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Optimization of Persian Hand- Knotted Wool ELK ASIA PACIFIC JOURNAL OF MECHANICAL ENGINEERING AND RESEARCH- SPECIAL ISSUE ISSN 2349-9368(Online);EAPJMER/ISSN.2454-2962/2016; National Conference on Futuristics in Mechanical Engineering Madan Mohan Malaviya University of Technology OPTIMIZATION OF PERSIAN HAND- KNOTTED WOOL CARPETS DURABILITY BY USING RESPONSE SURFACE METHODOLOGY Shravan Kumar Gupta Indian Institute of Carpet Technology, Chauri Road, Bhadohi, Uttar Pradesh, India – 221 401 ABSTRACT The effect of knot density, pile height, number of plies in pile yarn and pile yarn twist on durability behavior of Persian hand-knotted wool carpets has been studied by using formula given by Ince and Ryder (1984). The optimization of the process variables has been done by using response surface methodology based on the Box- Behnken design of experiment. The optimized values for durability factor were found seven knots per inch, sixteen millimeter, four plies and four twists per inch for knot density, pile height, number of plies in pile yarn and pile yarn twist, respectively. Keywords: Box-Behnken Design, Carpet Durability Factor, Response Surface Methodology, Persian Hand-Knotted Carpet Introduction Carpet is a three dimensional textile carpets is produced by the Persian, Tibetan, structure, used as the ornamentation of floor, Spanish, Kiwi or Turkish knots. Amongst, ceiling and wall. Base and pile are two parts Persian knots are broadly used for of the carpet. The base is produced by warp manufacturing of handmade carpets [1-4]. and filling yarns and the actual working surface is composed of pile yarns. Based on There is a strong dependence of carpet manufacturing technique, carpets are appeal (colour, design and texture) on classified as machine made or handmade purchase judgment-building. Still, clients carpets. Tufting, knitting, weaving, needle constantly seek to retain a balance between felting, braiding, flocking and fusion appeal and durability of hand-knotted bonding are the machine made carpet carpets. The carpet’s wear life in specified manufacturing techniques whereas; situations is known as carpet durability. handmade carpets are manufactured as Hand-knotted carpets should have high wear knotted, flat woven and tufted techniques. life because it is costlier than apparels. Generally, knotting is most preferred There are numerous parameters for carpet technique for handmade carpet manufacture. durability like surface pile mass density The working surface of hand- knotted factor, compression and recovery 455 ELK ASIA PACIFIC JOURNAL OF MECHANICAL ENGINEERING AND RESEARCH- SPECIAL ISSUE ISSN 2349-9368(Online);EAPJMER/ISSN.2454-2962/2016 National Conference on Futuristics in Mechanical Engineering Madan Mohan Malaviya University of Technology characteristics, thickness loss and recovery order (quadratic) model is the most common after prolonged heavy static forms of RSM [9], which is shown below: loading,thickness loss under dynamic h h h1 h z y y2 yy loading, tuft withdrawal force, pile abrasion 0 ii iii ijij i1 i 1 iji 1 1 loss, appearance retention etc. These …(1) parameters shows poor relation with actual where z is the process response; y1, floor wear when different pile fibres are y2,… yh are the independent variables; αo, αi, compared [5]. αii (i = 1,2,...,h), αij (i = 1, 2,..., h; j = 1, 2,..., Ince and Ryder gave an equation to h) are the constant terms and coefficients for calculate durability factor (D) for wool linear, quadratic and interaction terms, carpets [6]. respectively, and ϕ is a random experimental P 2 19R 1.4 error term assumed to have a zero mean. t D Box-Behnken design (BBD) is the most 1000 common second order RSM design. This is a Where R is the number of rubs on the three-level plan based on the structure of a 2 WIRA carpet abrasion machine and P /t is balanced incomplete block design [10]. 27 the surface pile mass density. Wool carpets experiments are conducted in four factors are graded to different wear intensities with and three levels BBD however in a full the help of durability factor. They suggested factorial design 34 or 81 experiments will be 180-280, 280-380 and greater than 380 required. values of D for light contract, medium contract and heavy contract wool carpets. SAMPLE PREPARATION Fibre, yarn and carpet constructional Pile, warp, thick weft and thin weft yarns variables are jointly affected to carpet were used for the developing of Persian durability factor [7-8]. The research on hand-knotted carpet samples. Pile yarns carpet durability factor is scanty where were manufactured from 100% wool fibres important yarn and carpet parameters have by woollen spinning system. Mean fibre been considered concurrently. Therefore, the aim of this study is to investigate the diameter and mean fibre length of wool durability factor of Persian hand-knotted fibres were measured as 37.65 µm and 75.03 wool carpets by varying knot density, pile mm with 24.4 and 28.5 CV% respectively. height, number of plies in pile yarn and pile The properties of pile yarns are depicted in yarn twist. Yarn and carpet parameters were Table 1. also optimized using Box-Behnken response surface methodology. CARPET DURABILITY FACTOR The carpet durability factor is the numerical METHODOLOGY value obtained from the following equation RESPONSE SURFACE METHODOLOGY – Response surface methodology (RSM) is useful for the modeling and interpretation of problems where a response is affected by some independent parameters. A second 456 ELK ASIA PACIFIC JOURNAL OF MECHANICAL ENGINEERING AND RESEARCH- SPECIAL ISSUE ISSN 2349-9368(Online);EAPJMER/ISSN.2454-2962/2016 National Conference on Futuristics in Mechanical Engineering Madan Mohan Malaviya University of Technology P 2 from Table 6 for ANOVA analysis of 19R 1.4 t durability factor of Persian hand-knotted D … (1) 1000 carpets, x1 (knot density), x2 (pile height), x3 Where R is the number of (number of plies), interaction terms of x1x3 revolutions on the WIRA abrasion tester and (knot density × number of plies), x2x3 (pile 2 P /t is the surface pile mass density. height × number of plies), x2x4 (pile height × pile yarn twist) and quadratic termx4 (pile 2 RESULTS AND DISCUSSION yarn twist ) are statistically significant RESPONSE SURFACE MODEL FOR model terms for carpet durability factor. CARPET DURABILITY FACTOR Table 4 depicts the values of experimental results for the number of revolutions on ANALYSIS OF 3-D SURFACE GRAPHS WIRA abrasion tester (R), surface pile mass Figure 8 depicts the effect of two carpet (P), carpet thickness (t) and carpet durability construction parameters (knot density and factor (D) of Persian hand-knotted carpets pile height) on the durability factor of respectively. carpets. It is observed that durability factor The response surface equation increases with the increase in knot density as (Equation 2) was got from the experimental well as pile height. Durability factor is values shown in Table 4. This equation dependent on the abrasion component and comprises total 14 terms which includes 4 density component. Obviously, these two linear, 6 interactions and 4 quadratic terms, components increase with the increase in respectively. knot density and pile height. This is The coefficient of determination (R2) explained by the fact that a carpet sample of of the durability factor of Tibetan hand- more knot density and pile height, and hence knotted carpet isR-Squared 0.942. This higher wool content, is able to sustain large indicates that this model can elucidate about number of abrasion cycles. Moreover, the 2 94% variability present in the experimental value of density factor, i.e. p /t, also data. Therefore, it can be concluded that the increases with the increase in shorn pile derivative model is fairly correct in concern weight [7-8]. with prediction accuracy.Table 5 represents Figure 9 depicts the effect of the the ANOVA results of the regression model. number of plies in pile yarn and pile yarn F-test and its associated p-value were used twist on durability factor of Persian hand- to check the significance of the whole model knotted carpets. It is also observed that and every term. The model is statistically durability factor increases with the increase significant at 95% level if the p-value is less in number of plies in pile yarn however than 0.05. The model F value of 13.98 durability factor first increases then reports that it is significant and there is only decreases with the increase in pile yarn 0.01 % chance that an F-value this large twist. could happen because of chance (Table 5). CONTRIBUTION OF PARAMETERS The model term is not significant if the p- The percent contribution of different terms value is greater than 0.1. It can be observed on the durability factor of Persian hand- 457 ELK ASIA PACIFIC JOURNAL OF MECHANICAL ENGINEERING AND RESEARCH- SPECIAL ISSUE ISSN 2349-9368(Online);EAPJMER/ISSN.2454-2962/2016 National Conference on Futuristics in Mechanical Engineering Madan Mohan Malaviya University of Technology knotted wool carpets is shown in Table 6. [3] Liu F, Maher A P, Lappage J and Wood E J, This parameter is measured by taking The Measurement of the Tuft-withdrawal individual sum of squares of a term and Force in Machine-made and Hand-knotted dividing it by the total sum of squares and Carpet. Journal of the Textile Institute, 93: then multiplying by 100. The percent 276-282, 2002. contributions can be used to determine [4] Topalbekiroglu M, Kireçci A and Dülger C which terms are larger contributors than L, Design of a Pile-Yarn Manipulating others, when all parameters have the same Mechanism Proceedings of the Institution of Mechanical Engineers, Part B: Journal of degrees of freedom. Knot density (x1), Engineering Manufacture, 219: 539-545, number of plies (x3) and pile height (x2) contribute 46.31, 30.74 and 8.03 % 2005.
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