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Effect of Raw Material and Processing Conditions on Yarn Neppiness

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Effect of Raw Material and Processing Conditions on Yarn Neppiness EFFECT OF RAW MATERIAL AND PROCESSING CONDITIONS ON YARN NEPPINESS Ma_gorzata Matusiak1, Iwona Frydrych1,2 1) Institute of Textile Architecture e-mail:[email protected] [email protected] 2) Technical University of Lodz e-mail: [email protected] 1. Introduction One of the most important quality problems of cotton yarns is the nep presence. Neps in a yarn are defined as “point agglomerations of fibers entangled into the yarn causing the increase of the yarn diameter” [1]. On the basis of the statistical data originated from world cotton spinning mills it can be stated that yarn neppiness is still not a diminishing problem. The sources of neps in a yarn are neps and trashes contained in a fiber stream, from which directly the yarn is formed [2]. The number of neps in cotton yarn depends on two main factors: - characteristics of raw material used for the yarn production, - conditions of the technological process in the spinning mill. The development of modern instrumental measurement systems afforded possibilities for the complex evaluation of cotton fibers in raw material and spinning semi-products, among the other assessment of parameters, which influence the neppiness of manufactured cotton yarn in a direct or indirect way. There were created conditions for the development of the methods enabling a prediction of cotton yarn quality in the aspect of its neppiness [3, 4]. 2. Changes of cotton fiber stream during processing Starting from harvesting cotton is exposed to the numerous processes, which in the final effect lead to the yarn creation. Mechanical outer actions during the yarn manufacturing cause significant changes of almost all average parameters of processed cotton. In the preliminary cleaning and ginning process the intensive trash removing already takes a place, but simultaneously it is observed the fiber damage as well as the nep formation. During the technological process in the spinning mill, there are a number of stages, which cause the significant changes of characteristics of the processed fiber stream. The number and kind of operations, to which cotton is exposed, depend on the quality of raw material as well as of the used spinning system. In the result there can be observed the significant changes of fiber stream parameters, like the average length and its irregularity, average linear density and maturity, immature and short fiber content and so on. Contamination of cotton decreases during the particular stages of processing. The most significant reduction of trash and dust content in cotton takes a place in the opening and blending processes, and next during the carding and combing processes. In the rotor spinning system trashes are removed also by the opening roller of rotor spinning frame (Fig. 1). 1 60 g / t 50 n C 40 30 h s a 20 r T 10 0 Raw Lap Sliver after Sliver after Fibers from material carding drawing rotor Blend A Blend B Fig. 1. The changes of trash content in cotton during the processing in the rotor spinning system In the beginning it is observed an increment of the nep number in the preliminary treatment of cotton in the scutching room. It is caused by occurring outer mechanical factors, which are connected with actions of the working machine elements on the fibers as well as by the pneumatic transport of fibers between particular machines in the technological line. The considerable (50 % - 90 %) reduction of the nep number (Fig. 2) occurs in the further stages of cotton processing, mostly during carding and combing process. 300 g 250 / t n 200 C 150 p e 100 N 50 0 Raw Lap Sliver after Sliver after Fibers from material carding drawing rotor Blend A Blend B Fig. 2. The changes of nep content in cotton during the processing in the rotor spinning system The mentioned above changes of cotton fiber stream during the technological process in the spinning mill cause that the number of neps and trashes in the spinning semi-products, from which directly the yarn is formed, i.e., in the roving feeding the ring spinning frame or in the fiber web in rotor of the rotor spinning frame, differs significantly from the initial nep and trash number in cotton raw material used for production. 3. The model of nep number in the cotton yarn Neps and trashes contained in cotton, which were not removed during processing in the process of sliver preparation get into the yarn and can be a source of yarn neps. But not all of them are the reason of yarn faults. Neps and trash particles of appropriate small sizes are not visible on the yarn surface and in the same way they are not registered by the measurement device as yarn neps. Only these neps and trashes contained in the fiber stream are registered as yarn neps, whose size is bigger than the given critical value. 2 Taking it into consideration as well as known tendencies of changes of the nep and trash number in cotton during the processing it is possible to formulate the following general equation expressing the number of neps per 1000 m of cotton yarn: ⎡ ⎛ NRE ⎞ ⎛ NRE ⎞ ⎛ CE ⎞ ⎛ CE ⎞⎤ = ⋅ ⋅ ()+ ∆ ⋅ ⎜ − 1 ⎟ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⎜ − k ⎟ + ⋅ ⎜ − 1 ⎟ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⎜ − p ⎟ N yUT Tt y ⎢n N c N t 1 1 u U c 1 ⎜1 ⎟⎥ (1) ⎣⎢ ⎝ 100 ⎠ ⎝ 100 ⎠ ⎝ 100 ⎠ ⎝ 100 ⎠⎦⎥ where: NyUT - the number of neps per 1000 m of yarn according to the Uster® Tester, Tty - linear density of yarn, n - the share of neps of size equal to and higher than the critical nep size for a given linear density of yarn in the total nep number in the fiber stream from which the yarn is created, Nc - the average nep number in cotton used for yarn manufacturing, _Nt - the increment of the nep number in cotton in the preliminary treatment in the scutching room, th NREi - the average nep removing efficiency by machines in the i stage of cotton processing, k - the number of spinning process stages causing the nep removing, u - the share of trash of size equal to and higher than the critical nep size for a given linear density of yarn in the total trash number in the fiber stream, from which the yarn is created, Uc - the average trash particle number in cotton used for yarn manufacturing, th CEj - the average trash removing efficiency by machines in the j stage of cotton processing, p - the number of spinning process stages causing the trash removing. Parameters characterizing the work effectiveness of machinery in the technological order can be determined basing on the intermill diagnostics carried out in the spinning mill using the AFIS system. The parameter characterizing the carding machine effectiveness in the aspect of nep reduction is the Nep Removing Efficiency (NRE %), which is expressed by equation (2) : NepCnt / g − NepCnt / g NRE = feed del ⋅100% (2) NepCnt / g feed where: NRE - nep removing efficiency, Nep Cnt/gfeed - the nep number per gram in fiber stream feeding the machine, Nep Cnt/gdel - the nep number per gram in the fiber stream delivered by the machine. Dependably on the spinning system there occur a few stages in the technological process, in which neps are removed. First of all the nep number reduction takes a place during the carding process. Correctly working carding frames can remove ca. 80 % ÷ 90 % of neps contained in the feeding fiber stream (web or lap). The value of NRE for a given carding machine does not change in a significant way in a longer period of time. It can be maintained on the similar level during 16÷18 weeks after upgrading of the carding frame coverings [5]. Analysis [6] showed that there are the considerable differences between the nep removing 3 efficiency of particular carding machines in the technological line. Therefore, in order to predict the nep number in cotton yarn on the basis of proposed equation (1) the average nep removing efficiency should be calculated for the set of carding machines. In the combed spinning system apart from carding the neps are also removed during the combing process. The nep removing efficiency by set of combing frames is an average value from the nep removing efficiency of all combing machines in the technological line. For particular combing frame the NRE should be calculated as an average from values of these coefficients for all machine heads. Similarly like in the case of carding machines the nep removing efficiency of the combing frames does not change significantly in a long period of time. Moreover, it was stated [6] that at a correct machine adjustment, there are not any significant differences in aspect of nep removing efficiency between the particular machine heads. In the case of the rotor spinning process apart from carding process it should be taken into consideration the action of the opening roller of the rotor spinning frame. Nep removing efficiency NRE of opening roller can be also calculated from equation (2). In this case as a fiber stream delivered by the machine the fiber web accumulating on the rotor circumference should be considered. Cleaning efficiency CE is expressed by the following equation: TrashCnt / g − TrashCnt / g CE = feed del ⋅100% (3) TrashCnt / g feed where: CE - trash removing efficiency, Trash Cnt/gfeed - the trash number per gram in fiber stream feeding the machine, Trash Cnt/gdel - the trash number per gram in the fiber stream delivered by the machine. Contaminants contained in cotton are removed during the preliminary treatment in the scutsching room, during carding and combing processes and in the case of the rotor spinning system in the zone of opening roller action. Generally, it can be stated that independently of the applied spinning system the number of stages, in which the reduction of cotton contamination occurs is smaller then the number of stages causing the nep number reduction.
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