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Simulation on the Yarn-Level and Experimental Validation of Spacer Fabrics Compression by a Rigid Punch. Influence of Seams in the Spacer Fabric Cover

Simulation on the Yarn-Level and Experimental Validation of Spacer Fabrics Compression by a Rigid Punch. Influence of Seams in the Spacer Fabric

Open Access
|Mar 2025

Figures & Tables

Fig. 1.

Principal construction of spacer fabrics – a) 3D-structure, b) front and back side, c) spacer area
Principal construction of spacer fabrics – a) 3D-structure, b) front and back side, c) spacer area

Fig. 2

Spacer fabric variations for experimental testing: (a) cross view, (b) top view; h cushion heigt, d seam distance
Spacer fabric variations for experimental testing: (a) cross view, (b) top view; h cushion heigt, d seam distance

Fig. 3.

Test setup for various compression tests (a) spacer fabric without seams, (b) spacer fabric with seams, (c) Edge-force-test to a spacer fabric without seams
Test setup for various compression tests (a) spacer fabric without seams, (b) spacer fabric with seams, (c) Edge-force-test to a spacer fabric without seams

Fig. 4

Experimental results of compression tests of spacer fabrics with a various seam distances
Experimental results of compression tests of spacer fabrics with a various seam distances

Fig. 5.

(a) Individual yarn types highlighted in purple, (b) + (c) the virtual spacer fabric sample on the right, compared to the physical sample in the middle
(a) Individual yarn types highlighted in purple, (b) + (c) the virtual spacer fabric sample on the right, compared to the physical sample in the middle

Fig. 6.

(a) Schematic representation of the double lock stitch, (b) measured force-strain curve for the yarn material
(a) Schematic representation of the double lock stitch, (b) measured force-strain curve for the yarn material

Fig. 7.

Axial stresses in the pre-stressed seams and yarns of the spacer fabric simulated with (a) + (b) TexMath- tool and (c) Abaqus - Colours indicate local stresses.
Axial stresses in the pre-stressed seams and yarns of the spacer fabric simulated with (a) + (b) TexMath- tool and (c) Abaqus - Colours indicate local stresses.

Fig. 8.

Visual comparison of the spacer fabric with 43 mm seam distance (a) simulated and (b) experimental manufactured and simulated spacer fabrics with (c) 24 mm seam distance and (d) 18 mm seam distance
Visual comparison of the spacer fabric with 43 mm seam distance (a) simulated and (b) experimental manufactured and simulated spacer fabrics with (c) 24 mm seam distance and (d) 18 mm seam distance

Fig. 9.

Spacer fabric with seam distance of 43 mm before and after applying the pre-stress to the stich yarn
Spacer fabric with seam distance of 43 mm before and after applying the pre-stress to the stich yarn

Fig. 10.

Qualitative comparison of compression profiles at increasing compression levels for unstitched spacer fabric sample
Qualitative comparison of compression profiles at increasing compression levels for unstitched spacer fabric sample

Fig. 11.

Simulative and experimentally attained compression values for unstitched spacer fabric and sample with seam distance of 24 mm. Visualization of compressed samples below
Simulative and experimentally attained compression values for unstitched spacer fabric and sample with seam distance of 24 mm. Visualization of compressed samples below

Fig. 12.

Critical area of contact search for the compression of stitched spacer fabric samples
Critical area of contact search for the compression of stitched spacer fabric samples

Fig. 13.

Visualization of attracting (top) and repulsing (bottom) contacts.The simulation setup is the same, apart from an additional right-hand side force applied on the crossing centre at the bottom, indicated by the blue arrow
Visualization of attracting (top) and repulsing (bottom) contacts.The simulation setup is the same, apart from an additional right-hand side force applied on the crossing centre at the bottom, indicated by the blue arrow

Fig. 14.

Found contacts after the final iteration of the removal algorithm and stitched fabric under different compressive loads
Found contacts after the final iteration of the removal algorithm and stitched fabric under different compressive loads

Technical data of the spacer fabric specimen

Spacer fabric variationParameterValue
Initial spacer fabricManufacturerEssedea GmbH/D
Density2.349 g/mm3
Material (knitting threads)Top/Back side: PES- multifilament
Space: PES monofiles
All sewn specimenSewing machineDelta Machine “M-Type (Dürkopp Adler, D)
StitchDouple lock stitch 301
Stitch length4 mm
Tension needle thread40 %
Foot strocke9 mm
Sewing foot pressure1 (intern machine parameter without unit)
Sewing threadsAmann Rasant Nm75 (PES)/D
Spacer fabric 18Seam distance d18 mm
Spacer fabric 2424 mm
Spacer fabric 4343 mm
Without seamsCushion height h20 mm (overall height/thickness)
Spacer fabric 188 mm
Spacer fabric 2415 mm
Spacer fabric 4320 mm
DOI: https://doi.org/10.2478/ama-2025-0009 | Journal eISSN: 2300-5319 | Journal ISSN: 1898-4088
Language: English
Page range: 70 - 76
Submitted on: Apr 13, 2024
Accepted on: Aug 8, 2024
Published on: Mar 31, 2025
Published by: Bialystok University of Technology
In partnership with: Paradigm Publishing Services
Publication frequency: 4 issues per year

© 2025 Maxime Krier, Julia Orlik, Kathrin Pietsch, published by Bialystok University of Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.