Nonwoven materials are engineered fabrics, produced by bonding constituent fibres together by mechanical, thermal or chemical means. Such a technology has a great potential to produce material for specific purposes. It is therefore crucial to develop right products with requested properties. This requires a good understanding of the macro and micro behaviours of nonwoven products. In last 40 years, many efforts have been made by researchers to understand the performance of nonwoven materials. One of the main research challenges on the way to this understanding is to link the properties of fibres and the fabric's random fibrous microstructure to the mechanisms of overall material's deformation. The purpose of this research is to study experimentally and numerically the deformation mechanisms of a low-density thermally bonded nonwoven fabric (fibre: Polypropylene; density: 20 gsm). The study started with tensile experiments for the nonwoven material. Specimens with varying dimensions and shapes were tested to investigate the size-dependent deformation mechanisms of the material. Based on obtained results, representative dimensions for the material are determined and used in other experimental and numerical studies. Then standard tensile tests were performed coupled with image analysis. Analysis of the obtained results, allowed the tensile behaviour of the nonwoven material to be determined, the initial study of the effects of material's nonuniform microstructure was also implemented. Based on the experimental results obtained from tensile tests, continuous finite-element models were developed to simulate the material properties of the nonwoven material for its two principle directions: machine direction (MD) and cross direction (CD). Due to the continuous nature of the models, they were only used to establish the mechanical behaviour of the material by treating it as a two-component composite. The effects of bond points, which are a stiffer component within the material, were analysed. Due to the limitations of the continuous FE models, experimental studies were performed focused on the material s microstructure. The latter was detected using an x-ray Micro CT system and an ARAMIS optical strain analysis system. According to the obtained images, the nonwoven fabric is a three-component material. The effects of material's microstructure on stress/strain distributions in the deformed material were studied using advanced image analysis techniques. Based on the experimental results, a new stress calculation method was suggested to substitute the traditional approach, which is not suitable for the analysis of the low density nonwoven material. Then, the fibres orientation distribution and material properties of single fibres were measured due to their significant effects on overall mechanical properties. Finally, discontinuous finite-element models were developed accounting for on the material's three-component structure. The models emphasised the effects of the nonuniform and discontinuous microstructure of the material. Mechanical properties of fibres, the density of fibrous network, the fibres orientation distribution and the arrangement of bond points were used as input parameters for the models, representing features of the material's microstructure. With the use of the developed discontinuous models, the effects of material's microstructure on deformation mechanisms of the low-density nonwoven material were analysed.

Les travaux effectués au cours de cette thèse portent principalement sur la construction de nouvelles bornes du comportement effectif des matériaux biphasés de type matrice-inclusions à comportement linéaire élastique. Dans un premier temps, afin d’encadrer le comportement effectif, nous présentons une nouvelle approche numérique, inspirée des travaux de Huet (J. Mech. Phys. Solids 1990 ; 38:813-41), qui repose sur le calcul des comportements apparents associés à des volumes élémentaires (VE) non-carrés construits à partir d'assemblages de cellules de Voronoï, chaque cellule contenant une inclusion entourée de matrice. De tels VE non-carrés permettent d'éviter l'application directe des CL sur les inclusions à l’origine d’une surestimation artificielle des comportements apparents. En utilisant les théorèmes énergétiques de l'élasticité linéaire et des procédures de moyennisation appropriées portant sur les comportements apparents, un nouvel encadrement du comportement effectif est obtenu. Son application au cas d'un composite biphasé, constitué d'une matrice isotrope et de fibres cylindriques parallèles et identiques distribuées aléatoirement dans le plan transverse, conduit à des bornes plus resserrées que celles obtenues par Huet. En nous appuyant sur cette nouvelle procédure numérique, nous avons ensuite réalisé une étude statistique des comportements apparents à l'aide de simulations de type Monté Carlo. Puis, à partir des tendances issues de cette étude statistique, nous avons proposé et mis en œuvre de nouveaux critères de tailles de VER. / This work is devoted to the derivation of improved bounds for the effective behavior of random linear elastic matrix-inclusions composites. In order to bounds their effective behavior, we present a new numerical approach, inspired by the works of Huet (J. Mech. Phys. Solids 1990 ; 38:813-41), which relies on the computation of the apparent behaviors associated to non square (or non cubic) volume elements (VEs) comprised of Voronoï cells assemblages, each cell being composed of a single inclusion surrounded by the matrix. Such non-square VEs forbid any direct application of boundary conditions to particles which is responsible for the artificial overestimation of the apparent behaviors observed for square VEs. By making used of the classical bounding theorems for linear elasticity and appropriate averaging procedures, new bounds are derived from ensemble averages of the apparent behavior associated with non square VEs. Their application to a two-phase composite composed of an isotropic matrix and aligned identical fibers randomly and isotropically distributed in the transverse plane leads to sharper bounds than those obtained by Huet. Then, by making use of this new numerical approach, a statistical study of the apparent behavior is carried out by means of Monte Carlo simulations. Subsequently, relying on the trends derived from this study, some proposals to define RVE criteria are presented.