Yarn Processing Research Articles

Effect of incident angle of oblique-blowing airflow on yarn in pneumatic tucked-in selvedge apparatus

With the increasing requirements of high-speed weaving on looms, more and more shuttleless looms begin to use pneumatic tucked-in selvedge apparatus for tucked-in. In this paper, the oblique-blowing process of yarn under different incident angles is analyzed, the oblique blowing-folding model of airflow and the yarn structure model are established, and the numerical simulation of the oblique blowing-folding flow field of yarn is carried out. The oblique blowing-airflow at different incident angles produces different oblique-blowing processes and pneumatic tucked-in airflow fields, resulting in different deformation and movement of the yarn during the oblique-blowing process, which will also affect the yarn tucked-in process. Therefore, the fluid–structure interaction simulation method is used to analyze the movement of yarn in oblique-blowing and folding-in airflow, and a visual experimental platform is designed to record the state of yarn tucked-in under different oblique-blowing airflow angles by high-speed camera. The research has engineering significance for improving yarn tucked-in quality and tucked-in efficiency, and provides theoretical support for further improving pneumatic tucked-in selvedge apparatus.

Cut-resistance of elastic high-performance composite yarn

Soft and lightweight personal protective equipment for civil or military use that is made of cut-resistant textiles is usually rigid and heavy, less elastic or flexible. Insertion of elastane fiber during the fabrication of rigid textiles seems to be working, but actually is not. Therefore, it presents a severe challenge in achieving an appropriate balance among elasticity, flexibility, and protection. To address this issue, an elastic cut-resistant composite yarn is fabricated by single wrapping ultra-high molecular weight polyethylene around elastic Spandex. The effects of wrapping parameters (including the twist, spindle speed, and yarn combination) on yarn elasticity and coverage are investigated to achieve a perfect wrapping, and the cut-resistance of the composite yarn is evaluated by using a self-improved AUTOGRAPH universal testing machine. It demonstrates that the cutting process of the composite yarn consists of four stages, the cut modulus and yarn elasticity are highly correlated with yarn structure and wrapping process parameters. The optimizing coverage and cut-resistance are achieved when the twist is 750 t/m, which is also with a high elastic recovery rate (79.79%) and low plastic deformation rate (10.11%). Groups of parallelized composite yarns with varying densities are fabricated by self-improved sample holders to simulate the cut-resistant weaving fabrics with different weaving densities, of which the cut-resistance is evaluated. The resistance against cutting varies significantly among different groups, which is directly proportional to their densities. Finally, two types of elastic cut-resistant fabrics with different structures are woven from fabricated elastic cut-resistant composite yarns practically. Both weft-backed weave and the double-layer weave fabrics have good flexibility and protection, of which the cut-resistance is level 1 and level 2, respectively. Thus, the composite yarn has an excellent elasticity and maintained cut-resistance, which is an ideal material for the production of highly elastic protective textiles.

Fuzzy Evaluation Model for Products with Multifunctional Quality Characteristics: Case Study on Eco-Friendly Yarn

Numerous advanced industrial countries emphasize green environmental protection alongside athletic healthcare. Many world-renowned sports brands are actively developing highly functional, environmentally friendly, and aesthetically pleasing products. For example, in the production of sports shoes, the eco-friendly yarn process is one of the important processes. This process involves multiple crucial larger-the-better quality characteristics closely tied to the functionality of sports shoes. Facing green environmental regulations and external competitors, it is evidently an imperative issue for enterprises to consider how to improve the quality of newly developed products, increase product value, and lower rates of both rework and scrap to accomplish the goals of saving energy and minimizing waste. Aiming to solve this problem, this study proposed a fuzzy evaluation model for products with multifunctional quality characteristics to assist the sporting goods manufacturing industry in evaluating whether all functional quality characteristics of its products meet the required quality level. This study first utilized the larger-the-better Six Sigma quality index concerning environmental protection for evaluation and then proposed product evaluation indicators for the eco-friendly yarn. Since the parameters of these indicators have not yet been determined, sample data need to be used for estimation. Enterprises require rapid response, so that the sample size is relatively small. Sampling error will increase the risk of misjudgment. Therefore, taking suggestions from previous studies, this study constructed the fuzzy evaluation model based on confidence intervals of quality indicators for the eco-friendly yarn. This method incorporated previous experience with data, thereby enhancing assessment accuracy.

Fabrication of nanofiber yarns via electro-blown and hang-fiber process

Continuous nanofiber yarns were prepared using the electro-blown and hanging yarn process. Unlike typical electrospinning devices, this method uniquely controls the spinning process to induce the hanging phenomenon, and the resulting hanging yarn is twisted to form nanofiber yarns. A polyvinylidene fluoride nanofiber yarn was successfully prepared using the electro-blown and hanging yarn process. Scanning electron microscopy observations confirmed that the nanofibers prepared by this method exhibited good orientation within the yarn. The results indicate that the conductivity of the polymer solution and the applied voltage are crucial for inducing the hanging yarn process, ensuring stable continuous spinning. A possible mechanism is proposed, suggesting that adjusting the solution’s conductivity and controlling the spinning voltage can utilize defects in the yarn-hanging process during spinning to prepare nanofiber yarns.

Behaviors of triaxial woven fabric composites reinforced concrete cylinders under eccentric compression

Concrete reinforced by textile composite materials has long been a focus of substantial interest in the engineering applications. In this paper, the compression performance of concrete cylinders confined by carbon fibers, glass fibers, and carbon–glass hybrid triaxial woven fabric composites under three different eccentricities were investigated. Moreover, the digital image correlation analysis method was introduced to observe the compression process and failure modes of reinforced concrete cylinders. Meanwhile, the strain process of yarns during the failure was also analyzed. The result showed that all of triaxial woven fabric composites can increase the strength of concrete cylinders, while the strength decreased with the increase of eccentricity and the mechanical performance converged gradually. In addition, using triaxial woven fabric composites made of glass fibers can promote the ductility of concrete cylinders. It also indicated that employing carbon–glass hybrid triaxial woven fabric composites can not only have the advantages of increasing the strength and ductility of concrete cylinders, and low cost, but also effectively reduces the eccentric sensitivity.

Developing a data-driven operational guide for the texturized yarn production process: data mining and intelligence approach

PurposeThe textile industry holds immense significance in the economy of any nation, particularly in the production of synthetic yarn and fabrics. Consequently, the pursuit of acquiring high-quality products at a reduced cost has become a significant concern for countries. The primary objective of this research is to leverage data mining and data intelligence techniques to enhance and refine the production process of texturized yarn by developing an intelligent operating guide that enables the adjustment of production process parameters in the texturized yarn manufacturing process, based on the specifications of raw materials.Design/methodology/approachThis research undertook a systematic literature review to explore the various factors that influence yarn quality. Data mining techniques, including deep learning, K-nearest neighbor (KNN), decision tree, Naïve Bayes, support vector machine and VOTE, were employed to identify the most crucial factors. Subsequently, an executive and dynamic guide was developed utilizing data intelligence tools such as Power BI (Business Intelligence). The proposed model was then applied to the production process of a textile company in Iran 2020 to 2021.FindingsThe results of this research highlight that the production process parameters exert a more significant influence on texturized yarn quality than the characteristics of raw materials. The executive production guide was designed by selecting the optimal combination of production process parameters, namely draw ratio, D/Y and primary temperature, with the incorporation of limiting indexes derived from the raw material characteristics to predict tenacity and elongation.Originality/valueThis paper contributes by introducing a novel method for creating a dynamic guide. An intelligent and dynamic guide for tenacity and elongation in texturized yarn production was proposed, boasting an approximate accuracy rate of 80%. This developed guide is dynamic and seamlessly integrated with the production database. It undergoes regular updates every three months, incorporating the selected features of the process and raw materials, their respective thresholds, and the predicted levels of elongation and tenacity.

Spinning Processing with Automation

Fibre and yarn processing and fabric manufacturing are the two division of textile industry. Electronic controls systems are functioning for optimal running with all machines under proper supervising in step wise improvement in each yarn manufacturing process. Modern automation techniques can manufacture in the textile processing to achieve greater number of smaller manufacturers, who can produce smaller organization to produce cost-effective and quick delivery products. Automation Solutions have their new generation of product lines for expert engineers to serve automation solutions for the whole of the value chain. With the installation of Rieter Automation Solutions from blow room to final packaged yarns, it reduces the number of personnel. Present day automation is used in yarn manufacturing from bale management to processing of cone winding. On one of the major key objectives in textile manufacturing is to improve quality and cost competitiveness. At present, spinning is one of the most applied areas where automation is successful in manufacturing processes. Voltas offers the wide range of machines in spinning processing for products as needed by the spinning industry.

Electromechanical Characterization of Commercial Conductive Yarns for E-Textiles

With the development of smart and multi-functional textiles, conductive yarns are widely used in textiles. Conductive yarns can be incorporated into fabrics with traditional textile techniques, such as weaving, knitting and sewing. The electromechanical properties of conductive yarns are very different from conventional yarns, and they also affect the processability during end-product manufacturing processes. However, systematic evaluation of the electromechanical properties of commercial conductive yarns is still elusive. Different conductive materials and production methods for making conductive yarns lead to diverse electromechanical properties. In this work, three types of conductive yarn with different conductive materials and yarn structures were selected for electromechanical characterization. A total of 15 different yarns were analyzed. In addition, the change of resistance with strain was tested to simulate and predict the possible changes in electrical properties of the yarn during weaving, knitting, sewing and other end uses. It was found that Metal-based yarns have good electrical properties but poor mechanical properties. The mechanical properties of Metal-coated yarns are similar to conventional yarns, but their electrical properties are relatively poor. The data shown in this research is instructive for the subsequent processing (weaving, knitting, sewing, etc.) of yarns.

Preparation and fluorescence performance of high elastic core-shell structure composite fibers based on electrospun nanofibers

Fluorescent fibers with light weight and good mechanical properties provide exciting opportunities for the development of flexible optical sensing textiles. This could accelerate the realization of the wearable technology goal of functional and large area display. Here, we synthesized a polyimide containing 20% pyrene group (Py-20) with excellent fluorescence and thermal properties. Then, fluorescent composite fibers with core–shell structure were prepared by using Py-20 electrospun membrane as surface layer and polyurethane (TPU) fiber as inner layer. The diameter and thickness of surface fluorescent fibers was 500 nm and 100 μm, respectively. Polarized infrared spectra analysis proved that the aggregation of polymer molecular chains in electrospun fiber could be reduced effectively. The DR (DR = I∥/I⊥) values of polymer film and electrospun fibers were 0.7553 and 0.5955, respectively. Therefore, the fiber samples exhibited higher fluorescence intensity than the polymer film. The maximum photoluminescence peaks of electrospun and composite fibers were located at about 595 nm. In addition, thanks to interlaced layered structure of electrospun fibers, the fluorescent composite fiber maintained a relatively uniform morphology at 40.84% (strain) and 4.96 MPa (stress). Importantly, this Py-20/TPU composite fiber could meet the complex weaving process of yarns and display bright yellow-orange colors under ultraviolet light irradiation. Thermal analysis exhibited that the initial decomposition temperature (Td) of composite fiber in the air could reach to 269 °C. This fiber material will become a competitive candidate in smart textiles with the excellent luminescence, mechanical and thermal properties.

A Review on Spinning Processing with Automation

Fibre and yarn processing and fabric manufacturing are the two division of textile industry. Electronic controls systems are functioning for optimal running with all machines under proper supervising in step wise improvement in each yarn manufacturing process. Modern automation techniques can manufacture in the textile processing to achieve greater number of smaller manufacturers, who can produce smaller organization to produce cost-effective and quick delivery products. Automation Solutions have their new generation of product lines for expert engineers to serve automation solutions for the whole of the value chain. With the installation of Rieter Automation Solutions from blow room to final packaged yarns, it reduces the number of personnel. Present day automation is used in yarn manufacturing from bale management to processing of cone winding. On one of the major key objectives in textile manufacturing is to improve quality and cost competitiveness. At present, spinning is one of the most applied areas where automation is successful in manufacturing processes. Voltas offers the wide range of machines in spinning processing for products as needed by the spinning industry.

Method for deriving twisting process parameters of large package E-glass yarn by measuring physical properties of bobbin yarn

Abstract Twisting is an important part in the production process of large package E-glass yarn. To derive the twisting process parameters of large package E-glass yarn, a method from the physical properties of bobbin yarn is proposed based on the study of the twisting principle of E-glass yarn. After unwinding the bobbin yarn and measuring its twist, loop pitch, and corresponding diameter, the calculation is completed according to the steps of first determining the descending speed of the traveler, then fitting the spindle speed data, and finally calculating the elevating speed of the traveler. The result is that the twisting spindle speed of D450 E-glass yarn with 31.8 T/m decreases from 5,015 to 4,550 rpm, the elevating speed of the traveler is 0.91 m/min, and the descending speed of the traveler is 1.50 m/min. The accuracy of the calculation is verified by monitoring the rotating speed of the roving cake and measuring the loop pitch of bobbin yarn in the twisting experiment. The result shows that the prediction error of this method is less than 1.1%, which can effectively derive the twisting process parameters of large package E-glass yarn, and provide a reference for the twisting process design scheme of glass fiber strand manufacturers.

Relationship between the specific work of rupture and the blended ratio for two-component blended yarn

The yarn specific work of rupture is a comprehensive index to characterize the resistance of yarn to mechanical destruction. For blended yarn, it is closely related to the blended ratio of the components. This paper established a model to express the quantitative relationship between the specific work of rupture and the blended ratio in blended yarn. This model was obtained by analyzing the breaking process of blended yarn and summarizing the empirical data. Then, the experimental data were used to verify the established model and a good agreement between the calculated and experimental results was found. According to this model, the curve of the specific work of rupture against the blended ratio can be obtained by simple plotting. Consequently, this work can be used to predict the specific work of rupture for blended yarn with various blended ratios.

A New Method to Calculate Cotton Fiber Length Uniformity Using the HVI Fibrogram

Knowledge of cotton fiber length uniformity is important for the cotton industry. The accurate and reliable measurement of fiber length uniformity would allow cotton breeders to release new cotton varieties with improved fiber length variation. This knowledge would also help spinning mills to optimize their machine setup, which would improve yarn processing performance. Currently, the high volume instrument (HVI) is most commonly used to characterize the cotton fiber length variation. The HVI length measurement is based on the fibrogram principle. The HVI length measurement characterizes 2 points, 1.8% as the upper half mean length (UHML) and 7.8% span length as the mean length (ML) from the fibrogram, and reports UHML and uniformity index (UI). The ratio of ML to the UHML is used to calculate the UI and is expressed as a percentage. UI measurement does not represent the shorter fibers as the above two span lengths only represent the longest fibers within a sample. We propose to calculate the uniformity of the cotton fiber length using the complete fibrogram as an alternative. First, the area of the measured fibrogram curve is calculated. Second, the area of a theoretical mono-length fibrogram with a length equal to the maximum length of the fibers for the same sample is calculated. Finally, we calculate a new length uniformity as the ratio of the measured fibrogram area to the mono-length fibrogram area expressed as a percentage. Based on the results obtained using a set of 991 commercial samples, the new length uniformity shows promise. We also applied this new length uniformity to a set of 60 commercial-like samples and developed partial least square regression (PLSR) prediction models to predict yarn quality. The results obtained demonstrate that the new length uniformity predicts yarn quality better than the current UI.

Research on a novel sheath core-wrap staple yarn based on the ring spinning frame with special-shaped roller

This work explored a novel method for producing sheath core-wrap staple yarn on a modified ring spinning machine. The sheath core-wrap staple yarn is a new composite yarn whose core layer and sheath layer are both composed of staple fibers. In this paper, the conventional front roller on the ring spinning machine was replaced by a special-shaped roller, named a coaxial front roller of different diameters. In the spinning process, two colored cotton rovings were fed into the back roller. Then they are conveyed to the coaxial front roller of different diameters and output at different speeds. Finally, they were spun in a sheath core-wrap staple yarn under the twist effect. The covering effect and properties of sheath core-wrap staple yarn are the critical concerns in this article. Mathematical equations have been derived to calculate the ideal twist multiplier. It is most favorable for the core fiber to be covered at the ideal twist multiplier 408. The effects of the twist multiplier and core proportion on core exposure ratio and yarn properties (tensile properties, abrasion resistance, evenness, and hairiness) were investigated. The results showed that the core exposure ratio of all sheath core-wrap staple yarns were less than 2%, and the minimum core exposure ratio was obtained at the twist multiplier 400. The results also demonstrated that the tensile property, abrasion resistance, evenness, and hairiness improved with the increase of the twist multiplier and the core proportion. The proposed method provides new insight for researchers to fully understand the production process of sheath core-warp staple yarn and improve the yarn quality.

Yarn modeling and winding process simulation based on 3D beam elements

In order to study the tension variation of cotton yarn in the winding process, a finite element model of yarn based on three-dimensional beam elements is proposed. As the size of yarn in the length direction is much larger than the cross-sectional size, this paper assumes that the yarn cross-section is circular and ignores the change of the cross-sectional area in the winding process. The winding process of yarn is simulated using Abaqus dynamic explicit, and the influence of the yarn fineness on the yarn tension during winding is analyzed. The results show that the average relative error between the simulation results and the experimental data is 14.09%, and the maximum relative error is 17.06%; therefore the model is reasonable. Compared with the solid element model of yarn, the yarn simulated by this model can save a lot of computing resources while taking into account the yarn stacking effect. The winding length that can be simulated in the same time is tens of times that of the solid element model, thus the winding simulation of nine-layer yarn on the bobbin is realized. The conclusion is that the inner yarn loop presents weak tension while the outer yarn loop has large tension.

Alkali-enzymatic treatment of Bambusa blumeana textile fibers for natural fiber-based textile material production

Bamboo is a promising natural fiber source for developing sustainable and green textile materials. Different fiber treatment techniques have been explored to produce natural bamboo textile fibers (BTF) with enhanced physical and chemical characteristics suitable for yarn processing and fabric weaving. This study presents a facile, low-cost, and environmentally friendly technique of transforming natural bamboo raw fiber into a yarn-spinnable BTF that can be developed into an all-natural fiber-based blended yarn. The combined alkali and multi-enzyme treatment of natural BTF resulted in a notable enhancement in the linear density, tenacity, and elongation by 106%, 30%, and 13%, respectively. The improvement in the physical properties of the fibers is highly correlated to the reduction in the non-cellulosic components such as lignin, residual gum, fats, and waxes by 29%, 56%, and 72%, respectively, which also led to an increase in surface roughness and crystallinity of the fibers. The alkali-enzymatic treated bamboo textile fiber underwent a further mechanically intensive process to attain nearly similar dimensions with cotton fibers that serve as its carrier fiber to produce natural fiber-blended yarns containing both the excellent properties of cotton and bamboo. Thin and thick cotton-bamboo blended yarns ranging from 60 tex to 120 tex were prepared and shown to have comparable characteristics such as tenacity and elongation, which are applicable in the weaving of medium-weight and heavyweight fabrics. The alkali-enzymatic fiber treatment of BTF strongly shows its viable potential in manufacturing green and environmental-friendly natural bamboo textile materials.

A method for yarn quality fluctuation prediction based on multi-correlation parameter feature subspace mechanism in spinning process

Yarn quality is a key indicator in spinning production process, which directly determines the processing quality of the finished fabric. Considering the problems that the yarn quality is difficult to predict due to many influencing factors and widely monitoring dimensions existed. This paper proposes a multi-correlation parameters-based feature subspace model for yarn quality fluctuation prediction method. Firstly, Kernel Principal Component Analysis (KPCA) algorithm is used to analyze the relationship between the relevant parameters affecting yarn quality, and the characteristic subspace of yarn quality fluctuation is reconstructed. Then, a feature subspace-oriented deep learning prediction structure based on Deep Belief Network (DBN) is constructed, and the intelligent prediction model of yarn quality is established by using Particle Swarm Optimization (PSO) algorithm to optimize the modeling parameters. Finally, a case for spinning spun yarn process data set is used to validate the effectiveness of the proposed method, result shows that the proposed method can effectively analyze the multi-correlation parameters fluctuation law, which shows good effect for predicting yarn quality accurately.

Recent progress in the fabrication and processing of triboelectric yarns

AbstractTriboelectric nanogenerators (TENGs) have recently enjoyed rapid development due to their easy fabrication, stable outputs, and wide range of applications. By combining conventional textiles with TENGs, textile‐based TENGs (t‐TENGs) can be employed with wearable devices and smart textiles. The t‐TENGs with a yarn structure, triboelectric yarns, can be directly used to conduct energy conversion and be processed into other energy‐harvesting textile structures due to their lightweight, flexibility, and processability. This review summarizes the research progress in triboelectric yarns. It starts with a systematic discussion of the working mechanism and manufacturing materials of triboelectric yarns. Subsequently, we discuss the four major methods of constructing triboelectric yarns including twisting/wrapping, coating, electrospinning, and other/composite methods. In particular, details about the energy harvesting performance, the triboelectric yarns' physical properties, and weaving/knitting capability are given. Finally, comments and perspectives are provided for the future design of high‐performance triboelectric yarns.

Role of Yarn Bintik Paramita Small and Medium Industries on the Economic Growth of the Industrial Sector in Palangka Raya City

The purpose of this study was to determine the role of Paramita Yarn Industry on economic growth in the Industrial Sector of Palangka Raya City and to determine the effect of Labor, Production Capacity and Production Value variables in the Palangka Raya Yarn Processing Industry on Economic Growth. This study uses multiple linear regression analysis techniques using IBM SPSS version 25. The type of data used is from this study primary data answers from business owners Benang Bintik Paramita. The results of this study indicate that the Paramita Spot Yarn Processing Industry has a fairly good role in Economic Growth. Labor, the level of production capacity has a partial and significant effect on economic growth and the value of production has no significant and negative effect on economic growth in the city of Palangka Raya. The results of this study are also labor, the level of production capacity has a simultaneous effect on economic growth.

Bond Modification of Carbon Rovings through Profiling.

The load-bearing behavior and the performance of composites depends largely on the bond between the individual components. In reinforced concrete construction, the bond mechanisms are very well researched. In the case of carbon and textile reinforced concrete, however, there is still a need for research, especially since there is a greater number of influencing parameters. Depending on the type of fiber, yarn processing, impregnation, geometry, or concrete, the proportion of adhesive, frictional, and shear bond in the total bond resistance varies. In defined profiling of yarns, we see the possibility to increase the share of the shear bond (form fit) compared to yarns with a relatively smooth surface and, through this, to reliably control the bond resistance. In order to investigate the influence of profiling on the bond and tensile behavior, yarns with various profile characteristics as well as different impregnation and consolidation parameters are studied. A newly developed profiling technique is used for creating a defined tetrahedral profile. In the article, we present this approach and the first results from tensile and bond tests as well as micrographic analysis with profiled yarns. The study shows that bond properties of profiled yarns are superior to conventional yarns without profile, and a defined bond modification through variation of the profile geometry as well as the impregnation and consolidation parameters is possible.