An Integrated Numerical Method to Predict the Strain Sensing Behavior of Flexible Conductive Fibers under Electric–Thermal Conditions

Flexible conductive textiles have attracted an increasing amount of attention due to being flexible and stretchable with multi-functions, in addition to the strain sensing function. In this paper, an integrated numerical method is established to predict the strain sensing behavior of PPy-coated flexible conductive fibers. Based on our previous investigation on the strain sensing behavior of the PPy-coated elastic conductive fibers, it has been known that the main strain sensing mechanisms of the conductive fibers are micro-cracks opening under stretching and closing under unloading. Therefore, in the numerical approach, extended finite element method is used to simulate the multi-crack initiation and propagation. Then, by establishing a representative element model including a single crack, the resistance variation with the increase in crack width/depth can be obtained using the electric–thermal package in ABAQUS software. Combining the relationship between crack width and strain, the relationship between fractional increment in resistance (\( \Delta R /R_{0} \)) and the strain can be obtained. The prediction of the fractional increment in resistance (\( \Delta R /R_{0} \)) versus strain is consistent with the experimental results of PPy-coated Lycra fibers. The new integrated method is further verified by experimental results of PPy-coated XLA fibers, showing that the integrated numerical approach can capture the complicated strain sensing mechanisms of PPy-coated elastic fibers and predict the strain sensing behavior of flexible conductive fibers. This approach will make it possible to shorten the period, and reduce the cost in R&D of the PPy-coated electrically conductive fibers, comparing with the corresponding experimental work.