Yarn Density Research Articles

Optimization of Process Parameters to Control Yarn Packing Density of Cotton Spun Yarn by Using Multiple Regression Models

Ring spinning frame is the most common and widely used technique for the production of yarn. This yarn subsequently utilized for the production of fabrics. Recently the research studies are more emphasis to create the living comfort condition. The yarn package density has a vital role to determine the feel, comfort, bulkiness and dyeing characteristics of the spun yarn. The yarn packaging density is largely influenced by the yarn process parameters. Ring spinning technique is the most common and widely used for the production of yarn. This yarn subsequently utilized for the production of fabrics. Recently the research studies are more emphasis to create the living comfort condition. The yarn package density is a vital role to determine the feel, comfort, bulkiness and dyeing characteristics of the spun yarn. It is largely influenced by the yarn manufacturing techniques and raw material used. The effects of spinning process parameters on packing density will be helpful to predetermine the yarn comfort behaviour prior to the complete the fabric manufacturing process. Mechanical behaviour of the staple yarn depends on the fiber characteristics and the yarn structure i.e. the arrangement of the individual fiber on the cross-section of the yarn. The fiber distribution on the cross section of the yarn and packing density of yarn has been investigated. The study provides how the spinning process parameters affect the internal structure of ring spun yarn. The aim of the study is to improve the package density of the yarn to achieve dynamometric and comfort properties of yarn to attract a wide variety of customers. Yarn Packing Density represents inter-fiber distance and friction, hence controlling the mechanical and comfort properties of the yarn. The main objective of this study is to control the packing density of yarn during the spinning process. In this work the 100 percent cotton used as raw material and spun on a ring spinning machine. The 135 ring yarns samples have been produced from three different types of yarn counts include (Ne 8, 16 and 24) with nine different samples of identical counts were produced. The three different variables within the count sample are TPI and spindle speed and count. Yarn packing density was calculated by using the driven equation by the application of multiple regression models. The final result shows that packing density has directly related to the TPI, Spindle speed and count

Optimization of Process Parameters to Control Yarn Packing Density of Cotton Spun Yarn by Using Multiple Regression Models

Ring spinning frame is the most common and widely used technique for the production of yarn. This yarn subsequently utilized for the production of fabrics. Recently the research studies are more emphasis to create the living comfort condition. The yarn package density has a vital role to determine the feel, comfort, bulkiness and dyeing characteristics of the spun yarn. The yarn packaging density is largely influenced by the yarn process parameters. Ring spinning technique is the most common and widely used for the production of yarn. This yarn subsequently utilized for the production of fabrics. Recently the research studies are more emphasis to create the living comfort condition. The yarn package density is a vital role to determine the feel, comfort, bulkiness and dyeing characteristics of the spun yarn. It is largely influenced by the yarn manufacturing techniques and raw material used. The effects of spinning process parameters on packing density will be helpful to predetermine the yarn comfort behaviour prior to the complete the fabric manufacturing process. Mechanical behaviour of the staple yarn depends on the fiber characteristics and the yarn structure i.e. the arrangement of the individual fiber on the cross-section of the yarn. The fiber distribution on the cross section of the yarn and packing density of yarn has been investigated. The study provides how the spinning process parameters affect the internal structure of ring spun yarn. The aim of the study is to improve the package density of the yarn to achieve dynamometric and comfort properties of yarn to attract a wide variety of customers. Yarn Packing Density represents inter-fiber distance and friction, hence controlling the mechanical and comfort properties of the yarn. The main objective of this study is to control the packing density of yarn during the spinning process. In this work the 100 percent cotton used as raw material and spun on a ring spinning machine. The 135 ring yarns samples have been produced from three different types of yarn counts include (Ne 8, 16 and 24) with nine different samples of identical counts were produced. The three different variables within the count sample are TPI and spindle speed and count. Yarn packing density was calculated by using the driven equation by the application of multiple regression models. The final result shows that packing density has directly related to the TPI, Spindle speed and count

Thermal resistance and water vapor permeability of compound woven fabrics containing silver multifilament

Two sets of compound woven fabrics containing three layers of simple woven fabrics were manufactured (five samples made of cotton yarns and five samples with one-third hybrid cotton/silver yarns). The thermal resistance and water vapor permeability of all the fabrics were measured and compared. It should be noted that the small dissimilarity in the thickness of the manufactured fabrics was due to the movement of the yarns through the thickness in the relaxing state of the fabrics. However, they were designed in a way to have the same thickness on the weaving loom. The results stated that the thermal resistance of asymmetric fabrics for both sets of fabrics (with and without silver) was different regarding which exterior face (face or back) was in contact with the hot plate (20°C). It should be noted that the fabric is not symmetric through its thickness due to the dissimilarity of weave pattern of the layers or the orientation of silver yarns. It affirms that the internal voids of each ply (which is correlated to the wave pattern) play a significant role in thermal resistance of the manufactured compound woven fabrics. As a result, the asymmetry of a compound woven fabric throughout the thickness makes it a potential fabric to be applied as double-face fabric for different climate conditions as the order of the layers changed the thermal resistance of the compound fabric due to the porosity of each ply. Furthermore, a reduction was observed in thermal resistance for the fabrics with silver presence (~40%) while the other parameters remained unchanged (e.g. yarn density, fabric structure, and fabric porosity). The reason is correlated to the high conductivity of silver as conductive materials improve the heat transfer of the fabrics. Moreover, the influence of silver presence on water vapor permeability was not significant although the water vapor permeability was slightly increased for the fabrics having silver in their structures.

3D warp interlocks p-aramid fabrics for composite reinforcement and ballistic vest applications: Effect of yarn density on its formability characteristics

The material forming capability becomes one of the most important characteristic of textile performance in the manufacturing of three-dimensional (3D) components to fit a 3D surface in various technical applications. In this study, different forming characteristics of 3D warp interlock fabrics in dry fabric condition were investigated. 3D warp interlock architecture with different areal density from same para-aramid yarn with a linear density of 168dtex were systematically designed and produced on automatic dobby loom with standard atmospheric conditions. The approach utilizes a low speed forming process with a predefined hemispherical shape of punch for the analysis of different forming behaviour of the fabrics specimen. The same blank-holder pressure was chosen for all the samples for better comparisons. Among several forming properties, some important characteristics have been observed, measured and analysed for a better understanding of the material forming behaviour of the different samples specimen. The research results with independent warp and weft yarn densities show a significant impact on the forming behaviours 3D warp interlock fabric. Moreover, the result of the investigation also will give a better understanding on different forming behaviours of 3D warp interlock fabric with various densities while applying in different textile application including women soft body armour.

Study on the tensile modulus of seamless fabric and tight compression finite element modeling

Tight compression garments are able to exert pressure on the surface of the human body, helping to relieve muscle fatigue and accelerate recovery. In order to study the effect of the tensile property on fabric pressure on the human body, by response surface methodology, in this paper 13 seamless knitting fabrics were designed with various knitting parameters, including the linear density of bare elastic yarn (33.3, 55.6 and 77.8 dtex), yarn feed tension (0.015, 0.030 and 0.045 cN/dtex) and fabric structure (1 × 1 mock rib, cross-float and plain stitch). Through tensile testing, the tensile moduli of 13 fabrics were measured and the effect of knitting parameters was analyzed. In addition, a finite element method was used to simulate the tight pressure on the human thigh of fabrics with different tensile moduli with ANSYS workbench 19.0. Furthermore, an actual pressure experiment was designed to prove the accuracy and validation of the simulation. The result showed that the effect of yarn feed tension on the elasticity modulus was the least significant, while linear density and structure had a great influence. A quadratic response surface regression model of the elasticity modulus was created, which could calculate a bare elastic yarn knitting fabric by using its parameters. It was proved that the finite element model was able to predict pressure accurately. Through the pressure numerical simulation of three fabric samples with different tensile moduli (0.111, 0.253 and 0.523 MPa), it was indicated that for fabric with a low tensile modulus, its tight compression merely changed as elongation increased; however, for fabric with a high tensile modulus, tight compression was promoted as elongation increased.

Influence of stabilization and short-term relaxation to compression generated by stocking welt

This research was carried out to investigate the influence of yarns and knitting parameters, stabilization, and relaxation processes on compression properties of knitted fabrics, used for stocking welt or other compression products. It is well-known that there is a high correlation between the mechanical properties of the fabric and its generated pressure. Also, it is proved that generated compression values decrease during the time they are being worn. In this research, it was found that course and wale density of knitted fabric, as well as tensile force values, increased after the stabilization process. Moreover, increases of linear density of core yarn (PU) of elastomeric yarn do not have direct linear influence to its generated tensile force. The results of short-term stress relaxation tests (300 sec) showed that the major alteration of the generated compression values appears during the first 100 sec period of relaxation process.

On the contribution of yarn–yarn slippage to woven fabric failure

Failure of woven fabrics involves an interaction between yarns, which can be predicted by yarn slippage. To investigate the contribution of yarn slippage to the failure, we analyzed the relation between various failure properties and critical slippage force (FS) using plain and twill weaves of fabrics with different characteristics. Results show that FS increases with yarn density and yarn linear density. The properties in tension for fabrics with different weaves, yarn density, and yarn linear density superimpose on master curves described by a linear relationship when expressed as a function of FS. The same linear behavior is observed when the critical jamming force of yarns expressed as a function of FS. For the tearing energy, a master curve is also obtained when expressed as a function of FS; however, the curve has a polynomial shape. FS thus appears as a valuable tool to predict the onset of damage in fabrics.

Influence of Woven Fabric Structural and Material Parameters on Dielectric Properties

There is much recent interest in antennas constructed from conductive fibers/ink and textiles. This study determines the influence of fiber material and the structure of a woven fabric on its dielectric properties. Results showed that both the dielectric permittivity and the dielectric loss tangent of the woven fabric were related to fiber contents and fabric structure properties, and generally decreased with increased porosity and decreased fabric compactness. ANOVA analysis showed that the linear density of yarn, fabric weaves, and fiber contents were major factors in determining the dielectric properties of woven fabrics. These results will provide a guideline for substrate selection in designing fabric-based electric device such as UHF RFID antennas.

Influence of thickness ratio and integrated weft yarn column numbers in shape memory alloys on the deformation behavior of adaptive fiber-reinforced plastics

The integration of functional material, such as actuator material, is an essential aspect for the multi-functionality and resource efficiency of fiber-reinforced plastics (FRPs). By integrating a textile-based actuator into reinforcing fabrics during the production process, single axis and intrinsic adaptive FRPs can be produced, and these can change their form according to requirements. However, this paper presents the effect of thickness ratio and integrated weft yarn column number in shape memory alloys on the deformation behavior of adaptive FRPs. In order to achieve this aim, shape memory alloys were converted into hybrid yarn in the form of a core-sheath structure before being textile-technologically integrated into the reinforcing fabrics using weaving technology. The thickness variation was achieved by the warp as well as weft yarn density and the type of interlacement. These preforms were infused by a thermosetting resin system. The adaptive FRPs were tested electro-mechanically with respect to their maximum deformation. Results reveal that the maximum deformation of adaptive FRPs is enhanced by increasing the thickness ratio and the integrated weft yarn column number in shape memory alloys.

Multi-objective Optimization of Woven Fabric Parameters Using Taguchi–Grey Relational Analysis

ABSTRACT Optimization technique is mainly used to find out the optimal value of control factors which yield the best response variables. In the case of more than one response variable, the optimization process using the Taguchi approach will give a different set of optimal level for each response variable. Consolidating Taguchi method with grey relation analysis will give optimal levels of control factors for all response variables. In the present study, multi-response optimization based on Taguchi-grey relational analysis was conducted to maximize tensile strength, breaking extension and air permeability of cotton woven fabrics. Cotton woven fabric parameters such as weft yarn count, weave structure, weft yarn density with three levels, and twist factor of the weft yarn with two levels were used as control factors. Using full factorial design, 81 experiments will be conducted. Whereas, using the Taguchi approach and L18 orthogonal array in particular, these experiments will be reduced to 16 experiments. Using Taguchi-grey relational method, optimal combination of the control factors which yield the best-woven fabric properties under study were obtained.

A study on the suitability of which yarn number to use for recycle polyester fiber

Recycling and reuse of materials is not new to the textile and apparel industry. Recycling refers to the breakdown of product into its raw materials in order for the raw material to be reclaimed and used in new products. The aim of the study is that the examining the usage of recycle polyester fiber (rPET) in different yarn count and blend ratio and so to determine which count and blend ratio is more suitable for rPET usage. For this aim, 24 yarns containing recycle polyester fiber, virgin polyester fiber and viscose fiber as raw material were obtained in different yarn counts which are Ne 10, Ne 20, Ne 30 and Ne 40, and in different blend ratios. Yarn diameter, density, shape (roundness), unevenness, imperfection, hairiness, and yarn tensile tests were applied to the obtained yarns. The findings obtained by experimental and statistical study show that rPET fiber has usually negative effects on the yarn properties in especially fine yarns due to physical and chemical deterioration caused by contaminants of during re-processing of recycle polyester fiber. Based on the findings it is revealed that the values of unevenness, imperfection, and density increase whereas the values of diameter, hairiness, and tensile decrease from coarse yarns to fine yarns. As a conclusion it is possible to say that rPET fiber is suitable for thick yarns which are especially Ne 10 and Ne 20 as pure and in all blend ratios, and rPET fiber is suitable if it is used in lower ratios than 65% for Ne 30 yarns, whereas it is suitable if it is used in lower ratios than 35% for Ne 40 yarns.

Flammability Characteristics of Animal Fibers: Single Breed Wools, Alpaca/Wool, and Llama/Wool Blends

Animal protein-based fibers used in textiles often are assumed to have uniform properties independent of source, and yet are different when considering texture, structure, and color. Differences between fibers from animal species have been studied in regard to general flammability behavior, but differences between fibers from breeds of the same species have not been studied. Fibers from two sheep breeds (Jacob, CVM/Romeldale) and two camelids (Alpaca, Llama) were studied for flammability effects on fabrics hand knit from yarns made from these different fibers. A total of five different yarns were studied: 100% Jacob, 100% CVM/Romeldale, 100% Alpaca, 50% Llama/Merino wool, and 50% Alpaca/Merino wool. Flammability was studied with cone calorimeter, microcombustion calorimeter, and vertical flame spread techniques. The results from this limited study demonstrate that there are differences between fibers from different breeds and differences between species, but the differences cannot be easily explained on the basis of inherent heat release or chemistry of the fiber. Sometimes yarn density and the tightness of the knit have more of an effect on self-extinguishment in vertical flame spread tests than does fiber heat release/chemistry. Pure Alpaca fiber, however, displays self-extinguishing behavior and low heat release when subjected to combustion conditions. This may be related to the amount of sulfur in its chemical structure, and its ability to be spun into a yarn which yields a tighter hand-knit density.

Green technology used in finishing process study of wrinkled cotton fabric by radial basis function (Experimental and modeling analysis)

The wrinkling of cotton fabric is an important factor that affects a garment's appearance. This paper evaluated the use of a non-toxic green anti-wrinkle material in the finishing process to address this issue. For this purpose, the chemical structure of the wrinkled cotton sample was evaluated and treated with a scouring and anti-creasing finishing material. Due to the environmental issues created by the toxic material used as finishes, the type of anti-wrinkle material used in this study had the least possible environmental impact. The mechanism of this anti-crease finishing was based on the crosslinking of cellulose molecular chains. This process limited the chain movements made by wrinkling. Accordingly, the effect of the mentioned mechanism and structural parameters such as the thickness, weight, density of the weft yarn, and linear density of the weft yarn (Ne) were evaluated. The wrinkle degree of the samples was analyzed by using a radial basis function neural network (RBFN). This RBFN modeled the relationships between the degree of wrinkling in the fabrics and the mentioned parameters, especially the anti-crease finishing of the samples. The simulation results confirmed the effectiveness of the proposed method.

The effects of metal type, number of layers, and hybrid yarn placement on the absorption and reflection properties in electromagnetic shielding of woven fabrics

In this study, stainless steel, copper, and silver wires were intermingled with two polyamide 6.6 filaments through the commingling technique to produce three-component hybrid yarns. The produced hybrid yarns were used as weft in the structure of plain woven fabric samples. The electromagnetic shielding effectiveness parameters of samples were measured in the frequency range of 0.8–5.2 GHz by the free space technique. The effects of metal hybrid yarn placement, number of fabric layers, metal types, and wave polarization on the electromagnetic shielding effectiveness and absorption and reflection properties of the woven fabrics were analyzed statistically at low and high frequencies separately. As a result, the samples have no shielding property in the warp direction. Metal types show no statistically significant effect on electromagnetic shielding effectiveness. However, fabrics containing stainless steel have a higher absorption power ratio than copper and silver samples. Double-layer samples have higher electromagnetic shielding effectiveness values than single-layer fabrics in both frequency ranges. However, the number of layers does not have a significant effect on the absorbed and reflected power in the range of 0.8–2.6 GHz. There was a significant difference above 2.6 GHz frequency for absorbed power ratio. An increase in the density of hybrid yarns in the fabric structure leads to an increase in the electromagnetic shielding effectiveness values. Two-metal placement has a higher absorbed power than the full and one-metal placements, respectively. The samples which have double layers and including metal wire were in their all wefts reached the maximum electromagnetic shielding effectiveness values for stainless steel (78.70 dB), copper (72.69 dB), and silver composite (57.50 dB) fabrics.

Design Method of Fabric Density Sensor Based on the Virtual Grating With Gradual Constant

In order to overcome the shortcomings of time-consuming and inefficient manual detection methods of fabric density, a fast and efficient automatic detection method of fabric density based on the digital grating is proposed. In order to realize automatic fabric density detection, the design method of the digital grating with gradual constant is described in detail on the basis of the principle of moiré pattern. The moiré pattern containing yarn density information of the fabric can be obtained by superimposing the captured fabric image and the digital grating image. After the moiré pattern is projected, the fabric density can be accurately determined by analyzing the distribution characteristics of projection curve. In the detection process, a digital grating image generated by computer is used to replace the physical grating, which not only makes the detection faster, but also make the system applicable for the fabric density detection of all kinds of specifications. Testing experiments were carried out on various fabric samples including fabrics in a plain weave and in a twill weave, the detection accuracy is more than 99.2% and the detection speed is much faster than the existing methods, which can meet the requirements of on-line detection in fabric production.

Multisection color-blended wool yarn produced by a new three-channel spinning method

By dynamically controlling the feeding amount and feeding ratio of the three feeding rollers with program logical control system under the requirements of yarn spinning parameters, it is possible to effectively configure the final yarn density and the blending ratio of three components to produce multisegment gradient yarns, segment-color yarn, and segment-color slub yarn named as multisegment blending yarns. The yarn-spinning new method was proposed. Different kinds of fancy yarns including gradient yarns, segment color yarns, and slub yarns were produced. The fiber blending effects were demonstrated by slices of yarn cross section, and the surface morphology of yarns were figured out by the photo of yarns. Integrally knitting seamless sweater and different type of pattern were designed and knitted by multisegment blending yarns. The free change of colors along the length direction on a single yarn provides an effective method for integrated rapid design and production of sweaters through mutual design of the overall pattern and the structure of the fabric.

EVALUATION OF ANTIBACTERIAL, MECHANICAL, AND COMFORT PROPERTIES OF WOVEN FABRICS CONSIST OF COTTON, BAMBOO, AND SILVER FIBERS

In this study, experimental and statistical evaluation of antibacterial, mechanical, and comfort properties of woven fabrics consisting of cotton, bamboo and silver yarns were presented. For the purpose of the study; cotton-bamboo and cotton-silver blended fabrics were produced, mechanical properties (such as tensile strength and tear strength) were investigated, antibacterial activities were determined, and thermal comfort properties (such as thermal conductivity, thermal absorption, thermal resistance, air permeability, water vapor permeability, and water vapor resistance) were measured. Statistical evaluations were performed by one way ANOVA and Tukey HSD and Tamhane’s T2 test methods. According to the outputs of the research, the mechanical and comfort properties can be improved and the antibacterial activities can be obtained of shirting and bedding fabrics by differing weft yarn type and density.

Study of Properties of Arselon Spun Yarn

The paper is devoted to development of the range of ring-spun yarns of Arselon fibers. Arselon is a polyoxadiazole heat-resistant fiber produced at JSC “SvetlogorskKhimvolokno” (Belarus). The investigated yarn count range was from 16 to 29 tex (Ne37 - Ne20). It was determined the influence of linear density of the Arselon yarn on its mechanical properties and evenness. In addition, it was shown that winding and assembling lead to significant reducing the number of frequently-occurred faults of 2-ply yarns. The developed range of Arselon yarns is the base for creation of new textile products such as woven and knitted fabrics and heat resistant goods which can be made of them.

Comparative study of cut and abrasion resistance performance of gloves made from high performance composite yarns

Cut resistant gloves are generally made from different types of high performance composite yarns. To achieve a certain level of cut resistance, material type, material composition and yarn linear density are changed which however make it sometimes difficult to decide the most suitable combination of the materials. In this work, eighteen seamless gloves were made by using core and sheath friction-spun yarns of various linear densities and core types, and their cut resistance performances were compared.For this purpose, eighteen composite yarns with three linear densities i.e. 118 tex (Ne 5), 98 tex (Ne 6) and 84 tex (Ne 7) were made on a friction spinning machine by using 5.55tex (50 denier), 11.11 tex (100 denier), 16.66 tex (150 denier), 33.33 tex (300 denier) multifilament glass yarns, and 89 denier (40 micron) and 139 denier (50 micron) monofilament steel yarn as core and Kevlar®29 staple fiber as sheath. Mechanical tests of the yarns showed that the tensile strength and tenacity of yarns increased as the linear density of glass yarns increased, whereas elongation at break and time to break increased with an increase of linear density of steel monofilament yarn. Coefficient of friction of all the yarns did not show any significant trend. Abrasion and cut resistance of the gloves made from 118 tex (Ne 5) composite yarn with 5.55tex (50 denier) glass yarn as core showed the best results, whereas no significant difference was seen in the dexterity of all the gloves.

New method for warp yarn arrangement and algorithm for pattern conversion for three-dimensional woven multilayered fabrics

Three-dimensional fabrics have an enormous potential for the manufacturing of semi-finished products in a direct preforming procedure for fiber-reinforced materials. The production of these three-dimensional fabrics involves the processing of coarse reinforcing yarns with high warp density. However, conventional weaving looms have not been designed for such applications, and their maximal achievable warp yarn density is therefore severely limited. Friction and clamping between warp yarns impede the shedding process, and fragments of damaged or fibrillated fibers interfere with the weaving process. Most of the solutions for these issues, which has been presented so far, are based on noncommercial technologies or require extensive modification on standard weaving machines. Hence this paper proposes a new shedding method based on double flat steel heddles, which is suitable for the use in conventional weaving looms. The paper gives a detailed description of the new shedding method including the required materials and the technological framework. Furthermore, a suitable algorithm for the fast pattern conversion under consideration of the special technological framework and requirements of the shedding is presented.