Recent studies on yarn tension and energy consumption in ring spinning

High energy consumption remains a key challenge for the widely used ring spinning system. Tackling this challenge requires a full understanding of the various factors that contribute to yarn tension and energy consumption during ring spinning. In this paper, we report our recent experimental and theoretical research on air drag, yarn tension and energy consumption in ring spinning. A specially constructed rig was used to simulate the ring spinning process; and yarn tension at the guide-eye was measured for different yarns under different conditions. The effect of yarn hairiness on the air drag acting on a rotating yarn package and on a ballooning yarn was examined. Models of the power requirements for overcoming the air drag, increasing the kinetic energy of the yarn package (bobbin and wound yarn) and overcoming the yarn wind-on tension were developed. The ratio of energy-consumption to yarn-production over a full yarn package was discussed. A program to simulate yarn winding in ring spinning was implemented, which can generate the balloon shape and predict yarn tension under a given spinning condition. The simulation results were verified with experimental results obtained from spinning cotton and wool yarns.

Conductive wool yarns by continuous vapour phase polymerization of pyrrole

Conducting polypyrrole (PPy) coated wool yarns were prepared by a continuous vapour polymerization technique, using a speed of 1 m/min with different iron(III) chloride (FeCl₃) as the oxidant at different concentrations. The resistivities, tensile properties, longitudinal and cross-sectional views of PPy-coated wool yarns were investigated. Optimum specific electrical resistances of 2.96 Ω g/cm² at 80 g/L FeCl₃ and 1.69 Ω g/cm² at 70 g/L FeCl₃ were obtained for 500 and 400 twist per meter (TPM) yarns, respectively. PPy-coated wool yarns exhibited higher elongation than uncoated yarns. Longitudinal and cross-sectional views of the yarns indicate that PPy coating penetrated deep into the yarn cross-section and a uniform coating was obtained on the surface of the yarn surface.

The new solo-siro spun process for worsted yarns

The aim of this paper was to explore whether the properties of worsted yarns, especially hairiness, can be improved by combining the Solospun and Sirospun processes into a single Solo-Siro spun process. Wool fibres of 19 and 21 μm in average diameter were spun into 40 tex yarns at different twist levels, using the conventional ring, Sirospun and Solo-Siro spun systems, respectively. These yarns were then tested for a range of properties, including hairiness, tenacity, elongation and evenness, for comparison purposes. The statistical analysis results indicate that the hairiness (S3 value) of Solo-Siro spun yarns was significantly less than that of both Sirospun and normal ring spun yarns. In addition, the tenacity of the Solo-Siro spun yarns was higher than that of the normal ring spun yarns, while changes in yarn breaking elongation were not statistically significant. For the 21 μm wool, it was found that the evenness of Solo-Siro spun yarns deteriorated slightly in comparison with that of Sirospun and conventional ring spun yarns.

Preparation of nanofibre yarns from electrospun nonwoven strips

From ancient to modern time, humans have been trying to use finer fibres to make fibrous products for various purposes and believing that finer fibres have better aesthetic qualities. So far, the commercial fibres have been reduced to microns in diameter, but it seems difficult to further reduce the fibre fineness to submicrons using conventional fibre-making techniques.
Electrospinning is a promising technique to produce continuous fibres with diameters on nanometre scales. This technique involves stretching a polymer fluid under a strong electric field into fine filaments, which are deposited randomly on the electrode collector forming a nonwoven nanofibre mat in most cases. Despite considerable efforts in exploring the applications of electrospun nanofibres in non-fibrous fields [1], very limited work has been conducted on using this material to process mechanically robust nanofibre yarns [2,3].

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.

An artificial neural network-based hairiness prediction model for worsted wool yarns

This study evaluated the performance of multilayer perceptron (MLP) and multivariate linear regression (MLR) models for predicting the hairiness of worsted-spun wool yarns from various top, yarn and processing parameters. The results indicated that the MLP model predicted yarn hairiness more accurately than the MLR model, and should have wide mill specific applications. On the basis of sensitivity analysis, the factors that affected yarn hairiness significantly included yarn twist, ring size, average fiber length (hauteur), fiber diameter and yarn count, with twist having the greatest impact on yarn hairiness.

Twist distribution in staple fibre yarns

Staple fibre yarns vary quite markedly in linear density (tex) along their length and the degree to which twist redistributes from thick to thin places will affect the strength, torque and extension behaviour of the yarn. Theory suggests that twist along worsted yarns should vary as 1/(tex)2 if fibres were locked in the structure, whereas themean torque of worsted yarns reported in the literature implies that twist should be proportional to 1/tex. This article examines twist distribution in ring-spun marl yarns, down to 5 mm resolution, as a function of linear density measured using a high-resolution capacitive sensor. It is found for moderate twist-level worsted yarns that twist is approximately proportional to 1/(tex)1.6. The results and theory provide a guide as to the effect the observed large variations in linear density will have on yarn properties such as tenacity and torque.

Recent research on natural fibres and textiles

This paper provides an overview of recent research on a range of natural fibres and textiles. The focus is on work carried out at Deakin University’s Centre for Material and Fibre Innovation, which is a multidisciplinary research centre with over 100 researchers. The fibres include hemp, wool, silk, and alpaca fibres. Research on yarns, fabrics, and fine powders made from wool and silk fibres are briefly discussed also.

The within-fibre diameter variation of wool has been examined systematically, which highlights the importance of this hard-to-measure fibre attribute. A relationship between hemp fibre fineness and residual gum content has been established, which provides a rapid means of assessing the residual gum content in the degummed hemp fibres. Silk and wool fibres have been converted into ultrafine powders for advanced applications. The Resistance to Compression (RtC) behaviour of wool and alpaca fibres has been closely examined, which challenges the belief that RtC is a good indicator of fibre softness. Ways of reducing the hairiness of natural fibre yarns, predicting the pilling propensity of wool knits, and functionalising fabrics for superhydrophobicity and photochromic or colour changing effects are discussed.

Estimating the diameter of yarns with irregular constituent fibres

Yarn diameter and packing density are difficult to measure directly. Existing models on fibre packing density in a yarn assume that all fibres are uniform and have an identical diameter. Yet real staple yarns, such as wool yarns, consist of fibres of varying diameters. This paper proposes an effective and simple yarn model for calculating the average diameter of yarns, in which fibres have circular cross-section and the close packing in the yarn cross-section. The concept of “area equivalent diameter” is introduced to transform fibres of varying diameters to identical fibres with one equivalent diameter to simplify the calculations of the average yarn diameter for a range of yarns.

Embeddable and locatable spinning

A novel spinning method: embeddable and locatable spinning, is reported for the first time in this paper. Analysis of the key restrictions of the conventional and some novel ring-spinning were studied; evolvement and principles of embeddable and locatable spinning were then introduced. Analysis indicated that embeddable and locatable spinning could overcome the existing restrictions of ring spinning and improve the spinning performance of fiber strands as well as the quality of the resulting yarn. Super-fine and colorful figured yarns could be produced successfully, and most fibers shorter than can be spun in traditional spinning could be well embedded into a yarn by embeddable and locatable spinning method; even staple fibers of low qualities could be used to produce a fine yarn of high qualities in the novel spinning system. This novel spinning method shows huge application potentials in textile industry by improving the yarn quality, developing super-fine yarn, and increasing fiber utilization rate.

Strip twisted electrospun nanofiber yarns: Structural effects on tensile properties

Nanofiber yarns with controlled twist levels were prepared by twisting a narrow fibrous strip cut directly from electrospun nanofiber mats. The effects of fiber morphology, diameter and orientation, as well as the yarn twist level on the yarn tensile properties were examined. For the yarns made from randomly oriented fine uniform nanofibers (e.g., diameter 359 nm) and beaded nanofibers, the tensile strength increased with increasing the yarn twist level. Higher fiber diameter (e.g., 634 nm) led to the tensile strength having an initial increase and then decrease trend. The modulus increased with the twist level for all the yarns studied. However, the elongation at break increased initially with the twist level and subsequently decreased. The orientation of aligned fibers within the fiber strip greatly influenced the yarn tensile properties. When the fibers were oriented along the fiber length direction, both tensile strength and modulus were the largest.

Improving fiber trapping with a contact surface during the ring twisting of two cotton yarns

In this study, a geometrical model was introduced to improve the hair trapping via a surface contacting the yarn-twisting triangle during ring twisting of two single yarns. The fiber-trapping improvement with the contact surface was analyzed theoretically. Then, single Ne 80 ring cotton yarns were used to produce two-ply yarns under different ring-twisting conditions, namely conventional twisting, dry twisting of yarns with a plane surface, wet twisting of yarns with a plane surface, dry twisting of yarns with a grooved surface, and wet twisting of yarns with a grooved surface. Plied yarn properties, including yarn hairiness, strength, and irregularity, were tested. The Student Newman Keuls (SNK) test and variation analysis were also carried out in the SPSS program to study the effect of different contact surfaces on related yarn properties; the significance level was 0.05 for the SNK test and variation analysis. The hairiness of plied yarns was significantly reduced when twisting with the plane or grooved surface, especially for the wet twisting cases. This corresponds well with our model on improving fiber trapping.

Effect of fibre, yarn and knitted fabric attributes associated with wool comfort properties

In this replicated experiment, we investigated the comfort properties of single jersey fabrics composed of cashmere in blends with superfine wools of different fibre curvature (crimp) where the fibre diameter of the wool and cashmere were tightly controlled. The 81 fabrics were evaluated using the Wool ComfortMeter (WCM) which has been calibrated using wearer trials of wool knitwear. General linear modelling determined the best prediction models for log10 transformed fabric WCM values using 27 fibre, 16 yarn and 30 fabric attributes. Tighter fabrics were less comfortable. Progressively blending cashmere with wool progressively increased comfort assessment. The WCM was able to detect differences between fabrics which were more supple and springy, thinner and lighter, and were composed of more elastic, uniform and stronger yarns. Together these attributes explained 82% of the variance in WCM value.