Modified Ring Spinning System Research Articles

Mechanically-enhanced structural composites yarns with multifilament-spreading technique using a modified ring spinning system and predicting modelling

To advance spinning technology for multifilament covered cotton fibers, a spreading apparatus was introduced to ring spinning. This innovation allowed the manufacturing of a composite yarn with a wrapped structure. However, an effective strategy for predicting the mechanical properties of multifilament spread composite structural yarns (FS-CSY) was urgently needed. In this study, researchers compared FS-CSY with bi-component composite yarn (b-CY) to determine if the addition of a spreading apparatus and twisting in the manufacturing process resulted in any improvements or enhancements. The FS-CSY structure was found to be novel and exhibited significant mechanical properties, including a 4.7% increase in tensile strength compared to b-CY. A strategy was developed to predict FS-CSY by considering the transfer impact of fiber enhancement within the yarn and by incorporating two-component interaction forces in the yarn-wrapped structure. Meanwhile, a modified three-element tensile constitutive model was established to effectively simulate the stress characteristics under different twist levels, which proved the composite yarn prediction theoretical model. Finally, the fracture morphology analysis shown the b-CY fracture surface was irregular, while FS-CSY exhibited a uniform fracture surface, and the 750TPM showed a more uniform and stable structure. By developing this predictive strategy, enhance existing structural composite yarn by maximizing the efficiency and quality of multi-filament covered cotton fibers. Ultimately, this research contributes to advancements in textile manufacturing processes and lays a foundation for future innovations.

A theoretical model to investigate the performance of cellulose yarns constrained to lie on a moving solid cylinder

Cellulose fibers, such as cotton and linen, are abundant in farmer’s fields. The traditional bottom-up technology to process these short staple fibers is spinning. State-of-the-art spinning technology requires not only high throughput processing of the cellulose fibers, but also the addition of functionalities and value into the supply chain. Recently, a modified ring spinning system has been developed which introduces a false twist into a traditional ring spinning frame. The modified system produces cellulose yarns that have a high strength but low twist, and a soft hand similar to cashmere. Unlike traditional textile finishing treatments which consume plenty of chemicals, water, and energy, this method is purely physical and sustainable. The superior properties of the modified cellulose yarns are attributed to the modified yarn morphology and structure. Theoretical investigation is, therefore, important in understanding of the spinning mechanisms of the modified ring spinning process that changes the morphology and structure of the cellulose yarns. In this paper, yarn behavior constrained to lie on a moving solid cylinder was theoretically and experimentally investigated. Equations of motion were derived based on the Cosserat theory and numerical solutions in steady-state were obtained in terms of yarn spatial path, yarn tension, twist distribution, yarn bending, and torsional moments. Effects of various spinning parameters including wrap angle, speed of the moving cylinder, yarn diameter, yarn tension, yarn twist, and frictional coefficient, on yarn behavior were discussed. The results suggested that in most cases the bending and torsional moments are of the same order of magnitude, and thus the effect of bending cannot be neglected. Experiments in the modified ring spinning system were conducted to verify the theoretical work, and good agreement has been made. Some simulation results of this study were compared with the results of earlier models as well as with experimental data, and it was found that the current model can obtain a more accurate prediction than previous models in terms of yarn twist and tension. The results gained from this study will enrich our understanding of the spinning mechanism of the modified ring spinning process and better handle of cellulose fibers for functional and value-added applications.

Twist-dependent behavior of helical-shaped elastic composite yarns containing metal wire produced on a modified ring spinning system

Herein, the effect of twist on physical properties such as tensile, hairiness and wicking behavior of our reported tri-component elastic-conductive composite yarns (t-ECCYs) was systematically studied. Experimental results revealed that an optimum twist value provided the maximum yarn strength. A positive relation between extension at break and twist was observed. Significant differences in the tensile behavior is established. Two-parameter Weibull distribution and boxplots were used to quantify the variation in yarn strength. The role of spinning geometry and variation in twists on hair formation was highlighted, with an increase in twist reducing yarn hairiness. In addition, t-ECCYs with higher twist exhibited poorer wickability, and there was a gradual increase of the equilibrium height of yarn under extension. Importantly, the results demonstrated that the Laughlin-Davies wicking model was valid for t-ECCYs under tested conditions. It is promising that the as-fabricated t-ECCYs is prerequisite for the next wave of smart yarns and large-scale stretchable protective devices, such as superstretchable helical-structured yarn heaters and elastic electromagnetic shielding fabrics.

A comparative study on performance characteristics of multicomponent core-spun yarns containing cotton/PET/elastane

This paper experimentally investigated the characteristics of different (filament and multicomponent) core-spun yarn type. Filament core-spun yarns comprised cotton covered drawn textured (DTY) polyester (PET) filaments with four different filament finenesses. Regarding the production of multicomponent (dual) core-spun yarns, both PET with four different filament finenesses and elastane with four levels of draft variable were fed simultaneously. Yarn samples were produced with modified ring spinning system at the same spinning conditions. As a control group, 100% cotton ring-spun yarn was also manufactured. Tensile properties, unevenness, imperfections and hairiness of yarn samples were determined. Also, fatigue characteristics of yarn samples were examined at two different loading of cycles. The results showed that filament fineness had a significant effect on all yarn properties being determined. Dynamic modulus and dynamic strain properties of yarns, filament fineness, elastane draft and number of cycle were found to be statistically significant at 0.05 level.

Yarn and fabric properties in a modified ring spinning system considering the effect of the friction surface of the false-twister

This paper experimentally studies the relationship between the friction surface of a false-twisting unit and the quality of cotton yarns produced by a modified ring spinning system, with the adoption of the single friction-belt false-twister. The friction surface of the false-twisting unit, as a key twisting component, has been studied in terms of material, surface roughness, hardness and diameter, as well as the interaction between these factors and resultant yarn properties, with particular attention to yarn imperfections. Experimental results showed that the false-twisting unit with a short interactive path demonstrated significant reduction of yarn imperfections, especially yarn neps. With the optimal false-twisting unit, performances of the modified yarns and their knitted fabrics were evaluated and compared with the conventional ones.

Yarn and fabric properties in a modified ring spinning system considering the effect of the friction surface of the false-twister:

This paper experimentally studies the relationship between the friction surface of a false-twisting unit and the quality of cotton yarns produced by a modified ring spinning system, with the adopti...

Systematic investigation of twist generation and propagation in a modified ring spinning system

Twisting is an important process used to form a continuous yarn from short staple fibers and to determine the structure and properties of the resultant yarn. This paper systematically examines the yarn twisting process in a modified ring spinning process based on a theoretical model proposed recently. To reduce the number of experiments, response surface methodology (RSM) involving a central composite design (CCD) in three factors—twist multiplier, speed ratio and wrap angle—was successfully employed for the study and analysis. The significant terms of the models were studied, and it was discovered that the speed ratio and wrap angle are statistically significant for the responses of twist efficiency, propagation coefficients of twist trapping, and congestion. More importantly, linear relationships were found among the three responses.

Theoretical study of the effects on yarn strength in a modified ring spinning system

A modified ring spinning system using a dynamic twist-resistant device has been employed to produce yarn. The modified device blocks twist to propagate to the spinning triangle, which changes the distribution of twist in the spinning area and increases the height of the spinning triangle. In this paper, two kinds of yarn counts (30 and 40 Ne) are spun in the conventional and modified ring spinning with twist multipliers of 3.2, 3.6, and 4.0. The results show that the yarn spun by the modified ring spinning system possesses a higher strength compared with the conventional yarn except in the higher twist multiplier. The increase in yarn strength was theoretically analyzed according to the model of yarn strength. The yarn strength was calculated by considering the original fiber strain in the yarn and the fiber strain due to yarn strain. In the model, the fiber migration was considered and the fiber entanglement caused by fiber migration was ignored to simplify the calculation. Four potentially important parameters of the spinning triangle, the height of the spinning triangle, the migration coefficient, the inclination angle, and the spinning tension, were proposed and their individual and interaction effects on yarn strength were analyzed. The results demonstrate that yarn strength increased with the increase of height of the spinning triangle and the migration coefficient. The inclination angle and the spinning tension have a relatively small influence on yarn strength when the height of the spinning triangle is higher.

Comparative Study on Carded Cotton Yarn Properties Produced by the Conventional Ring and New Modified Ring Spinning System

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Porosity and air permeability relationship of denim fabrics produced using core-spun yarns with different filament finenesses for filling

In this article, porosity and air permeability of denim fabric produced from filament core-spun yarns with different filament fineness and yarn linear density were demonstrated. For this purpose, 110 dtex drawn textured polyester filaments with conventional, fine, and micro finenesses were used as core part, and combed cotton fiber was used as sheath part to obtain core-spun yarns with four different yarn linear density on a modified ring spinning system with the same spinning parameters. Besides the production of core-spun yarns, 100% cotton ring-spun yarns were produced as control group at the same conditions for each yarn linear density, as well. To evaluate the effect of filament fineness and yarn linear density on air permeability and total porosity, denim fabrics were obtained by using 24 yarn samples as weft at the same cover factor with four determined weft densities. Results showed that filament fineness and yarn linear density have a significant effect on total porosity and air permeability at a significance level of 0.05. In addition, high correlation (79.4%) between air permeability and total porosity of denim fabric samples was observed at a significance level of 0.01.

Fatigue behaviour of core-spun yarns containing filament by means of cyclic dynamic loading

The behaviour of yarns under dynamic loading is important that leads to understand the growth characteristics which is exposed to repetitive loadings during usage of fabric made from these yarns. Fabric growth is undesirable property that originated from low resilience characteristics of fabric. In this study, the effects of the filament fineness and yarn linear density on fatigue behaviour of rigid-core spun yarns were determined. Cotton covered yarns containing different filament fineness of polyester (PET) draw textured yarns (DTY) (100d/36f, 100d/96f, 100d/144f, 100d/192f and 100d/333f) and yarn linear densities (37 tex, 30 tex, 25 tex and 21 tex) were manufactured by using a modified ring spinning system at the same spinning parameters. Repetitive loads were applied for 25 cycles at levels between 0.1 and 3 N. Dynamic modulus and dynamic strain of yarn samples were analyzed statistically. Results showed that filament fineness and yarn linear density have significance effect on dynamic modulus and dynamic strain after cyclic loading.

A Study on Physical Properties of Microfilament Composite Yarns

In the textile industry, composite yarns with multifilament cores are used to impart strength. There are various spinning systems to produce composite core-spun yarns. In this study, to determine the effects of filament fineness on yarn characteristics of composite yarns, polyester filaments with medium, fine and micro fiber linear densities were used as the core portion and cotton fiber was used as the sheath material. Yarn samples were manufactured using a modified ring spinning system with four different yarn counts and constant twist factor (ae). The effect of filament linear density on yarn tensile properties, unevenness and imperfections was determined. Yarn evenness and tensile properties were compared with 100% cotton ring spun yarn and to each other. When relative amount of core increases, it was observed that composite yarns had improved tenacity and elongation compared to 100% cotton ring spun yarn. Although filament fineness was found to have a significant effect on the CVm % properties, there was no statistical effect on imperfections other than yarn count parameter.

Research on flow field in a modified ring spinning system with the air nozzle

Twisting is one of the most important steps in the yarn spinning, which influences the geometry of spinning triangle and determines the properties of spun yarns. Airflow is one of the most important measures on improving yarn spinning. In this paper, a kind of air nozzle with vortex guiding channel was designed and used on the modification of ring spinning system, and the spun yarn qualities was studied by analyzing the airflow field in the nozzle. Firstly, the three-dimensional physical model of nozzle was given using CAD software according to the geometrical size of the practical nozzle model. Then, the numerical simulations of the three-dimensional flow field in the nozzle were given using Fluent software. Finally, two different kinds of yarns 10Ne and 20Ne were spun in the modified ring spinning system with the nozzle installed. The airflow pressure 0.01 Mpa and two different swirling directions, anticlockwise and clockwise, were chosen. The qualities of spun yarns, hairiness, strength, evenness, and number of snarling were measured and analyzed. It is shown that the high vortex airflow can be produced in the nozzle, and then corresponding twist can be produced. For the Z(S) twisting spun yarn, under the effects of the clockwise (anticlockwise) vortex airflow, the pre-twisting would be produced and the yarn twist can be strengthened, while under the effects of the anticlockwise (clockwise) vortex airflow, the untwisting effect would be produced, and the yarn twist can be decreased.

Theoretical Study of Effect of Ring Spinning Triangle Division on Fiber Tension Distribution

The spinning triangle is a critical region in the spinning process of staple yarn. Its geometry influences the distribution of fiber tension at spinning triangle directly and affects the qualities of spun yarns. Taking appropriate measures to change the ring spinning triangle geometry and improve the qualities of yarn has attracted more and more interest recently. Spinning triangle division is one of the most effective measures, such as solospun technology. Therefore, in this paper, the effect of ring spinning triangle division on fiber tension distribution was studied theoretically. The general case that the spinning triangle is divided into two parts, primary triangle and final triangle, was investigated. Firstly, theoretical models of the fiber tension distributions in the final and primary spinning triangles are given respectively using the principle of minimum potential energy. Secondly, the fiber tension distributions in the spinning triangle with different shape parameters are numerically simulated. Finally, the possible effects of ring spinning triangle division on yarn qualities are analyzed according to the numerical simulations and previous results. In addition, the properties of spun yarns produced by the modified ring spinning system were evaluated and analyzed.

Investigation on production, analytical models, and characteristics of monofilaments/staple fibers composite yarn

This study aims to develop a composite yarn comprising monofilaments/staple fibers with distinctive structures and performance. A modified ring spinning system was proposed for producing the composite yarn with three monofilaments and staple fibers. The spinning mechanism was analytically modeled, and the structures of composite yarn were studied by scanning electron microscopy and optical microscopy. The characteristics of polyester monofilaments/cotton composite yarns and the conventional cotton yarns were compared. Analytical and experimental results showed that three monofilaments were distributed around the yarn center forming a 3D spiral, and the staple fibers interlaced inside and wrapped outside of the composite yarn. Experimental results showed that the composite yarn had better tensile properties, less hairiness, and stronger abrasion resistance. As a result, the composite yarn exhibited a remarkable improvement over the conventional yarn, which could be a valuable proposition for specific purposes, such as offering fabrics with shape preservation based on good yarn’s rigidity, and even electromagnetic shielding effectiveness with metal monofilaments in yarns.

Theoretical study of fiber tension distributions at the twist point

Purpose – Spinning triangle is a critical region in the spinning process of staple yarn, which geometry influences the distribution of fiber tension and determines the qualities of yarn directly. Therefore, the purpose of this paper is to investigate the fiber tension distribution at the twist point. Design/methodology/approach – First, one theoretical model of fiber tension distributions at the twist point is given according to the motion law of fibers in the spinning triangle. Then, one calculation method of fiber tension at the twist point is given by two steps. First, the initial tension of each fiber at the front nip line caused by the yarn load should be calculated according to the models obtained based on the principle of minimum potential energy. Second, the fiber tensions at the twist point can be calculated using the obtained model in this paper. Finally, as an application of the proposed method, spinning triangles of a modified ring spinning system with a pair of offset device which can change the horizontal offset of the twist point to the symmetric axis of nip line of the spinning triangle continuously are studied. The fiber tension distributions are simulated numerically. Findings – It is shown that the fiber tension distributions at the twist point can be determined by fiber feeding into and out the spinning triangle speed, the initial tension of each fiber at the front nip line, fiber tensile Young’s modulus and cross-sectional area, the number of fibers at spinning triangle and the individual fiber angle with the center fiber. The spinning experiment shows that taking appropriate right or left offset of the spinning triangle can help to improve the spun yarn qualities. Originality/value – In this paper, the fiber tension distribution at the twist point is investigated. One theoretical model of fiber tension distributions at the twist point is given according to the motion law of fibers in the spinning triangle first. Then, one calculation method of fiber tension at the twist point has been given under the assumption that the initial tension of each fiber at the front nip line is caused by the yarn load.

Investigation and evaluation on fine Upland cotton blend yarns made by the modified ring spinning system

A modified ring spinning technology has been successfully applied to the production of yarns with reduced twist level and improved performance. Various US cottons and Chinese cottons have been covered in previous studies. In this paper, three combed rovings with different blending ratios of Upland and Extra Long cottons were adopted in a systematic investigation and evaluation on a fine modified ring yarn produced on a new modified spinning system that was developed to reduce the imperfections of fine yarns. The potentially important spinning parameters were proposed and their individual and interaction effects of spinning system parameters on the properties of fine modified ring yarn were quantitatively examined using the response surface methodology. Then with the optimum parameters, physical properties of the yarns and their knitted fabrics produced from three rovings were evaluated by comparing them with the conventional ones. Experimental results showed that yarns produced in the new modified spinning system had reduced imperfections; at low twist levels, fine modified yarns and resultant fabrics also showed improved performance. Moreover, properties of fiber materials and roving quality influenced the properties of modified yarns and knitted fabrics.

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.

Systematic investigation and optimization of fine cotton yarns produced in a modified ring spinning system using statistical methods

A modified ring spinning technique has been recently developed by incorporating false twisting devices into a conventional ring frame for producing a low torque and soft handle singles yarn. Our previous studies showed that this technology can be applied for producing coarse modified yarns (7–32 Ne) with improved yarn and fabric performance. The present paper extends the work for the production and optimization of modified yarns at a fine yarn count (80 Ne). Compared with the conventional ring spinning system, the modified system presents a different and complicated spinning condition in terms of yarn tension and twist distributions, as well as the interaction between the false twisting device and conventional ring frame. Therefore, this paper aims to systematically investigate the quantitative relationship between spinning system parameters and physical properties of the fine modified yarns using the combined statistical methods of fractional factorial and response surface methodology. In this paper, potential spinning system parameters are proposed and the significances of their effect on yarn properties are quantitatively evaluated. Then the statistical relationships between the significant system parameters and the properties of fine modified yarn are fully examined and optimized. With these optimum parameters, the fine modified yarn and woven fabric were produced and their properties were assessed and compared with the conventional ones.

A Modified Ring Spinning System with Various Diagonal Yarn Path Offsets

A modified ring spinning system was proposed to make various diagonal yarn paths and offsets by equipping a traverse guide between delivery roller nip and lappet guide while the yarn leaving the front roller nip threaded through the traverse guide and went to bobbin below. Test properties of yarn counts 20s, 40s, 60s (100% cotton), spun on the modified yarn path system under various right & left diagonal offset d = 0, 6, 12, 18mm. with a high speed camera, photographs of spinning triangle in different diagonal paths were captured and studied. The results suggested this modification system could improve yarn hairiness without changing tensile and unevenness properties greatly in right diagonal path. The maximum reduction of 3-9mm long hairiness from Ne 20, Ne 40 to Ne 60 was 42.6%, 28.5% and 21.3%. The coarser yarns received more significant improvement on hairiness. It is observed that diagonal path is the most important factor to decide yarn hairiness over all counts of yarns.