Anisotropic mechanical response of layered disordered fibrous materials

Mechanically bonded fabrics account for a significant portion of nonwoven products, and serve many niche areas of nonwoven manufacturing. Such fabrics are characterized by layers of disordered fibrous webs, but we lack an understanding of how such microstructures determine bulk material response. Here we numerically determine the linear shear response of needle-punched fabrics modeled as cross-linked sheets of two-dimensional (2D) Mikado networks. We systematically vary the intra-sheet fiber density, inter-sheet separation distance, and direction of shear, and quantify the macroscopic shear modulus alongside the degree of affinity and energy partition. For shear parallel to the sheets, the response is dominated by intrasheet fibers and follows known trends for 2D Mikado networks. By contrast, shears perpendicular to the sheets induce a softer response dominated by either intrasheet or intersheet fibers depending on a quadratic relation between sheet separation and fiber density. These basic trends are reproduced and elucidated by a simple scaling argument that we provide. We discuss the implications of our findings in the context of real nonwoven fabrics.