Structural analysis of finer cotton yarns produced by conventional and modified ring spinning system

Yarn structure plays an important role in determining the properties of spun yarns. Recently, a modified spinning technique has been developed for producing a low torque and soft handle singles yarn by modifying the fiber arrangement in a yarn. Comparative studies revealed that the finer modified yarns possess significantly higher strength and lower hairiness over the conventional yarns of the same twist level, implying a different structure of finer modified yarn. Thus this paper aims to quantitatively study the structures of the finer conventional and modified cotton yarn (80 Ne) produced at the same twist level. Various measuring techniques, namely the Scanning Electron Microscope (SEM), cross section technique and tracer fiber technique, are adopted to analyze their structural characteristics, including fiber configuration, fiber spatial orientation angle, fiber packing density, yarn surface appearance, and fiber migration behavior. Results showed that finer modified yarns exhibit a smoother surface and much more compact structure with less hairiness. The fibers in the finer modified yarn have a complicated fiber path with relatively lower fiber radial position, larger migration frequency and magnitudes. In addition, it was noted that 73% of fibers in the finer conventional yarn follow concentric conical helix, which is contrary to those in the coarser conventional yarn. The analyses conducted in this paper provide deep insights into the mechanism of modified spinning technique and evidential explanations on the difference of properties between the finer conventional and modified yarns.     

Effect of two separate fibre feed systems in rotor spinning on yarn properties

Opening of the fibres in all industrial rotor spinning units is being done by an opening roller, which intakes the fibres from one feed point. Increasing number of feed rollers from one to two may improve fibre opening on the opening roller by gradual loading of the opening roller, which may improve fibre orientation in the final yarn and yarn properties. In this research a modified SE-8 rotor spinning unit of Suessen was used in which two separate fibre feed systems were employed. Raw material used was 38 mm, 1.7 den viscose fibre, to spin a 40 tex yarn. Yarn properties produced with this unit, were compared with that of the original yarn. Yarn properties tested were tenacity, extension, work of rupture, mass irregularity and imperfections, abrasion resistance and hairiness, which were measured on Shirley (SDL) and keisokki yarn testing machines. Test results were analyzed by ANOVA for any difference between the means, and Tukey and Duncan for classification and ranking of the yarn properties. Test results showed that, tenacity, extension and work of rupture of the modified yarn increased in comparison to the original yarn. Its mass irregularity, number of thin places and neps, and hairiness decreased. Number of thick places and yarn abrasion didn’t change. According to the test results, it was concluded that increasing the number of feed rollers on the opening roller from one to two has improved yarn properties.     

Impact of yarn extension on packing density of ring spun yarn

The present paper deals with a detailed study on the effect of progressive yarn extension on diameter, overall packing fraction, radial packing fraction at different radial positions and partial packing fraction at different segments along the length of a fibre. An image processing based system to characterize and visualize the configuration of fibers in yarn in extended mode has been adopted. It has been observed that with the increase of yarn extension at different intervals, yarn diameter continuously decreases but at different yarn extension intervals, the percentage decrease value in the yarn diameter is different. But the packing density of yarn does not follow the exact trend of yarn diameter with the extension of yarn at different intervals. The yarn packing density initially increases at very high rate, then at very low rate and finally the packing density of yarn rather slightly decreases with the increase in yarn extension. The radial packing density of the yarn is not uniform across the cross-section of the yarn and it is not maximum near the yarn axis, rather it is maximum at some distance from the yarn axis. The location of maximum radial packing densities of yarn changes with the yarn extension. The partial packing density along the length of yarn is not uniform and the results are equally applicable for all level of yarn extension.     

Fabrication of hollow nanofibrous structures using a triple layering method for vascular scaffold applications

This study aims to develop a new approach for fabricating hollow nanofibrous yarns by engineering a triple-layer structure (polyvinyl alcohol (PVA) multifilament core surrounded by a layer of PVA nanofibers and a polylactic acid (PLA) nanofiber outer layer). After fabrication of this 3-layer structure, the core portion was extracted, leaving the outer layer intact after dissolving the PVA nanofibers in water. To determine the optimum thickness of the outer layer, hollow nanofiber yarns with five different thicknesses were produced. A hollow nanofiber yarn was also produced using a common method to enable comparison of the methods. In the common method, a core sheath yarn consisting of a PVA multifilament core and a PLA nanofiber outer layer was fabricated, and a hollow yarn was produced by placing the core yarn in hot water. The results revealed facilitation of core extraction from the yarn body of the new 3-layer structure, which occurred due to rapid dissolution of the middle layer. The wicking behavior in the hollow yarn fabricated using the novel method followed the Locus Washburn equation and that of the hollow yarn produced from the core sheath yarn deviated from it. The results demonstrated that tensile properties of hollow nanofiber yarns were improved by increasing the thickness. Furthermore, hemolysis and cytotoxicity assays indicated that the fabricated hollow nanofibrous structure is non-toxic and blood compatible, indicating its potential for use in biomedical applications such as vascular scaffolds.     

Investigating the effect of yarn count and twist factor on the packing density and wicking height of lyocell ring-spun yarns

The moisture transport expressed with wicking is one of the most important aspects in clothing science and strongly effects on the quality of clothes. Wicking is a spontaneous transport of liquid driven into a porous system by capillary forces. Furthermore, the packing density has a direct relation with the yarn structure. At the present work, the effects of yarn count and twist factor on the wicking height and packing density of lyocell ring-spun yarns was investigated. Achieving the objectives of this research, an image processing method was developed to determine the packing density of samples. Experimental results were also used to develop a regression model to predict the wicking height based on the packing density, yarn count, twist factor and rising time. The results demonstrated that the correlation coefficient between the predicted and measured wicking height was 0.98 indicating the capability of the presented model to predict the wicking height of lyocell ring-spun yarns.     

Effect of chemical softening of coconut fibres on structure and properties of its blended yarn with jute

Coconut fibres were subjected to chemical treatment to obtain softer and finer fibres, suitable to blend with other finer fibre like jute. The chemical softening recipe was optimized using Box-Behnken design of experiments as 40 % Na₂S, 10 % NaOH and 6 % Na₂CO₃, which notably reduced the fineness (33 %) and flexural rigidity (74 %) and improved tensile property of coconut fibre. Effect of softening of coconut fibre on its process performance was studied in high speed mechanized spinning system at different blend ratios with jute. Blending with jute assists in spinning of coconut fibre to produce yarn of 520 tex at production rate of 5-6 kg/h, as compared to 15 kg/day for hand spun 5300 tex raw coconut fibre yarn in manual system. Analysis of blended yarn structure in terms of packing density, radial distribution of fiber components (SEM) and mass irregularity were investigated. SEM shows yarns made from softened coconut fibre -jute blends are more compact than raw coconut fibre -jute blend yarns. Coconut fibres were preferentially migrated to core of the yarn. Major yarn properties viz., tensile strength, and flexural rigidity of raw and chemically softened blended yarns were compared against their finest possible 100 % coconut fibre yarn properties. Yarn made up to 50:50 chemically softened coconut fibre-jute blend showed much better spinning performance, and having superior property in terms of reduced diameter, higher compactness, strength, initial modulus and less flexural rigidity than 100 % raw, 100 % chemically softened coconut fibre rope, and raw coconut fibre-jute blend yarns.     

The effect of spinning parameters on mechanical and physical properties of core-spun yarns produced by the three-strand modified method (TSMM)

The effect of spinning parameters on core-spun yarns properties manufactured using three-strand modified method (TSMM) was analyzed. Of the various spinning parameters, strand spacing, yarn linear density and yarn twist have a crucial effect on core-spun yarn properties. To achieve the objectives of this research, general physical properties of core-spun yarns together with existing standards were thoroughly studied. First of all, the strand spacing and yarn linear density were optimized. Afterwards, the effects of variation of yarn twist and sheath roving linear density on core-spun yarns properties were investigated. Finally, the physical and mechanical properties of TSMM yarns were compared with those of siro and conventional ring core-spun yarns counterparts. It was found that, the best strand spacing and yarn linear density to produce core-spun yarns are 8 mm and 45 tex, respectively. Results showed that, tenacity of TSMM yarns increases up to a certain twist level beyond which it reduces. The result confirmed that 45 tex yarns produced by three rovings of the same count are superior with regards to tenacity and hairiness. The optimized yarns produced by three-strand modified method enjoy superior physical and mechanical properties in comparison to the ring and siro core-spun yarns.     

Effect of fibre cross-sectional shape on the properties of POY continuous filaments yarns

There are various structural parameters (number of filament, cross-sectional shape, linear density, etc.) determined during the production of synthetic fibre and these parameters influence product features. Among these parameters, cross-sectional shape of fibres has a significant importance. Desired features can be added to the products by varying the cross-sectional shape and in this way; new products with improved features or with high added value can be produced. As a consequence, studies on this subject have increased recently. In this study, the effects of different cross-sectional shapes and yarn linear density on the features of polyester partially oriented yarn (POY) have been investigated. Five different cross-sectional shapes named round, trilobal, tetra, hexsa and octolobal and two different linear densities have been used in the study. Tenacity-elongation and unevenness tests have been applied onto yarns. As a result of the study, it was seen that round, tetra and octolobal cross-sectional shapes lead to production of yarn with high tenacity and breaking elongation while trilobal and hexsa leads to production of yarn with low tenacity. In addition, due to its deep-channelled structure, hexsa crosssectional shape led to POY yarn structure with a high unevenness rate. It was also seen that an increase in the rate of linear density decreased the tenacity and breaking elongation rates of yarn and reduced POY unevenness.     

Prediction of strength and weavability of blended spun yarns

In this paper, we report on predicting the strength of polyester/viscose spun yarns made on ring, rotor and air-jet spinning systems. A system has been developed to measure the weavability of yarns. Hamburger’s fibre bundle theory is modified to predict the strength of blended yarns from the strengths of single-fibre component yarns. The modified model predicts blended yarn strength more accurately than the original Hamburger’s model emphasizing the importance of yarn structure on blended yarn strength. The weavability of blended yarns is measured on a CTT instrument incorporating a shedding device which addresses the stresses viz., cycle extension, flex abrasion and beat up occur during weaving. The measured weavability compared well with that obtained on a commercial Sulzer Ruti Reutlingen Webtester. Yarn structure and strength and cohesion of fibres affect the strength and weavability of yarns.     

Effect of fiber friction, yarn twist, and splicing air pressure on yarn splicing performance

The impact of fiber friction, yarn twist, and splicing air pressure on mechanical and structural properties of spliced portion have been reported in the present paper. The mechanical properties include the tensile and bending related properties and, in the structural properties, the diameter and packing density of the splices are studied. A three variable three level factorial design approach proposed by Box and Behnken has been used to design the experiment. The results indicate that there is a strong correlation between retained spliced strength (RSS) and retained splice elongation (RSE) with all the experimental variables. It has been observed that RSS increases with the increase in splice air pressure and after certain level it drops, whereas it consistently increases with the increase in yarn twist. The RSE increases with the increase in both fiber friction and yarn twist. It has also been observed that the yarn twist and splicing air pressure have significant influence on splice diameter, percent increase in diameter and retained packing coefficient, but the fiber friction has negligible influence on these parameters. Yarn twist and splicing air pressure has a strong correlation with splice flexural rigidity, where as poor correlation with retained flexural rigidity.     

Studies on structural integrity of polyester-cotton friction spun yarn by cycling extension test

Yarns and fabrics are subjected to a low level of stresses or strains of repetitive nature in processing and actual use which leads to breakage, permanent deformation, bagging and loss of useful life of the product. The ability of the spun yarns and fabrics to withstand such stresses depends upon their structural integrity. A structurally rigid yarn (i.e. yarns in which fibres are tightly bound) would behave more like an elastic solid and consume more energy during deformation as the constituent fibres have to be deformed. Once the strain is released, the recovered energy will also be more. On the other hand if the structural integrity of the same yarn is poor, fibres would easily slip during deformation and would consume much less energy. The recoverable energy also will be much less. The present investigation reports on the structural integrity of friction spun yarns in terms of energy loss or decay by employing cyclic extension test. It has been observed that friction spun yarns in which the core is immediately wrapped by long and strong polyester fibre layer make the structure strongest as polyester is expected to form tight wrappings. The decay in deformation energies during extension cycling depends upon sheath structure i.e. its composition and location of constituent fibres in sheath layers. With increase in core fibre %, the decay has been found to increase. However, the decay values discriminate more between core% differences than between sheath fibre layer arrangements.     

Seeding depth and soil packing affect pure live seed emergence of cuphea

Cuphea viscosissima Jacq. × C. lanceolata f. silenoides W.T. Aiton is a new crop being developed in the north-central USA as an industrial oilseed crop. Adequate plant stand is essential for successful commercial production of cuphea. The objective of this study was to determine the effect of seeding date, depth and soil packing on stand establishment and subsequent crop performance. The study was conducted at Carrington and Prosper, ND, in 2005 and 2006. The experimental design was a randomized complete block with four replicates, with a split–plot arrangement, where the whole plot was a factorial arrangement (2 × 2) of two seeding dates, optimum and late, with or without soil packing after seeding. The subplot treatments were three seeding depths (surface, 13, and 25 mm). The same plot planter was used to adjust seeding depth to 13 and 25 mm. Each experimental unit had six rows 4.6-m long with a between-row spacing of 0.31 m. Traits evaluated were pure live seed emergence (PLSE), plant stand, plant height at harvest and seed yield. The main effect for seeding date did not have an effect on PLSE and resulted in adequate stands from both late May and mid June plantings averaged across environments. The seeding depth by soil packing interaction was significant for PLSE, plant stand and seed yield. Pure live seed emergence, plant stand, and seed yield were greater if the soil was packed compared with non-packed for the surface seeded treatment. The soil packing treatment did not influence PLSE, plant stand, or seed yield at the 13- and 25-mm seeding depths. Plant stands obtained from the non-packed surface and 13-mm seeding depths was adequate for high seed yield, as the plants branched to compensate for the lower plant density. Although surface seeding with packing produced satisfactory plant stands, reliance on timely rainfall is required for this to be successful. For this reason, the recommendation for seeding at the 13-mm depth without soil packing would ensure a better chance for sufficient soil water absorption by the seed to initiate germination. If surface seeding is practiced, a roller-packer to incorporate seeds and firm the seedbed after planting is recommended.     

Fabrication and characterization of PET nanofiber hollow yarn

In this study, various concentrations of polyethylene terephthalate (PET) polymeric solution were investigated to produce hollow nanofiber yarn. First, the electrospining apparatus was designed in a way that to put PVA multifilament in the core and to twist PET nanofibers onto multifilament yarn as a sheath simultaneously, followed by dissolving PVA yarn in hot water, PET hollow nanofiber yarn was produced. In this survey, it has been observed that the average thickness of sheath increased by increasing concentrations of PET polymeric solution. Results showed that maximum efficiency of extracting the PVA multifilament from the hollow yarn under certain conditions (concentration of 18 % (w/v) of PET, applied voltage of 10 kV, and flow rate of 0.0526 ml/h) was more than 85 %. The mechanical and physical properties of PET hollow yarns were investigated and indicated that the hollow nanofiber yarns at concentration of 30 % and 18 % polymeric solution had the lowest strength and the highest regain moisture, respectively.     

A study on the structural properties of plain fabrics using the lenticular model

The structural properties of a plain fabric were considered using the lenticular model. The structure of a plain woven fabric can be defined in terms of warp yarn number, weft yarn number, warp fabric density, weft fabric density, warp crimp, and weft crimp. Many structural variables of the plain fabric could be calculated by the lenticular model using these terms. Also, this model can be used to explain the geometry of the flattened yarns that occur during the weaving process. Flattening factors of threads for various types of fibers were calculated, compared, and explained with the number of yarn twist. Flattening factors were found to affect the structural variables of the fabric such as fabric thickness, air permeability, and yarn crimp. Yarn crimp was also studied with variation of the structural variables of the fabric.     

Mechanical properties of composites made from locally manufactured carbon fabrics and the composites produced from air-textured glass yarns

Composite materials have a wide range of applications in structural components because of their high strength-to-weight and stiffness-to-weight ratios. However, the most crucial and common life-restricting crack growth mode in laminated composites i.e. delamination is of great concern. Air jet texturing was selected to provide a small amount of bulk to the glass yarn. The purpose was to provide more surface contact between the fibres and resin and also to increase the adhesion between the neighbouring layers. These were expected to enhance the resistance to delamination in the woven glass composites. The development and characterisation of core-and-effect textured glass yarns was presented in the previous paper. This paper describes the comparison of the mechanical properties of composites produced from air-textured glass yarns and the composites made from locally manufactured carbon fabrics. The tensile, flexure and inter-laminar shear strength (ILSS) were compared and it was observed that although glass fibres are inferior to carbon fibres in terms of mechanical properties however, the flexure strength and ILSS of glass based composites increases after texturing and were found closer to the properties of carbon based composites.     

Study on the static and dynamic strengths and weavability of spun yarns

This study reports on the analysis of tenacity and breaking elongation of ring-, rotor- and air-jet-polyester/viscose spun yarns measured using static- and dynamic tensile testers. The weavability, a measure of performance of these yarns in post spinning operations is quantified. The yarn diameters and helix angles of fibres in these yarns are measured in order to analyze the effect of types of spun yarn and blend proportion on yarn elongations. The dynamic tenacity is highly correlated with the weavability than the average static tenacity measured at 500 mm gauge length. The minimum static tenacity obtained from 100 tests has high correlation with the dynamic tenacity. The present study indicates that it is appropriate to evaluate the performance of spun yarns in winding, warping and weaving based on the dynamic yarn tenacity measured while running a 200 m length of yarn in a constant tension transport tester or the minimum static yarn tenacity obtained using any conventional constant rate extension (CRE) tensile testers corresponding to a total test length of 50 m.     

Modeling of abrasion resistance of Persian handmade wool carpets using response surface methodology

The effect of knot density, pile height, number of ply in pile yarn and pile yarn twist on abrasion resistance of Persian handmade wool carpets has been studied. The interaction between the process variables has been analyzed by using response surface methodology based on the Box-Behnken design of experiment. Knot density, pile height, interactions between knot density and pile height; pile height and pile yarn twist; as well as squares of the knot density, pile height and number of ply in pile yarn are significant process variables. The minimum abrasion loss occurs at the combination(s) of medium values of knot density (six knots per inch) and number of ply in pile yarn (three ply) as well as lower values of pile height (ten mm) and pile yarn twist (three and a half twists per inch).     

Effect of strand spacing and twist multiplier on structural and mechanical properties of Siro-spun yarns

The effect of strand spacing and twist multiplier on strength of Siro-spun yarns with reference to the yarn structural parameters was investigated. Of the various structural parameters for staple yarns, fiber migration has a crucial influence on the yarn strength, which in turn to a considerable extent is influenced by the strand spacing and twist multiplier. Achieving the objectives of this research, the yarns were produced from lyocell fibers at five strand spacings and four different twist multipliers. Tracer fiber technique combined with image analysis were utilized to study the yarn migration parameters. Afterwards, the yarns were subjected to uniaxial loading by a CRE tensile tester. The measured results are presented in forms of diagrams and tables. The findings reveal that, as strand spacing is increased, yarn tenacity increases up to strand spacing of 8 mm beyond which it reduces. Analysis of the results indicates that the higher tenacity values at the strand spacing of 8 mm can be attributed to the higher mean fiber position, higher migration factor, higher proportion of broken fibers and lower hairiness.     

Evaluation of the structural properties of plain fabrics woven from various fibers using Peirce’s model

Peirce’s fabric model has been widely used to predict the structural behavior of various plain woven fabrics. The structure of plain woven fabric can be defined in terms of the warp yarn number, weft yarn number, warp fabric density, weft fabric density, warp crimp, and weft crimp. The warp and weft yarn diameters are calculated from the warp and weft yarn numbers, and the effective coefficient of the yarn diameter is defined by using this model. We have investigated structural properties, such as the effective coefficient of the yarn diameter, yarn crimp, and fabric thickness for two different fabrics in which the constituent yarns are assumed to be either incompressible or compressible. This model is also applied to various plain fabrics woven from cotton, rayon, wool, linen, nylon, acetate, polyester, and silk yarns.     

Predicting the air permeability of polyester/cotton blended woven fabrics

The aim of this study was to model the air permeability of polyester cotton blended woven fabrics. Fabrics of varying construction parameters i.e. yarn linear densities and thread densities were selected and tested for air permeability, fabric areal density and fabric thickness. A total of 135 different fabric constructions were tested among which 117 were allocated for development of prediction model while the remaining were utilized for its validation. Four variables were selected as input parameters on basis of statistical analysis i.e. warp yarn linear density, weft yarn linear density, ends per 25 mm and picks per 25 mm. Response surface regression was applied on the collected data set in order to develop the prediction model of the selected variables. The model showed satisfactory predictability when applied on unseen data and yielded an absolute average error of 5.1 %. The developed model can be effectively used for prediction of air permeability of the woven fabrics.