Determination of the Dependence of Fabric Structure on Warp and Weft Yarn Tension

This study investigates how warp and weft yarn tensions influence the formation of woven fabric structure. Yarns in the fabric are modeled as curved spatial elastic rods, and their stress–strain state, bending behavior, equilibrium conditions and interaction at crossover points are analyzed. The theoretical framework combines elasticity theory, Euler–Bernoulli beam theory, Hertzian contact mechanics, the principle of minimum potential energy, the Peirce geometric model and dynamic tension equations for the weaving process. Relationships are derived between yarn tension and bending radius, curvature, crimp, contact pressure, fabric thickness, porosity and air permeability. The analysis shows that increasing warp tension straightens the warp yarns, increases weft bending, reduces fabric thickness and air permeability and raises tensile strength, whereas increasing weft tension reduces fabric width and weft crimp. Contact pressure at crossover points increases inter-yarn friction and structural stability, but excessive pressure distorts yarn cross-sections and reduces fabric flexibility. The relationship between yarn tension and fabric strength is nonlinear: strength increases up to a limiting tension and then declines. An optimal balance between warp and weft tensions produces a stable microporous structure with good air permeability and moisture transport while maintaining mechanical strength and abrasion resistance. A multiple regression model linking warp tension, weft tension and weft density to fabric properties is proposed for selecting rational technological parameters. The results provide a theoretical basis for automated tension control systems and the design of high-performance woven fabrics.