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Blending Cotton and Polyester Fibers

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Blending Cotton and Polyester Fibers BLENDING COTTON AND POLYESTER FIBERS-- EFFECTS OF PROCESSING METHODS ON FIBER DISTRIBUTION AND YARN PROPERTIES A THESIS Presented to The Faculty of the Graduate Division by Nelson Ping Ching Chao In Partial Fulfillment of the Requirements for the Degree Master of Science in Textiles Georgia Institute of Technology September, 1963 3^ 12,^ ^ BLENDING COTTON AND POLYESTER FIBERS- EFFECTS OF PROCESSING METHODS ON FIBER DISTRIBUTION AND YARN PROPERTIES Approved! "—xy '—17 Date Approved by Chairman: ^^ysu^.^1^ ^h^ R^^ li ACKNOWLEDGMENTS The author wishes to express his sincere gratitude and apprecia­ tion to Dr. James L. Taylor, Director of the A. French Textile School, £or granting him a graduate assistantship and a Celanese fellowship which made this study possible; to Professor R. K. Flege, his thesis advisor, and to Professor R. L. Hill, both of the A. French Textile School, for their advice and recommendations; and to Dr. Joseph J. Moder of the School of Industrial Engineering for his assistance with the statistical aspects of the experiment. He also extends his thanks to Mr. R. C. Freeman, technician of the A. French Textile School, for his kind assistance. iii TABLE OF CONTENTS Page ACKNOWLEDGMENTS ii LIST OF TABLES iv LIST OF ILLUSTRATIONS vii SUMMARY vill Chapter I. INTRODUCTION I Some Aspects of Blending Fibers Stateioent of the Problem II. INSTRUMENTATION AND EQUIPMENT 11 Raw Materials Used Processing Equipment Testing Equipment III. PROCEDURE 13 Processing Blended Yarn Physical Tests Tests for Uniformity Tests for Breaking Strength and Elongation of Yarn Examination of Fiber Distribution Analyses of Data IV. DISCUSSION OF RESULTS 24 V. CONCLUSIONS 44 VI. RECOMMENDATIONS 47 APPENDIX 48 BIBLIOGRAPHY 74 Iv LIST OF TABLES Table Page la. Identification of Processes 15 lb. Organization of Weights and Drafts 16 2a. Analysis of Variance for Drawing Sliver Evenness 25 2b. Tukey Test for Significance of Drawing Sliver Evenness Differences Between Drawing Processes 25 3a. Analysis of Variance for Roving Evenness 28 3b. Tukey Test for Significance of Roving Evenness Differences Between Drawing Processes 28 4a. Analysis of Variance for Yam Evenness 31 4b. Tukey Test for Significance of Yarn Evenness Difference Between Drawing Processes 31 5. Sunmary of Per Cent Coefficient of Variation for Product Evenness 33 6a. Analysis of Variance for Yarn Breaking Strength 35 6b. Tukey Test for Significance of Yarn Strength Differences Between Drawing Processes 35 7. Analysis of Variance for Yarn Elongation 36 8. Sunmiary of Yarn Breaking Strength Test 38 9a. Analysis of Variance for Yarn Nep Count 39 9b. Tukey Test for Significance of Yarn Nep Count Differences Between Drawing Processes 39 10a. Analysis of Variance for Fiber Migration Index 41 10b. Tukey Test for Significance of Fiber Migration Index Differences Between Drawing Processes 41 11. Sunmary of Yarn Nep Count Test 42 Table Page 12. Summary of the Migration Index of Cotton Component 42 13. Operating Data for H & B Revolving Flat Card 49 14. Settings for H & B Revolving Flat Card 50 15. Operating Data for Saco-Lowell Roller Top Card 51 16. Settings for Saco-Lowell Roller Top Card 52 17. Operating Data for Saco-Lowell, 4 Over 5, DS-4 Drawing Frame 53 18. Operating Data for 10-1/2" Saco-Lowell Lap Winder 54 19. Operating Data for Saco-Lowell Model 57 Comber 54 20. Operating Data for Whitin Woonsocket Roving Frame 55 21. Operating Data for Saco-Lowell SS-2 Spinning Frame 56 22. Operating Data for Uster Evenness Tester 57 23. Operating Data for Uster Automatic Yarn Strength Tester . 58 24. Fiber Fineness Test Using Sheffield Micronaire 59 25. Cotton Fiber Strength Test Using Pressley Tester 60 26. Fiber Length Test Using Servo-Fibrograph 61 27. Uniformity of Cotton Picker Lap 62 28. Uniformity of Dacron Picker Lap 62 29. Per Cent Coefficient of Variation for the Evenness of Slivers 63 30. Summary of Per Cent Coefficient of Variation for the Evennesses of Sliver, Roving and Yarn 64 31. Per Cent Coefficient of Variation for the Evenness of Blended Sliver 65 32. Per Cent Coefficient of Variation for the Evenness of Roving 67 33. Per Cent Coefficient of Variation for the Evenness of Yarn 69 vi Table Page 34. Summary of Results from Yarn In^erfectlon Indicator .... 71 35. Results of Fiber Count for Fiber Migration Index 72 36. Summary of Results from Uster Automatic Yarn Strength Tester 73 vli LIST OF ILLUSTRATIONS Figure Page 1. Sequence of Operations for Producing Blend of Dacron/Combed Cotton 14 2. Effects of Drawing Process and Drawing Speed on the Evenness of Drawing Sliver 26 3. Effects of Drawing Process and Drawing Speed on Roving Evenness 29 4. Effects of Drawing Process and Drawing Speed on Yarn Evenness 32 5. Effects of Drawing Process and Drawing Speed on Yarn Breaking Strength and Elongation 37 6. Effects of Drawing Process and Drawing Speed on Fiber Migration Index 43 viti SUMMARY The blending of cotton and man-made fibers at the drawing frame has been a common practice In the textile Industry. In order to reduce the processing cost, the newer high speed drawing frames have been adopted to Increase the production, and the number of drawing processes has also been reduced, In most of the mills, from three to two processes. This Investigation was conducted to statistically evaluate the effects of the speed of drawing frame and the number of drawing processes on the fiber distribution, In terms of fiber migration Index, and other physical properties of the blended yarns made from the silvers blended at the drawing frame. The blend of 35 per cent combed cotton and 65 per cent polyester was made at the drawing frame where three different processes--one- process, two-process, and three-process drawlngs--and three levels of front roll speed--100, 200, and 300 feet per mlnute--were Introduced to yield nine lots of blended silver. These silvers were then processed Into 30's yarn through roving and spinning operations. The silvers, rovlngs, and yarns were tested for evenness. The yarns were tested for breaking strength, elongation, nep content, and fiber migration Index. All the data obtained were statistically analyzed to evaluate the results. It was found that the number of drawing processes had a signifi­ cant effect. In a statistical sense, on the evenness of silvers, rovlngs, and yarns. An Increase In the number of drawing processes had Improved Ix the evenness of the products. Speed of the dravlng frame was found to have but little effect on the product evenness. All evenness tests were performed on the Uster Tester. The yarn breaking strength and elongation tests, made on the Uster Automatic Yam Strength Tester, revealed that the number of drawing proc­ esses significantly affected the yarn strength, while the quadratic com­ ponent of the drawing frame speed significantly affected the yarn elonga­ tion. Both breaking strength and per cent elongation increased with each additional drawing process. The speed of 200 feet per minute was found to have yielded the strongest yarn with the highest per cent elongation. The nep content in the yarns was determined by the Uster Imper­ fection Indicator. The number of drawing processes had a significant effect on the nep content but only at the 10 per cent level. Two- process drawing produced fewer neps in the yarns. Also, nep count was lower in the yarns produced at the slower speed. Microscopic examination of yarn cross sections revealed that the cotton fibers had an outward migratory tendency, while the polyester fibers had an inward migratory tendency. The migration index was lower as the number of drawing processes increased. As the migration index decreases, uniformity of the fiber distribution increases. Three-process drawing yielded the yarn with the most uniform distribution of fibers. Also, the yarn processed at the lowest drawing frame speed showed the most uniform distribution of fibers in the cross section. The effects of the number of drawing processes, and drawing fraxoe speed, were found to be significant only at the 10 per cent level. CHAPTER I INTRODUCTION Some Aspects of Blending Fibers The blending or mixing of natural and/or man-made fibers has been practiced for many years, but only recently has it attracted great at­ tention from textile manufacturers. Reduction in number of processes required on modern machinery, differences in harvesting and ginning practices and increased usage of new man-made fibers have greatly in­ creased the importance and significance of blending processes and procedures. Blending nay be defined as the mixing of two or more masses of fibers so that the resulting mixture has the characteristics of the average of the component items. Blending of cotton is done for at least three purposes (1): (a) To reduce the variation in fiber characteristics so that a homogeneous sliver or roving is produced for the spinning frame. The fiber properties vary with the variety of the cotton, area of growth, cultural practices, weather conditions, time of harvest, harvesting methods and ginning treatments. The coefficient of variation of fiber fineness and strength within the bale has been estimated to be as much as 40 per cent. Thorough blending is, therefore, necessary to reduce the variation and yield more uniform yarn of controlled quality. (b) To provide the mill aiachinery with a continuous supply of cotton of the same average quality. This is done to maintain a uniform stock from day to day, week to week or even longer periods of time. (c) To take advantage of the price differentials in cotton between grades and fineness levels, etc. It may be more economical to blend cot­ tons of different price ranges than to use only one cotton with the same average properties.
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