Fiber tufts were modeled as random fibrous materials based on the statistical orientations of the observed fibers. The tufts with different fiber properties were analyzed experimentally and simulated well. It was found that the distribution of fiber orientation angles is not uniform. The simulations of tufts have confirmed that the sizes of tufts could also be affected by the orientation angle distribution of the constituted fibers. The model was verified by the simulated tufts and the tested ones. Good agreement was achieved between the sizes of simulations and the observed ones. The above model can further explore the underlying principles of carding in yarn manufacture. Furthermore, the modeling method can also be widely used to simulate other fibrous materials where fibers are highly tangled.
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