Finite element analysis of sewing process

Sewing is one of the most commonly used manufacturing processes in the world. Millions of parts are sewn every day ranging from cloths, shoes, furniture, to automobile seat covers. However, it is also one of the least understood processes. In fact, according to literature survey, few know how to calculate the sewing force or the fabric deformation during the sewing. This paper presents our research on using finite element model (FEM) to study the sewing process. The model is developed using ANSYS software system. In the model, the fabric is approximated by a number of perpendicular beam elements with elastic and plastic capabilities. On the other hand, the needle is modeled by a simple elastic beam. The contact between the two parts is modeled by contact elements. The variations of the needle geometry and the fabric material properties as well as the sewing conditions are also included in the model. The model can simulate the needle piercing through a material, and calculates the sewing forces as well as the fabric deformation forming a hole. It has been verified experimentally and can be used to study the effects of the key sewing parameters such as the fabric material properties and the needle geometry.