Accuracy of hygro-expansive curl predictions for paper sheets based on homogenised 2D and 3D network representations

Paper, a porous-fibrous network, is made up of hydrophilic fibres, which are notably susceptible to deformations due to variations in moisture content. The response of paper sheets to full or partial wetting, based on the water-induced fibre swelling, has mostly been predicted in the past using highly idealised two-dimensional network geometries. The purpose of the present paper is to establish how precisely the two-stage process of determining effective hygro-expansivity under uniform wetting by a two-dimensional model followed by bending analysis using a continuum model predicts the curl of a fully three-dimensional network. In the present multi-scale modelling work, the moisture-induced homogenised sheet scale curl, derived from hygro-elastic deformations using non-uniform moisture profiles, is analysed based on an idealised non-woven three-dimensional fibrous network finite element model. First, the effective paper sheet swelling properties, derived computationally for the uniform wetting condition, are compared with analytically homogenised hygro-elastic properties. Whereas the analytically predicted elastic modulus has an inaccuracy of only ∼5%, the hygro-expansivity coefficient is over-predicted by roughly a third for a network with straight fibres. The difference is smaller if waviness of the fibres and wrap-around in the fibre bonds are taken into account. Fibre alignment turns out to have little influence. Subsequently, paper sheet curl predictions made by the analytical model are compared with that computed from the three-dimensional network model. The inaccuracy of the fully analytical model, based on the two-dimensional network description, relative to the fully detailed three-dimensional computational model with straight fibres is on the order of 40%–50%. The fidelity of the simple model is primarily constrained by the inaccuracy of the effective hygro-expansion coefficient. If the expansivity extracted from the three-dimensional simulations under uniform wetting is inserted, the inaccuracy drops to less than 10%. The continuum bending description hence performs adequately, provided it is based on a reliable estimation of the uniform expansion behaviour of the material.