Numerical simulation of fiber motion in airflow during yarn formation: A review

In modern spinning technologies, airflow serves as a flexible and efficient driving force for fiber motion during yarn formation. To better understand yarn formation mechanisms, numerical simulation has become a primary method for analyzing fiber dynamics in airflow. This review focuses on the numerical simulation of fiber motion in airflow during yarn formation. The evolution of fiber models is systematically introduced, including rigid particle models, multiple-rigid-body chain models, and finite-element models, along with their respective modeling methods and applicability. In addition, a comparative evaluation of three common numerical methods, namely the arbitrary Lagrangian–Eulerian method, the immersed boundary method, and the lattice Boltzmann method, is presented, highlighting their strengths and limitations in addressing fluid–structure interaction problems. Finally, the research progress in fiber motion simulation is reviewed for representative airflow-assisted spinning technologies, such as pneumatic compact spinning, rotor spinning, air-jet spinning, and vortex spinning. Existing challenges in simulation accuracy are highlighted, and potential directions for future research are proposed. The review indicates that significant progress has been achieved in refining fiber models and improving the accuracy of airflow simulations. However, challenges remain in multifiber coupling and large deformation simulations. Future studies should focus on developing high-accuracy multiscale simulation methods and enhancing the integration between simulation results and experimental validation.