The interaction of moving yarns with stationary surfaces

Ever since the spinning process was developed, numerous research studies have been conducted and many precision instruments have been developed to control the tension in moving yarn. These efforts, however, have remained insufficient because many factors that need to be considered have not been handled in an integrated manner. To overcome this limitation, various parameters that affect the tension must be examined and the relationships among them must be discovered. Hence, the present paper reviews a variety of parameters for yarn moving from a ring spinning machine to a winding machine. These two machines, in particular, involve a series of phenomena in which the yarn passes over a stationary surface. In addition, the relevant parameters related to force, tension, and yarn motion need to be separately investigated in each spinning section (e.g., the balloon, the section from the bobbin to the traveler, and the section from the bobbin to the unwinding package) and at each part (e.g., the traveler, yarn guide, package, and tensioner).     

Performance of cotton single yarns and knitted fabrics produced by a 2-step spinning method

A low torque spinning method has been recently developed by integrating the ring spinning process with false twisting techniques. As a result of false twist and true twist, a novel single yarn of low torque and soft handle is generated. Based on the similar spinning principle, this paper proposed a 2-step spinning method, which is composed of twisting-anduntwisting operation and can be considered as a variant of the low torque spinning method. The proposed spinning method separates the false twisting process into twisting and untwisting processes which are combined in one step in the low torque spinning method. In this paper, physical properties of yarns produced by the proposed spinning method were evaluated and compared with the conventional yarns. Influences of various spinning parameters on the properties of 2-step yarns were also examined. Furthermore, a systematic study of the physical properties of the 2-step yarns and resultant fabrics with respect to the conventional and low torque ones was carried out. The experimental results showed that the 2-step yarns exhibit slightly higher tenacity, lower wet snarl and much less hairiness than the conventional yarns, which, however, are inferior to the low torque yarns, particularly the evenness. The fabrics made by the 2-step yarns show the softest handle feeling, best airpermeability and moderate spirality angle with acceptable pilling resistance.     

Studies on reduction of yarn hairiness by nozzles in ring spinning and winding by airflow simulation

Reduction of yarn hairiness by nozzles in ring spinning and winding is a new approach. Simulation of the airflow pattern inside the nozzles provides useful information about actual mechanism of hairiness reduction. The swirling air current inside the nozzles is capable of wrapping the protruding hairs around the yarn body, thereby reducing yarn hairiness. Since production rate of winding is very high and the process itself increases yarn hairiness any method to reduce the hairiness of yarns at this stage is a novel approach. A CFD (computational fluid dynamics) model has been developed to simulate the airflow pattern inside the nozzles using Fluent 6.1 software. In this study, both S- and Z-type nozzles having an axial angle of 50° and diameter of 2.2 mm were used for simulation studies. To create a swirling effect, four air holes of 0.4 mm diameter are made tangential to the inner walls of the nozzles. S- and Z-twisted yarns of 30 tex were spun with and without nozzles and were tested for hairiness, tensile and evenness properties. The total number of hairs equal to or exceeding 3 mm (i.e. the S3 values) for yarn spun with nozzle is nearly 49–51 % less than that of ring yarns in case of nozzle-ring spinning, and 15 % less in case of nozzle-winding, while both the yarn types show little difference in evenness and tensile properties. Upward airflow gives best results in terms of hairiness reduction for nozzle-ring and nozzle wound yarns compared to ring yarns. Yarn passing through the centre of the nozzle shows maximum reduction in S3 values.     

Effects of twisting parameters on characteristics of rotor-spun composite yarns with spandex

Spandex fibers have superior stretch and elastic recovery ability. Composite yarns containing spandex are frequently used to manufacture elastic textile products and accessories. We have developed a composite yarn spinning system that produces different kinds of composite yarns containing spandex on a modified open-end rotor spinning frame. By changing the twisting parameter of composite yarns, we studied the structure and properties of rotor-spun composite yarns with spandex. The results indicate that the twisting parameter has great influence on the structure and properties of rotor-spun composite yarns with spandex. The linear density of spandex filament has influence on the properties of composite yarns too. In comparison with normal rotor-spun yarn, the appearance of composite yarns is clearer, the structure is much tighter, and the properties are improved.     

Wet-chemical silvering of inert polyethylene terephthalate yarn in a spool dyeing apparatus

Inert polyethylene terephthalate (PET) yarns, which were spooled crosswise onto a cylindrical dyeing bobbin, were silvered successfully with a wet-chemical method by using a newly developed one-bath method on a laboratory scale. In order to characterize the silver coating such as design, homogeneity, and crack formation, the surface morphology (SM) was analyzed using scanning electron microscopy (SEM). The chemical compositions of the surface (percentage of carbon, oxygen, nitrogen, silicium, and silver) were investigated with energy-dispersive x-ray spectroscopy (EDX). Furthermore, the testing of textile-chemical and textile-physical properties such as the washing-fastness, tensile strength, and electrical conductivity was carried out.     

Effect of weaving process on tensile characterization of single and multiple ends of air-entangled textured polyester yarns

The tensile properties of air-entangled textured polyester single and multiple yarn ends before and after weaving were analyzed. The effects of weaving process considering fabric unit cell interlacement and number of yarn ends were evaluated by regression model. For this purpose, plain, ribs and satin woven fabrics were produced. The yarns were raveled from fabrics, and the tensile tests were applied to these yarns. The developed regression model showed that the number of interlacement and crimp ratio on the warp and weft yarns influence their tensile strength. Tensile strength of raveled yarns decreased compared to that of the bobbin yarn due to the effect of weaving process. This property degradation on the ravel yarns considered process degradation. Generally, when the number of warp and weft yarn ends increases, the warp and weft yarn tensile strengths for each fabric type decrease, whereas the warp and weft yarn tensile elongations slightly increase. The results from regression model were compared with the measured values. This study confirmed that the method in the study can be a viable and reliable tool. The research finding could be useful those who work on preform fabrication.     

Continuous twisted nanofiber yarns fabricated by double conjugate electrospinning

In order to fabricate continuously twisted nanofiber yarns, double conjugate electrospinning had been developed using two pairs of oppositely charged electrospinning nozzles. The principle and process of this novel yarn spinning method were analyzed, and the effect of applied voltage, nozzle distance between positive and negative, solution flow rate and funnel rotating speed on the diameters, twist level and mechanical properties of resultant PAN nanofiber yarns were investigated in this paper. The results indicated that electrospun nanofibers aggregated stably and bundled continuously at the applied voltage of 18 kV, the nozzle distance of 17.5 cm between positive and negative, the overall flow rate of 3.2 ml/h and the flow ratio of 5/3 for positive and negative nozzles. The resultant nanofiber yarns had favorable orientation and uniform twist distribution, and the twist level of nanofiber yarns increased with the increase of the ratio of funnel rotating speed and winding speed. The diameters and mechanical properties of nanofiber yarns depended on their twist level. The diameters of prepared PAN nanofiber yarns ranged from 50 µm to 200 µm, and the strength and elongation of PAN nanofiber yarns at break were 55.70 MPa and 41.31%, respectively, at the twist angle of 41.8 °. This method can be also used to produce multifunctional composite yarns with two or more components.     

Effect of blends proportion on the characteristics of dry and Pre-wet nylon/viscose blended air-jet textured yarns

Blending of nylon filament with viscose can overcome the drawbacks of these yarns. Thermoplastic and thermoset filament yarns can be blended in air-jet texturising method. The characteristics of nylon/viscose blended filament yarns are required to be understood in order to convert them in to useful products. Therefore, nylon/viscose blended yarns in different proportions were produced using nylon 6 and viscose filament yarns in air jet texturising machine. The textured yarns were also produced in dry and pre-wet conditions to understand the effect of water on textured yarn characteristics. It was found that the loops frequency, bulkiness of nylon/viscose blended textured yarns increase with increase in viscose proportion. The Loops stability, tenacity and breaking elongation decrease with increase in viscose proportion. Pre-wet textured yarn show higher loops, bulkiness, and good loop stability than their corresponding dry textured yarns.     

Structures and mechanical properties of plied and twisted polyacrylonitrile nanofiber yarns fabricated by a multi-needle electrospinning device

Polyacrylonitrile (PAN) nanofiber filaments were manufactured continuously for several hours by a homemade multi-needle electrospinning device. The yarns were continuously obtained by plying and twisting nanofiber filaments using a self-made twisting device. The structures and mechanical properties of yarns were investigated. The influences of twist setting temperatures and periods of time on morphology and mechanical properties were discussed. The results showed that the alignment degree of nanofibers along the filament axis could reach 70.9 %. The twist angle increased with increasing twists and the number of filaments. With increasing twists, the breaking stress and strain increased initially and then decreased; the maximum breaking stress and strain were 34.7 MPa and 26.1 %, respectively; the initial modulus decreased with increasing twists and plies, the maximum modulus was 391.3 MPa. Both the breaking stress and strain increased with the increase of twist setting temperatures and times. The optimal setting temperature and time were 90 °C and 30 min, respectively, the maximum breaking stress and strain were 32.8 MPa and 20.8 %, meanwhile, the crystallinity improved from 34.5 % to 39.9 %. This study demonstrates the possibility of continuously and stably manufacturing PAN nanofiber yarns.     

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.     

Study on the strength retention of technical cord yarn

This research studies the factors which influence the tensile strength of tire cords. Five yarn samples are made by changing the spinning conditions and viscosity to get various physical properties. Different twisting methods are introduced and the yarns are twisted under different processing conditions for each twisting process. With the experimental results, various analyses are performed to find the important factors in retaining strength after the twisting process. SEM and optical microscopic photographs are taken along with some measurements to assist the analysis.     

基于EDEM的茶叶揉捻机参数优化及试验研究

为解决目前茶叶在揉捻过程中揉捻质量不稳定的问题,以6CR-40型茶叶揉捻机为研究对象,基于Solidworks对茶叶揉捻机进行三维建模,运用离散元仿真软件EDEM对茶叶揉捻机的揉捻过程进行数值模拟,探求各试验因素对茶叶揉捻机性能指标的影响规律。运用二次正交旋转试验,通过Design-Expert软件进行优化求解,获得揉捻质量最佳的结构参数组合。结果表明,当揉桶转速为42 r·min^-1、棱骨高度为10 mm、揉盘倾角为3.8°时,茶叶的成条率为88.55%、碎茶率为1.83%。茶叶揉捻机具有较好的揉捻质量。验证试验结果与仿真优化结果基本一致。     

茶园中耕机械杂草缠绕力计算与分析

贵州省是茶叶生产大省。中耕机械是茶园管理中常用的机械,中耕除草是茶园田间管理的重要环节。在田间试验中,发现中耕机械缠草是常见问题。本文对贵州省茶园杂草种类和长度进行调查,并对缠草现象分析,通过对杂草缠绕力分析和计算,建立了缠绕力数学模型,进一步对模型进行数学分析,得出了防缠草和减少缠草的措施和方法。     

Theoretical study of fiber tension distribution at Solospun spinning triangles

Spinning triangle is a critical region in the spinning process of staple yarn. Its geometry influences the distribution of fiber tension in the spinning triangle and affects the properties of spun yarns. Taking appropriate measures to influence the spinning triangle geometry and improve the quality of yarn has attracted great interesting recently. Solospun technology is one of the most important representatives, which is implemented by dividing ring spinning triangle into several small primary triangles and one final triangle using a Solospun roller. Therefore, theoretical study of fiber tension distributions at Solospun spinning triangles is presented in this paper. First, a theoretical model of the fiber tension distributions in Solospun spinning triangles is given by using the principle of minimum potential energy. Second, the relationships between fiber distributions and spinning triangle parameters are analyzed theoretically. Especially, the effects of horizontal offset of the twisting point to triangle symmetric axis of nip line d on fiber tension distributions are discussed and numerical simulations are given. Finally, the properties of spun yarns are evaluated and analyzed by using the simulation results.     

A study on siro-jet spinning system

Nowadays, there is ever increasing interests regarding with the nozzle usage in spinning systems and also winding process. In this study, an air nozzle was attached on to the sirospun spinning system and the system was called as siro-jet. Sirospun is a spinning system combining spinning and doubling in one operation and a yarn like a two fold is produced. The principle of the siro-jet system is based on the placement of the nozzle at the exit of drafting unit on sirospun spinning system and pressurized air was fed into the nozzle by the compressor during the spinning. In literature, air nozzle application in this manner is not common and hence the system is very less known. For that reason, siro-jet and siropun yarns were produced with different fibre types, material qualities and yarn counts, and the properties of the yarns were compared. At the end of the study, it was determined that siro-jet spinning system truly improves the yarn hairiness in comparison to sirospun spinning system. Even, the siro-jet yarns are less hairy after winding process. Interestingly, hairiness results of siro-jet and sirospun yarns produced with short, non-uniform fibres showed that siro-jet spinning system allows working with low cost raw materials while maintaining yarn quality. Therefore, siro-jet can be considered as an innovative spinning system regarding with less hairy yarn production opportunity.     

Study on characteristics of compact yarns under dynamic state

The dynamic testing conditions simulate actual manufacturing conditions more closely than static testing. In most cases, as results from dynamic tests differ significantly from static tests, dynamic tests are more relevant from the point of view of processing of yarn. The yarns are in motion when they are running on different machines during the production process viz. weaving; knitting etc. Compact ring spun yarns have created a fundamental change how the industry views the ring spinning. The new technology compact yarns such as EliTe® yarns need to be compared with the normal doubled yarns in a dynamic way. This study involves dynamic testing of the EliTe® compact yarns and normal ring spun doubled yarns using CTT (Constant Tension Transport) machine, a versatile test instrument to measure the yarn properties such as dynamic breaking strength, elongation, abrasion, lint, yarn faults (thick, thin places, neps), hairiness etc. EliTe® compact yarns showed higher breaking strength, more elongation, with lesser yarn faults and hairiness, less abrasiveness and less lint generating tendencies during the dynamic testing as compared to the normal ring spun doubled yarns.     

苎麻／壳聚糖抗菌纱喷气纺研究

对苎麻/壳聚糖(55/45)抗菌纱,采用喷气纺纺制的可行性进行了探讨,结果表明:通过对喷嘴的设计,选取优化后的工艺参数,同时,喷气纱具有较佳的纱线结构及良好的抗菌性。     

The effect of the processing factors on the physical properties of high shrinkable nylon composite yarns

This paper is aiming to develop high shrinkable differential shrinkage and mixed fibre nylon composite yarns by applying the high shrinkable polyester manufacturing technology. The wet and dry thermal shrinkages and mechanical properties of developed nylon composite yarns are measured and discussed with processing factors in the spinning and texturing processes. And the effects of the processing factors on the physical properties of high shrinkable nylon composite yarns are investigated. For this purpose, twenty seven nylon 30d/12f SDY were prepared with variation of spinning temperature, 2nd godet roller temperature and draw ratio on the spinning machine. The optimum spinning condition which showed maximum wet thermal shrinkage and stress was determined and high shrinkable nylon 30d/12f SDY spun under this optimum condition used as a core and three kinds of regular nylon filaments used as sheath were processed on the texturing machine with variation of 1st and 2nd heater temperatures. The optimum texturing process condition was decided through analysis of dry thermal shrinkage of these core and sheath nylon filaments. Finally, high shrinkable differential shrinkage and mixed fibre nylon composite yarns were made under the optimum texturing condition on the texturing machine, its wet thermal shrinkage was 13.8 %, which was much more higher than that of regular nylon composite yarns. The differential shrinkage effect of the developed nylon composite yarns was found in the yarn surface and cross section profiles by microscope and SEM.     

Study on dynamic needle thread tensions in a single needle lock stitch (SNLS) sewing machine. II. Effect of sewing speed,thickness of fabric plies,thread linear density and pre-tensions of threads

This paper reports on the effect of pre-tensions on needle and bobbin threads, sewing speed, thickness of fabric plies and the linear density of the threads on the tension peaks occurring on needle thread during sewing on a single needle lock stitch machine. The needle thread tensions are measured at two locations: above the needle bar (bottom segment) and above the needle thread tensioner (top segment). A factorial design approach is used to study the four parameters. The role of bobbin tension is studied in a separate experiment, while keeping the pre-tension on the needle thread constant. The highest tension observed on the needle thread is the stitch tightening tension which is directly affected by the pre-tension set on the needle thread disc tensioner. Heavier threads develop lower tightening tension which may affect the seam balance. The thickness of fabric plies does not affect the needle thread tension. Sewing speed has marginal influence on the stitch tightening tension near the needle thread tensioner. The pre-tension on the bobbin thread affects only the needle thread tension when the take up lever pulls up the needle thread loop to release it from the rotary shuttle hook gib.     

Yarn setting and hairiness reduction with a steam jet during winding

This paper examines the use of pressurized steam for wrapping and setting the yarn hairs concurrently via a new steam-jet process during winding. Yarn torque can also be stabilized as an added advantage. The results obtained with two batches of pure wool yarns suggest that there is potential to achieve yarn hairiness reduction of up to 60 % with minimum deterioration in hairiness even after subsequent rewinding.