Yarn modeling and winding process simulation based on 3D beam elements

In order to study the tension variation of cotton yarn in the winding process, a finite element model of yarn based on three-dimensional beam elements is proposed. As the size of yarn in the length direction is much larger than the cross-sectional size, this paper assumes that the yarn cross-section is circular and ignores the change of the cross-sectional area in the winding process. The winding process of yarn is simulated using Abaqus dynamic explicit, and the influence of the yarn fineness on the yarn tension during winding is analyzed. The results show that the average relative error between the simulation results and the experimental data is 14.09%, and the maximum relative error is 17.06%; therefore the model is reasonable. Compared with the solid element model of yarn, the yarn simulated by this model can save a lot of computing resources while taking into account the yarn stacking effect. The winding length that can be simulated in the same time is tens of times that of the solid element model, thus the winding simulation of nine-layer yarn on the bobbin is realized. The conclusion is that the inner yarn loop presents weak tension while the outer yarn loop has large tension.