a parking garage or a skier-bridge with over 50 m span,
while the technology has also an enormous potential for temporary
structures such as shelters, tents or bridges. Among the fabrics
used in civil engineering, PVC-coated polyester is the most popular
material mainly due to its favourable price. Furthermore, PVCcoated polyester fabrics can easily be folded and unfolded which
is an important aspect for temporary structures.
The design and analysis of fabric structures relies on numerical
calculations. Different approaches based on the force density
method, nite element method or discrete element method have
been developed during the last years. A common feature of all
numerical methods is that the accuracy of their predictions relies
on the accuracy of the material models. Fabrics are non-isotropic
and non-linear materials. Nevertheless, often only very simple
439
in fteen parameters, fourteen of these representing the yarn-parallel behaviour and one the shear behaviour. The model was found
to faithfully represent the mechanical response of the fabric. However, its complexity led to large computation times, and the large
number of required parameters did not make it easy to use. Cavallaro et al. [4] also used the unit cell method to study the behaviour
of fabric in the case of inated beams. They showed that the material did not behave like an orthotropic material but rather like a
heterogeneous material, whose properties depended on the weave
geometry, on the contact areas of interacting tows and in this particular case also on the internal pressure of the beam. Nevertheless,
they mentioned that performing an analysis on a complete airbeam structure was computationally impossible.
The other approach is to describe the fabric behaviour directly
from experimentally determined stressstrain relationships [8
13]. In this case, a plane stress orthotropic model is generally chosen. In the simplest approach, the compliance matrix is tted to the
experimental data to obtain the material constants. While this is a
numerical efcient material model, the non-linear behaviour of the
fabric is obviously not treated in this approach. The use of three
dimensional stressstressstrain representations is a simple approach to determine the plane stress elastic properties as described
by Gosling [8]. Warp and ll strains are both represented as a function of the stresses. Then, a best plane t is used to nd the terms
of the compliance matrix and thus the elastic properties. The main
disadvantage of this procedure is that one gets four independent
parameters, i.e. two Youngs moduli and two Poissons ratios. It is
possible to force the compliance matrix to be symmetrical by averaging the interaction terms. However, this results in a loss of accuracy. Gosling [8] argued that having two independent Poissons
ratios could be admitted since the material is not homogeneous.
This model gave a good correlation with experiments performed
on different types of PTFE-glass and PVC-polyester fabrics but the
physical meaning of such an asymmetric stiffness matrix is an
open issue.
Bgner and Blum [9,10] also described a simple method to estimate the elastic moduli of coated fabrics based on plane stress
orthotropic assumptions. With the use of a special load history
where warp and ll directions are loaded separately, they calculated the elastic constants on the test interval for a particular load
ratio (the method will be presented in more detail in Section 3).
This method can also be repeated for every part of the load history
in order to obtain the variation of the elastic moduli over the range
of loading. A similar multi-linear method was proposed by Minami
[11]. The biaxial tensile behaviour of a PTFE-glass fabric was represented with three dimensional stress-stress-strain curves. The
material response surface formed by these curves was then divided
into several quadrilaterals. In each quadrilateral a plane stress linear orthotropic material model was assumed, from which the elastic constants could be calculated. Both methods can be particularly
interesting in the case of non-linear behaviour, but their main disadvantages are the high amount of required experimental data and
Table 1
Specications of different PVC-coated polyester fabrics.
Sample code
Manufacturer/reference
V700
V900
V1000
V1400
F702
F1002
B1617
FR700
FR900
FR1000
FR1400
Polyester type
Weave pattern
Yarn (dtex)
Weight
(g/m2)
Thickness
(mm)
Warp/Fill tensile
strength (N/50 mm)
Type
Type
Type
Type
Type
Type
Type
Plain
2-2 Basket
2-2 Basket
3-3 Basket
Plain
2-2 Basket
2-2 Basket
1100
1100
1670
1670
1100
1100
1100
850
900
1050
1350
750
1050
900
0.6
0.75
0.9
1.15
0.6
0.8
0.75
3000/3000
4200/4000
6000/5500
7500/6500
3000/2800
4200/4000
4400/3900
I
II
III
IV
I
II
II
440
Fig. 3. Finite element calculation of the stress distribution in the centre of the
cruciform test specimen.
avoid tearing of the fabric. One fth of the tensile strength also corresponds to a typical maximum design stress in fabric structures
[16]. The pre-stress was set to one fth of the maximum test stress.
For every load ratio, the loading/unloading cycle was repeated ve
times in order to remove the residual strains. Only the last load cycle was used to determine the material properties. The loading
time was set to 360 s for every cycle and every specimen. The loading velocity varied between 2 and 50 (N/m)/s depending on the
material and load ratio. The biaxial testing machine was installed
in a climatic room ensuring a constant temperature of 23 C and
a constant humidity level of 50%.
3. Preliminary experimental investigations
A convenient method to estimate the elastic moduli for a particular load conguration was presented by Bgner and Blum [9,10].
This method is used to study the inuence of different load ratios
on the elastic properties of the fabric.
For a plane stress orthotropic fabric, the yarn-parallel behaviour
is described by
ew
Ew
4 mwf
ef
Ew
mfw
Ef
1
Ef
3
5
rw
rf
1
mwf
Ew
mfw
Ef
mfw
1
Drw
Dr f
Ew
Ef
mwf
1
Dr w Dr f
Ef
Ew
Dew
Def
The load history and the corresponding load path used to obtain the
elastic properties for a 2:1 load ratio are presented in Fig. 4. First,
the load was only changed in the warp direction (Drf = 0) and Ew
and mwf were calculated from Def and Dew by means of Eqs. (3)
and (4). Then, in a second test, only the ll direction was loaded
(Drw = 0) and Ef and mfw were obtained. Since the Poissons ratios
mwf and mfw are not independent (Eq. (2)), ratios mwf/Ew and mfw/Ef
were averaged to determine the effective Poissons ratio.
This method was applied to a PVC-polyester sample V700 (Table. 1) for ve different load ratios (5:1, 2:1, 1:1, 1:2 and 1:5) in order to study the dependency of the elastic properties of the fabric
on the applied loads. The denition of the load ratio is of common
Fig. 4. (a) Load path and (b) load history used for a 2:1 load ratio.
441
use and denotes the ratio of the warp stress to the ll stress. Different expressions can be taken to represent the applied loads. We
use the normalized load ratios in warp and ll direction dened as
rw
cw q
r2w r2f
rf
cf q
r2w r2f
5
6
Material properties obtained from the experiments are presented in Fig. 5, where Ew and mwf are plotted as a function of cw
and Ef is plotted as a function of cf. Results show that the Youngs
moduli signicantly change with the normalized load ratios. A
higher load ratio in one direction results in a higher modulus in
that direction and a lower modulus in the orthogonal direction.
This strong interaction between warp and ll yarns is due to crimp
interchange. The yarn waviness depends on the weave geometry
(Fig. 1) as well as on the load ratio. Locally, at yarn crossing, the
contact forces balance the loads that are applied in the bre directions. As a result, increasing the load in one direction straightens
the yarns in that direction while it increases the waviness of the
orthogonal yarns. Moreover, it has been proven that yarn waviness
has a direct inuence on the in-plane moduli of woven fabric composites [17]. Such materials become stiffer, as the yarn waviness
decreases. This is why the highest value of Ew is observed for a
5:1 ratio, and the highest value of Ef for a 1:5 ratio. Fig. 5 also
shows that the Youngs modulus is higher in the warp direction.
This is a common observation with coated fabrics, because warp bres are pre-tensioned during the material manufacturing process,
resulting in a much lower initial waviness of these bres compared
to the ll bres.
Fig. 5. Inuence of the normalized load ratios on the elastic constants (V700
specimen).
442
"
Dew
Def
2
6
4
1
Ew cw
mwf
Ew cw
mwf
Ew cw
1
Ef cf
"
#
7 Dr w
5
Dr f
1
Ew cw DEw cw p E1:1
w
2
1
Ef cf DEf cf p E1:1
f
2
8
9
1:1
are the refThe material model has ve parameters: E1:1
w and Ef
erence
and
ll
Youngs
moduli
given
for
the
1:1 load
values ofpwarp
minW min
m X
n h
X
1:1
exp
emod
wkl Ew ; DEw ; mwf ewkl
k1 l1
h
i2
1:1
1:1
exp
emod
fkl Ew ; Ef ; DEw ; DEf ; mwf efkl
i2
!
10
with m the number of tested load ratios and n the total number of
data points measured for each load ratio. A numerical solver was
used to obtain the minimum. The initial value for the Poissons ratio
was set to zero and initial values of the moduli E1:1
w;f and DEw,f were
set to 1 (to avoid division by zero). All parameters were also
constrained to remain positive and the Poissons ratio was restricted to be less than 0.5. Seven PVC-polyester fabrics from Type
I to Type IV were tested under biaxial tension with varying load
ratios (Table 1).
To investigate the material behaviour, various load ratios were
selected so that the fabric response was explored as much as possible including the uniaxial behaviour. Thirteen load ratios were
measured, namely 1:0, 11:1, 5:1, 3:1, 2:1, 7:5, 1:1, 5:7, 1:2, 1:3,
1:5, 1:11, 0:1. The corresponding load path is shown in Fig. 6a in
Fig. 6. (a) Load path and (b) part of the load history (load ratios 5:1, 3:1 and 2:1)
used for each specimen.
443
Orthotropic NS
V700
V900
V1000
V1400
F702
F1002
B1617
Orthotropic S
Ew (kN/m)
Ef (kN/m)
mwf
mfw
Ew (kN/m)
Ef (kN/m)
mwf
657.6
922.4
1304.3
1488.7
654.5
884.3
927.8
561.3
815.7
1124.3
1304.1
673.0
1044.3
889.5
0.031
0.038
0.022
0.000
0.213
0.165
0.050
0.433
0.341
0.345
0.376
0.245
0.340
0.410
764.2
1027.3
1468.0
1714.2
660.5
917.5
1042.2
501.6
748.2
1025.8
1169.3
666.7
1001.5
804.1
0.313
0.236
0.238
0.238
0.228
0.235
0.268
Table 3
Estimated parameters for the proposed non-linear material model determined from 5
different load ratio measurements.
Sample code
E1:1
w (kN/m)
E1:1
(kN/m)
f
DEw (kN/m)
DEf (kN/m)
mwf
V700
V900
V1000
V1400
F702
F1002
B1617
653.2
882.0
1200.0
1374.1
635.3
830.2
865.8
444.5
679.6
881.7
1003.4
661.9
976.0
707.5
521.2
803.8
941.2
1204.7
295.0
766.7
662.9
403.7
437.6
782.5
981.7
168.5
123.9
662.5
0.327
0.263
0.318
0.314
0.196
0.213
0.308
Fig. 7. RMS and maxima of the strain difference between experiments and
predictions due to the models.
444
Fig. 8. Stressstressstrain representation of experimental data and model prediction (V700 specimen).
ANSYS passes the stresses rti , strains etj and the strain increment
Detj into the usermat for each time step. The usermat then updates
Dt
. The routine must also provide
the stresses in order to obtain rt
i
the stiffness matrix for the current time increment.
The procedure is described in Fig. 9 for the proposed non-linear
material model. Two conditions were applied. First, the Youngs
moduli are chosen to be equal to the moduli for a 1:1 load ratio
for the initial time step as the initial stresses are both equal to zero
and thus the load ratio not dened. Second, the absolute values of
the stresses are taken in order to ensure that the normalized load
ratios are between zero and one.
6.2. Modelling and results
A non-linear static analysis was performed. The biaxial specimen, as shown in Fig. 10, was modelled in 2D with 6432 four nodes
shell elements (Shell 181). The load was applied separately on each
strip. The strip connections to the grips could move transversely to
the loading direction to reproduce the experimental set up of the
biaxial test rig. All 13 experimentally investigated loading paths
were calculated.
The proposed model was compared to the linear orthotropic S
material model. The model parameters given in Tables 2 and 3
have been used. The stressstrain diagrams for the V700 specimen
(experiments, proposed model and orthotropic S material) are
445
Fig. 10. Deformed nite element mesh (magnitude 4) of the cruciform V700
specimen: 1:1 load ratio, tensile load 12 kN/m.
parameters, namely the warp and ll Youngs moduli for a 1:1 load
ratio, the change in warp and ll Youngs moduli and the Poissons
ratio. Only ve different load ratios have to be measured in order to
obtain reliable parameters.
Based on these results, we propose the following procedure for
PVC-coated polyester fabrics to estimate the material mechanical
properties:
1. A cruciform test specimen as presented in Fig. 2 is cut out of a
roll of fabric so that the load directions will be parallel to the
yarn directions.
2. The specimen is loaded on a biaxial test machine from prestress up to maximal test stress with ve load ratios: 5:1,
2:1, 1:1, 1:2 and 1:5. Maximal test stress is set to one fth
Fig. 12. RMS and maxima of the strain difference between experimental strains and
nite element predictions.
Fig. 11. Stressstrain relation for the experimental data and nite element predictions for ve different load ratios (V700 specimen).
446
Table 4
Variation in stress and strain given by the experimental data of the last load cycle as
shown in Fig. 9 (V700 specimen).
Load ratio
Drw (kN/m)
Drf (kN/m)
Dew (%)
Def (%)
5:1
2:1
1:1
1:2
1:5
9.6
9.6
9.6
4.8
1.92
1.92
4.8
9.6
9.6
9.6
1.17
1.12
1.17
0.23
0.41
0.42
0.92
1.65
1.75
1.7
Fig. 13. Experimentally obtained Youngs moduli from ve load ratios and tted
moduli of the proposed material model (V700 specimen).
Acknowledgements
The authors would like to thank HP Gasser Membranbau for
providing the material samples. The nancial support of Festo is
gratefully acknowledged.
Appendix.
The parameters of the proposed model were obtained by minimizing the difference between modelled and experimental strains.
A different approach is to obtain these parameters by minimizing
the difference between modelled and experimentally determined
elastic moduli. This simpler method is especially useful, when only
plots of measured stressstrain curves are available as it may happen when biaxial test results are supplied by an external laboratory. In such a case, the variation of stress between pre-stress
and maximal stress and the according variation in strain both in
warp and ll direction can still be read from the graphs with a reasonable accuracy, although the exact stressstrain relation is not
available. As an example, the maximal stress and strain variations
obtained from the curves presented in Fig. 11 are given in Table 4
(V700 specimen). From these values one can then estimate the
experimental elastic moduli in warp and ll direction for each load
ratio by means of
mwf
Def Eexp
Dr w
Eexp
w
11
Eexp
f
12
The estimated experimental elastic moduli depend on the Poissons ratio mwf which is not known a priori and is thus also a parameter which has to be optimized. The experimental elastic moduli
are compared with the moduli of the proposed material model
1:1
(Eqs. (8) and (9)) and the parameters E1:1
w ; Ef , DEw, DEf, and mwf
are obtained by the least square t
minW min
m
X
2
1:1
exp
mod
1:1
Emod
wk Ew ; DEw Ewk mwf Efk Ef ; DEf
k1
2
Eexp
fk wf
!
13
447