Open-end Rotor Spinning Research Articles

Quality Assessment of Socks Produced from Viscose and Lyocell Fibers.

Most casual socks are produced from cotton and are usually combined with synthetic fibers. The suitability of viscose and lyocell fibers for knitting socks needs to be investigated further. Therefore, three series of plain socks were produced, composed in the largest content from single-spun viscose or lyocell yarns fully plated with texturized polyamide 6.6 multifilament yarn. The quality of three types of main yarns manufactured by ring, open-end rotor, and air-jet spinning processes and two types of polyamide plating yarns used in the production of socks were assessed together with the structural, usage, and comfort quality of the socks before and after simulating household laundering. In comparison with cotton socks produced from ring-spun yarns under the same conditions, the results showed that viscose and lyocell socks have better moisture absorption and breathability, comparable dimensional stability, and lower abrasion resistance; lyocell socks have lower thermal resistance; and viscose socks are less prone to surface pilling after wet pretreatment.

Valorization of fabric wastes through production of recycled cotton yarns by compact ring and open-end rotor spinning

This study aims to determine the appropriate methods and parameters for the eco-friendly and sustainable production of finer yarns from recycled cotton fibers with acceptable quality and high recycled fiber ratios to transform pre-consumer textile wastes into better-quality products with value-added in the ready-made clothing industry. Cotton fibers were mechanically recycled from dyed fabric wastes. Mélange 100% cotton yarns were produced with different recycled/virgin fiber blend ratios (80/20, 72/28, 64/36, and 56/44) at different yarn counts (30 and 20 tex) and by different spinning methods (compact and open-end spinning) without any chemicals treatment. The yarn properties were tested and compared to determine the best production parameters. As a result of the study, it was seen that the yarn properties improved when the proportion of virgin cotton fiber in the yarn increased in parallel with previous studies. Besides, the yarn hairiness and unevenness of open-end yarns were better than compact yarns. On the other hand, using the compact spinning method led to higher yarn tenacity. The results indicated that the compact spinning method is advantageous in achieving the target of increasing the ratio of recycled fiber use with good tenacity for the production of %100 cotton yarns.

The quality comparison of open-end rotor-spun yarns produced from cotton waste in gray state and after dyeing

To demonstrate the limits of open-end rotor spinning, the outstandingly contaminated slivers were prepared from various blowroom waste mixed with virgin cotton and noils and processed to yarn. The aim was to simulate the processing of highly contaminated cotton waste to open-end rotor yarn sustainable way and analyze the impact of trash, dust, or fiber neps in slivers to yarn quality. To verify whether the dyeing of these yarn for given final use should be adjusted, yarns with high rustic appearance and yarns containing 20% residual bleached and optically brightened fibers possibly not evenly distributed are analysed before and after dyeing. The experiment proves that the processing of 98tex and 29.5tex yarns from outstandingly contaminated sliver via R37 with exchangeable trash channel is possible at acceptable quality for denim, home textile, or linen and ensures most of the demands related to user properties and durability, including uniform staining.

Effect of ring and rotor spun yarns on denim fabric properties

PurposeThe purpose of this study is to investigate the mechanical properties of denim fabrics constructed from ring-spun and open-end rotor spun yarns.Design/methodology/approachYarns of 10s Ne count using cotton fibers were spun using the ring and open-end rotor spinning technologies. The yarns were used to produce a denim fabric on an air-jet loom with a 3/1 twill weave structure. Mechanical tests – tensile strength, tear strength, abrasion resistance and pilling resistance – of denim fabrics were evaluated. The test results were analyzed using analysis of variance with the help of Software Package for Social Sciences.FindingsDenim fabrics made by using ring-spun yarns exhibited better tensile and tear strength properties than denim fabrics made by using open-end rotor spun yarns. On the contrary, denim produced using open-end rotor yarns have better abrasion resistance, pilling resistance and air permeability than those produced using ring-spun yarns.Originality/valueBoth spinning techniques have a significant influence on the properties of denim fabrics. Whenever better tensile and tear strength is required, it is better to use ring-spun yarns, while if the requirement is better abrasion resistance and pilling resistance with high air permeability, then open-end rotor spun yarns shall be used.

Analysis of Cotton Yarn Properties Spun on Aerodynamic Compact and Open-End Rotor Spinning

This article presents a comparative analysis of the properties of cotton yarn spun on aerodynamic compact spinning and open-end rotor spinning systems. Yarn samples with a linear density of 50 Tex, 37 Tex, 30 Tex, 25 Tex, and 20 Tex were spun both on the aerodynamic compact and rotor spinning systems using the same finisher drawn sliver of medium staple cotton which were produced by a specific mixing. The quality parameters such as mass variation, imperfection index, hairiness, and tensile behavior (strength in count strength product, elongation percentage) of the yarn samples were assessed and analyzed. The results revealed that aerodynamic compact spun yarn had a lower unevenness and mass variation, a higher imperfection in case of a finer count, less hairiness, higher tensile strength, and lower elongation% compared to the open-end rotor spun yarn samples. Finally, paired- samples t-test and regression analysis were carried out by using IBM SPSS 25 to check the significance of yarn quality parameters and correlation among them.

A Comparison of Color Fastness Properties of Mulberry Silk and Tussah Silk Fabrics in Blends with Cellulosic Fibers

ABSTRACT Although it has been used for centuries; silk’s appearance, touch, and other high-quality properties maintain the popularity of the fiber. However, there are different types of silkworms, so different types of silk fibers are available. Other than Mulberry silk there are some others: eri, muga, tasar and tussah, which are generally deemed “wild silk”. In this study, color fastness properties of one of these wild silk fibers: tussah was investigated in comparison with mulberry silk fiber. For comparison, mulberry and tussah silk fibers were blended with cotton, viscose rayon, and modal fibers and spun using open-end rotor spinning system. After yarn productions; single jersey fabrics were knitted, pretreated and dyed. Color fastness tests were made to evaluate the performances. Results indicate that both types of silk fibers are appropriate for spinning and knitting processes and the fastness results revealed that mulberry fibers resulted with better color fastness properties in comparison with tussah silk fibers

Simulation of the Effect of Geometric Parameters of the Fibre Transport Channel in Open-End Rotor Spinning

assa

Use of Taguchi Method and Grey Relational Analysis to Optimize Multiple Yarn Characteristics in Open-End Rotor Spinning

Abstract Rotor speed and twist per metres (tpm) are two key parameters in open-end rotor spinning of cotton yarns. High spinning productivity can be obtained by keeping the rotor speed high and twist level as low as possible. However, too high rotor speed may result in yarn imperfections and too low twist level may result in lower tenacity yarns. This study aimed at optimising the multiple yarn characteristics in open-end rotor spinning using the Taguchi method and the grey relational analysis. Cotton yarn samples of 30 tex were produced on rotor spinning machine with different twist levels (i.e. 500, 550, 600 and 700 tpm) at different rotor speeds (i.e. 70,000, 80,000, 90,000 and 100,000 rpm) according to the Taguchi design of experiment. Optimal spinning process parameters were determined using the grey relational grade as the performance index. It was concluded that for the cotton fibres and yarn count used in this study, optimum properties of the yarns could be obtained at 90,000 rpm rotor speed and 700 tpm.

Theoretical Modeling for Predicting the Optimum Twist Angle of Cotton Fiber Movement on OE Yarn Made by Rotor Spinning Machine

This paper presents theoretical modeling for predicting the optimum twist angle on yarn made by open end rotor spinning machine in textile industry. Fiber movement on yarn can be used for predicting the optimum twist angle which can be used to reduce yarn breaking in spinning process. In this research the twist angle has been found and the result of this research shows the twist angle around 45°; and the theoretical result of the ratio of rotor diameter to fiber length is .

A study of processing parameters in open-end spinning process for organic cotton (Ne 24)

Organic cotton has become a popular product in recent years due to its environmental friendliness. Different from conventional cotton, the planting of organic cotton does not use pesticides, herbicides, or fertilizer, which can cause degradation in soil fertility, water and natural equilibrium. Organic cotton crop rotation can build strong soil, retain water more efficiently, maintain a balance between pests and their natural predators, and control weed growth. This study presented a yarn spinning process using organic cotton as the raw material. An open-end rotor spinning machine was used in the spinning process. To analyze the processing parameters affecting yarn qualities, the Taguchi method and response surface methodology were used to design an orthogonal array experiment and to find the relationship between controllable input parameters (i.e. feed speed, winding speed, and rotor speed) and output qualities (i.e. strength, unevenness, imperfection indicator/km, and hairiness). To find the optimal parameter combination, two popular optimization methods, particle swarm optimization and genetic algorithm, were used. The results showed that with optimal parameters (0.345 m/min, 34.717 m/min, 82,599 rpm for feed speed, winding speed, and rotor speed, respectively), the proposed method can find optimum values in all observed qualities. A confirmation experiment was conducted to validate the results.

Prediction system of open-end rotor spinning process based on LM-neural network for bamboo charcoal fibers

In line with the environmental protection trends of the 21st century, bamboo charcoal fiber is invented to meet the requirements of the fields of science and technology. Its special functionalities, namely, antistatic, moisture adsorptive, perspiring, antibacterial, deodorizing, anti-radiation, and far infrared properties make it extremely suitable for applications in medicine, sports, and recreational fields, as well as an important breakthrough for environmentally-friendly textile materials. To achieve rapid manufacturing, this study processes bamboo charcoal fibers by open-end (OE) rotor spinning. The Taguchi orthogonal array is applied to the design of this experiment, and the significant factors of fibers quality are obtained through ANOVA in order to facilitate the follow-up processes of quality control. The process prediction system is built based on the test data, and is combined with the back-propagation neural network and the Levenberg-Marquardt (LM) algorithm in order to establish an OE rotor spinning process prediction system. The rotor speed, feed speed, and winding speed are set as the network input parameters, while the yarn strength, the hairiness, the unevenness, and the imperfections indicator (I.P.I.) are the output parameters. Through network learning and training, this system reports a prediction error below 5 %, proving that this prediction system has excellent predictability.

Optimization of Open-end Rotor Spinning Frame Parameter and Estimation of Relevant Quality Characteristics

The high-cleaning Lyocell fibers are used to spin the Ne 32 yarns for an open-end rotor spinning frame. The optimal processing parameters were obtained in demonstrating output speed, stretching roller speed, feed speed and rotor revolution. The quality characteristics, such as yarn count, strength, elongation and Um (%), are far beyond the rating standard of the combed yarn. No yarn breaking for continuous spinning during the experimental confirmation. The result presents lower yarn breaking rate and maintains stabilized output status of spinning conditions. The back propagation neural network was employed for learning, forecast and verification of the processing parameters.

Processing parameters optimization of multiple quality characteristics of open-end rotor spinning process for Bamboo charcoal and CVC blended fibers

In the field of yarn spinning engineering, the importance of the processing parameters taken depends directly on the quality characteristics of the yarn. This study aimed to find the optimal processing parameters for an open-end rotor spinning frame at work to identify its multiple quality characteristics for yarn. In this study, Bamboo charcoal and cotton 70 %/polyester 30 % (CVC) blended fibers were adopted as the materials, and the open-end rotor spinning frame was used to spin the yarn. In order to identify optimal conditions of an open-end rotor spinning frame, the Taguchi experimental method was applied to design open-end rotor spinning experiments, and the L9 orthogonal array was chosen in accordance with nine sets of experiments and contained four control factors and three levels. Furthermore, a response surface methodology (RSM) was used to obtain the models of significant processing parameters for the strength, unevenness, I.P.I, and hairiness. Based on experiments designed to obtain an open-end rotor spun yarn Ne 30, the strength, unevenness, imperfection indicator/km (I.P.I) and hairiness were then chosen as the quality characteristics. In addition, grey relational analysis integrated the optimal processing parameter of multiple quality characteristics, and a confirmation experiment was performed. In conclusion, the optimal processing parameters under steady spinning conditions were a rotor speed of 88000 rpm, a feed speed of 0.392 m/min, and a winding speed of 39.466 m/min.

Spinning performance and antibacterial activity of SeaCell® active/cotton blended rotor yarns

Microorganisms can lead to functional, hygienic and aesthetic (e.g. deterioration, staining) problems on textile products. Natural fibers especially cotton are more easily affected by microorganisms. Blending of cotton fibers with antimicrobial fibers can enhance the protective properties of products against microorganisms. Demand of antimicrobial performance from the products changes depending on the application area. Therefore determination of suitable antimicrobial fiber quantity for the desired application is important. In this study the spinning performance of SeaCell Active/cotton blended open end rotor yarns and antibacterial activities of fabrics produced by these blended yarns were investigated. Five different cotton/SeaCell Active blended slivers with SeaCell Active content from 3 % up to 53 % were prepared on drawframe machine and all slivers were spun into yarns on open end rotor spinning machine at a yarn count of 20 tex with αTt=3827 twist coefficient. The effects of rotor speed, opening roller speed, rotor, opening roller and navel type on the quality parameters of SeaCell Active/cotton blended yarns were investigated. Tensile properties, hairiness, unevenness and IPI values of the yarns were reported. All types of cotton/SeaCell Active blended yarns were knitted on a circular knitting machine. Antibacterial activity of the fabrics was analyzed quantitatively. Antibacterial tests showed that good antibacterial activity can be achieved after several washings even with 3 % of SeaCell Active fibers in fabrics.

Stretch Properties of Cotton Hollow Yarns Made by Hybrid Open-End Rotor Spinning Frame

Many yarns are made from chemical fibers with various kinds of functional properties, and filament yarn surpasses spun yarn in terms of mechanical properties. However, in this century, “comfort”, “safety”, “user-friendly” and “green” are key concepts. The Food and Agriculture Organization of the United Nations (FAO) officially launched the International Year of Natural Fibers (IYNF) 2009 to celebrate the virtues of cotton, flax, sisal and hemp, and also those of wool, alpaca, camel hair and angora. In order to make effective use of natural fibers and reduce carbon dioxide emission, it is worthwhile to design and develop new spun yarns from vegetable fibers.It is also known that, in comparison with ring spun yarn, open-end spun yarn is inferior in quality. So, to produce open-end rotor spun yarn with novel functional properties, we investigated how to give it greater extension (and/or stretch), as in synthetic filament yarn. Thus, 100% cotton hollow yarns were produced using a hybrid open-end rotor spinning frame and an experimental covering machine, and the resulting mechanical properties were assessed.

Comparison of the new methodologies for predicting the CSP strength of rotor yarn

This paper provides preliminary results on the relative performance of the adaptive neuro-fuzzy system inference (ANFIS) model versus linear multiple regression method, when applied to the use of cotton fiber properties to predict spun yarn strength obtained from open-end rotor spinning. Fiber properties and yarn count are used as inputs to train the two models and the output (dependent variable) would be the count-strength-product (CSP) of the yarn. The predictive performances of the two models are estimated and compared. We found that the ANFIS has a better average prediction successful in comparison with linear multiple regression model.

Effect of Filament Over-Feed Ratio on Surface Structure of Rotor-Spun Composite Yarns

Different kinds of rotor-spun composite yarns are produced by combining staple fibers with filament yarns under various filament over-feed ratios on a modified open-end rotor spinning frame. The effects of filament over-feed ratio on the surface structure of composite yarns were studied and the results showed that the filament over-feed ratio had a remarkable effect on the pathway of the filament in the composite yarns. As the filament tension increased with decreasing filament over-feed ratio, the filament moved from the surface into the center of the composite yarn, the pitch of the filament pathway increased and the filament twist decreased gradually. The surface structure of the rotor-spun composite yarn was improved in comparison with the normal rotor-spun yarn.

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.

Characteristics of Rotor Spun Cotton/Spandex Composite Yarns

Spandex fibers have superior stretch and elastic recovery ability, which is why clothes containing spandex fibers fit well and are comfortable. The most common methods of producing elastic yarns are core-spun on a modified ring frame and hollow spindle technique. Rotor spinning has many advantages over ring spinning and has been adopted worldwide. In this paper, a method of producing the cotton/spandex composite yarns on a modified open-end rotor spinning is introduced. By changing the draft ratio and linear density of spandex filaments, different kinds of cotton/spandex composite yarns are produced on a modified rotor spinning frame, and their appearance and properties are tested and analyzed at the same time. The results show that the spandex draft ratio has great influence on the appearance and properties of rotor spun cotton/spandex composite yarns. The linear density of spandex filaments also has influence on the properties of composite yarns.

Structure and Properties of MVS Yarns in Comparison with Ring Yarns and Open-End Rotor Spun Yarns

The structure and properties of Murata vortex spun yarns are investigated and compared with ring and open-end rotor spun yarns. Cotton yarns are spun from the same lot of Australian raw cotton fibers using the Murata vortex, ring, and open-end rotor spinning methods. Yarn structures are observed with an optical microscope equipped with a digital camera. Based on the digitized photographs, fiber arrangements are classified as wild, wrapper-wild, wrapper, belly-band. and core. Yarn diameter, yarn helix angle, wrapper fiber pitch, wrapper fiber crest, wrapper fiber length for a one-turn twist, and wrapper fiber helix angle to the yarn axis are examined, and yarn parameters such as tenacity, evenness, and hairiness are evaluated. The mechanical properties of dry relaxed yarns are measured with Kawabata Evaluation System instruments. Attempts are made to relate yarn structure differences to differences in the yarn formation mechanism for the three spinning meth ods. The differences in measured yarn properties such as evenness, hairiness, bulkiness. tenacity, compression properties, and bending properties can be explained by the observed differences in the yarn structure.