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Impact of Carding Parameters and Draw Frame Doubling on the Properties of Ring Spun Yarn

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Impact of Carding Parameters and Draw Frame Doubling on the Properties of Ring Spun Yarn Impact of Carding Parameters and Draw Frame Doubling on the Properties of Ring Spun Yarn Abdul Jabbar, Tanveer Hussain, PhD, Abdul Moqeet National Textile University, Faisalabad, Punjab PAKISTAN Correspondence to: Tanveer Hussain email: [email protected] ABSTRACT The impact of card cylinder speed, card production and draw frame delivery speed, and that an increase rate and draw frame doubling on cotton yarn quality in card draft beyond a certain point leads to parameters was investigated by using the Box- deterioration in yarn quality [3]. The percentage of Behnken experimental design. It was found that yarn leading and trailing fiber hooks in the roving fed to tenacity, elongation and hairiness increase by the ring frame also affects the yarn quality. It has increasing the number of draw frame doubling up to a been found that percentage of trailing, leading and certain level and then decrease by further increase in total fiber hooks decrease with the increase in card doubling. Yarn unevenness increased by increasing coiler diameter, card draft, and draw frame delivery card production rate and total yarn imperfections speed [4-5]. increased by decreasing card cylinder speed and increasing card production rate. The effect of lap hank, card draft, speed frame draft, and ring draft on the physical and tensile properties Keywords: Spinning; carding; drawing; cotton yarn of yarns has also been investigated. It was found that yarn spun at higher speed frame draft and INTRODUCTION corresponding lower ring frame draft has better Ring spinning is one of the most commonly used tenacity, breaking elongation and evenness in spun yarn manufacturing technologies for producing comparison to yarn spun at lower speed frame draft high strength carded and combed cotton yarns in the and higher ring frame draft. It was also noted that widest range of linear densities. Various processes card draft followed by lap hank is a major involved in the spinning of carded spun yarn include contributing factor influencing the changes in yarn cleaning and blending cotton in the blow room, properties [6-7]. Increasing carding rate and total carding, breaker and finisher drawing, roving spinning draft improves the yarn strength and formation on the simplex and yarn formation on the evenness, whereas lowering spindle speed results in a ring frame. The effect of different parameters of these stronger and more uniform yarn with fewer processes on the resulting yarn quality, have been imperfections [8]. studied by various researchers in the past. The influence of spindle speed on yarn strength, The effect of fiber opening in the blow room on the breaking elongation, imperfections and hairiness has yarn quality has been studied and it has been found also been investigated. It has been reported that the that increase in fiber opening in the blow room yarn tenacity improves whereas imperfections, results in improvement in yarn tenacity and yarn hairiness and breaking elongation deteriorate with the imperfections (IPI) up to a certain level of opening, increase in spindle speed [9]. The influence of fiber beyond which these parameters deteriorate sharply friction, top arm pressure, and roller settings at [1]. Similarly, fiber openness at carding also results various drafting stages, namely, draw frame, roving in improvement in yarn irregularity and tenacity only frame, and ring frame has also been studied [10], and up to a certain level and then these parameters it has been found that top arm pressure and roller deteriorate on further increase in fiber openness [2]. settings at all three drafting stages affect the yarn Card draft, coiler diameter and draw frame delivery properties in a similar way, and that fiber-to-fiber speed are also found to have significant effect on friction is a leading factor influencing the tensile yarn properties. It has been reported that yarn properties of ring spun yarn. tenacity, breaking elongation, evenness and hairiness are improved with increase in card coiler diameter Journal of Engineered Fibers and Fabrics 72 http://www.jeffjournal.org Volume 8, Issue 2 – 2013 The carding process has a vital role in the production All yarn samples were prepared by using Reiter C 60 of staple spun yarn and has significant effect on the Card, Reiter SB-2 Breaker Draw Frame, Reiter RSB- properties of the resulting yarn. In addition, drawing 35 Finisher Draw Frame, FA 458ASpeed Frame, and and doubling at the subsequent production stages also FA 1520 Ring Frame. The linear densities of the play an important role in determining the consequent prepared card sliver, finished sliver, and roving were yarn quality. It is evident from the literature review 6.38 ktex, 5.95 ktex, and 0.738 ktex respectively. The that previous work does not reveal the impact of yarn samples of 24tex were prepared from these preparatory process variables such as card cylinder rovings at a spindle speed of 18500 rpm with a twist speed, production rate, and number of draw frame multiplier of 4.54. doubling on the quality of ring spun yarn. This study was carried out to fill this gap using the Box Behnken Before testing, all the prepared yarn samples were statistical design of experiments. conditioned in the laboratory under standard atmospheric conditions of 21±1°C and a relative MATERIALS AND METHOD humidity of 65±2 for 24 h. A Zweigle G 566 Three process variables, card cylinder speed (rpm), hairiness tester was used to measure distribution of card production rate (kg/hr), and number of hairs per unit length on the yarn surface according to doublings at breaker drawing, were selected for ASTM D5647-01. Only the hairiness parameter ‘S3’ experimentation. Coded levels and actual values of (number of hairs greater than 3mm) was considered, these variables are given in Table I. which is known to significantly affect the appearance and performance of yarns. TABLE I. Experimental factors and their levels. Yarn unevenness and imperfections were determined by using Uster Tester-4 according to ASTM D 1425- 96. Total yarn imperfections (IPI) were calculated by adding -50% thin, +50% thick and +200% neps. A Uster Tensojet-4 was used determine the breaking elongation and tenacity of yarn samples according to ASTM D-76. RESULTS AND DISCUSSIONS The complete Box-Behnken experimental design and the yarn test results are given in Table II. The Yarn samples were prepared according to the experimental design and statistical analyses were combinations of different factor levels as determined performed using the Minitab16® statistical software by Box-Behnken factorial experimental design. Box- package. The regression coefficients and p-values of Behnken is one of the most advanced response all the terms are given in Table III. The terms with p- surface methodology (RSM) experimental designs values less than 0.05 are considered statistically employed to understand the quantitative relationships significant with 95% confidence. The regression between multiple input variables and response equations, considering the actual values of input variables. variables, are given in Table IV for all the response variables. The R2 values give the percentage of Pakistani Cotton with upper half mean length of variation in the response variables that can be 27.18 mm, strength of 31.5 g/tex, elongation of 5.8 % explained by the factors/terms included in the ,and micronaire of 4.6 µg/inch respectively, was used regression equations. The impact of all the factors on to prepare the yarn samples of 24 tex linear density. each response variable is separately discussed in the following sections. Journal of Engineered Fibers and Fabrics 73 http://www.jeffjournal.org Volume 8, Issue 2 – 2013 TABLE II. Box-Behnken experimental design and yarn test results. S. No. Factors/Input Responses/Output variables x1 x2 x3 Hairiness (S3) Um (%) IPI Elongation (%) Tenacity (RKM) 1 -1 -1 0 1081.1 11.5 426 4.26 18.29 2 1 -1 0 1324.7 11.42 277 4.42 17.97 3 -1 1 0 1222.91 12.16 565 4.42 17.12 4 1 1 0 1224.3 12.02 475 4.28 17.46 5 -1 0 -1 331.4 11.93 491 3.67 17.29 6 1 0 -1 733.9 11.95 382.5 3.63 16.35 7 -1 0 1 485.2 11.91 536 3.69 16.77 8 1 0 1 815.4 11.73 368 3.78 16.11 9 0 -1 -1 1204.5 11.66 332 3.96 16.59 10 0 1 -1 377.5 12.27 612.5 3.62 17.1 11 0 -1 1 1491.6 11.45 332 4.42 15.64 12 0 1 1 466.1 11.95 538.5 3.68 16.54 13 0 0 0 1643 11.76 451 4.4 17.81 14 0 0 0 1579 11.39 340 4.29 17.68 15 0 0 0 1480 11.77 391 4.35 18.11 TABLE III. Regression coefficients for different response variables using coded values of the input variables. Hairiness (S ) Um% IPI Elongation (%) Tenacity (RKM) Term 3 Coeff. P-Value Coeff. P-Value Coeff. P-Value Coeff. P-Value Coeff. P-Value x1 122.21 0.322 -0.0475 0.402 -64.438 0.011* 0.00875 0.899 -0.1975 0.381 x2 -226.39 0.097 0.2962 0.002* 103.000 0.001* -0.13250 0.100 -0.0337 0.876 x3 76.38 0.523 -0.0962 0.123 103.000 0.751 0.08625 0.246 -0.2838 0.226 2 x1 -323.77 0.105 0.0913 0.286 16.188 0.528 -0.11458 0.289 0.0029 0.993 2 x2 -30.32 0.860 0.0437 0.591 25.563 0.333 0.11292 0.296 -0.1596 0.620 2 x3 -652.09 0.010* 0.1487 0.109 34.188 0.212 -0.53958 0.003* -1.2396 0.009* x1x2 -60.55 0.716 -0.0150 0.846 14.750 0.549 -0.07500 0.456 0.1650 0.595 x1x3 -18.08 0.913 -0.0500 0.526 -14.875 0.545 0.03250 0.741 0.0700 0.819 x2x3 -49.63 0.765 -0.0275 0.723 -18.500 0.457 -0.10000 0.331 0.0975 0.751 *Statistically significant terms TABLE IV.
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