INTRODUCTION

• A critical investigation of the structure at the region of yarn

break reflects some interesting information from which an insight
into the mechanism of spun yarn failure is obtained
• The failure zone is defined by the length of yarn immediately
adjacent to the failed end and its appearance is significantly
different from the remaining yarn structure
• The length of the failure zone depends on the proportion of
broken fibres during tensile rupture of yarn
OBJECTIVES

•To investigate the failure zone of

yarns corresponding to different
spinning technologies at variable
strain-rates and gauge lengths
MATERIALS AND METHODS

• After tensile failure, the broken pieces of yarns were

collected
• Lieca digital microscope: Magnification 20 x
• The images of the failure zones were recorded
• Image analysis was applied to determine the size and
structure of the failure zone
• Lieca- Quin image analyzer
RING YARN FAILURE ZONE

Ring yarn broken ends at 5 mm/min

Ring yarn broken ends at 5000 mm/min

ROTOR YARN FAILURE ZONE

Rotor yarn broken ends at 5 mm/min

Rotor yarn broken ends at 5000 mm/min

AIR- JET YARN FAILURE ZONE

Air-jet yarn broken ends at 5 mm/min

Air-jet yarn broken ends at 5000 mm/min

DREF-II YARN FAILURE ZONE

Dref II yarn broken ends at 5 mm/min

Dref II yarn broken ends at 5000 mm/min

EFFECT OF STRAIN RATE ON FAILURE ZONE LENGTH

Spinning system Strain rate Yarn tenacity Broken fibre Failure zone
(mm/min) (cN/tex) (%) length (mm)

5 11.7 55.9 3.12

50 12.9 64.4 2.46
Ring spun
500 14.0 72.3 1.84
5000 17.3 83.4 1.30
5 8.5 47.2 4.82
50 9.5 52.5 3.50
Rotor spun
500 9.8 59.1 3.06
5000 11.6 69.5 2.33
5 6.1 38.5 6.26
50 7.1 46.4 5.19
Air-jet spun
500 8.1 51.5 3.50
5000 9.9 58.8 3.00
5 4.1 29.4 10.59
50 4.8 33.2 7.97
OE-friction spun
500 5.2 36.4 7.56
5000 5.7 40.3 5.92
EFFECT OF GAUGE LENGTH ON FAILURE ZONE LENGTH

Spinning system Gauge Length Yarn tenacity Failure zone length (mm)
(mm) (cN/tex)

5 18.4 0.84

50 14.9 1.46
Ring spun
500 13.8 1.98

5 16.3 0.97

50 11.4 2.39
Rotor spun
500 9.5 3.34

5 19.1 0.73

50 10.2 3.25
Air-jet spun
500 7.4 4.92

5 11.0 4.06

50 6.3 5.22
OE-friction spun
500 4.4 9.76
CONCLUSIONS

• The structures of failure zones at low rate of extension

show the torpedo like section for all the yarns and the
tapering of the failure ends is more prominent for air-jet and
open-end friction spun yarns than ring and rotor yarns

• The failure zone structure differs substantially at higher

rate of extension as compared to the lower one, but the
structure of failure ends of open-end friction spun yarn
remains torpedo like even at high rate of extension

• The size of failure zone increases continuously with the

test length
Tensile Properties of Blended Yarns
 Tensile Properties of Blended Yarn
When a blended yarn is extended by an applied load, the fibres
of the least extensible component are strained to the breaking
point first.

As they break, the fibres of second component will have to

bear an extra share of load.
It will depend on their tensile properties and the number of
them present in the blend.
Consider yarn linear density T tex
Consist of two different fibre components A and B
Percentage of component A a%
Percentage of component B b%
Fig. 1 (a) and Fig. 1(b)
 TA = aT/100
TB = Bt/100

Where TA is the tex number for component A and TB tex number

for B.
When the strain reaches x1 all the fibres of A will be on the point
of breaking.
And total load P1 supported by the composite yarn will be the
sum of the loads supported by the two components P1A and
P1B
Where, P1A = aTSA/100
P1B = bTS1B /100
If S1 is yarn tenacity at x1

S1 = P1/T = (aTSA /100 + bTS1B /100 )/T g/tex

= (aSA + b S1B )/100
All fibres of component A will break, and the second rupture point at x2
when all fibres of B break.

P2 = P2B
= bTSB/100
If S2 is yarn tenacity at x2

S2 = P2 / T = bTSB /100T = bSb /100

It will be seen that in Fig.1(a) and Fig. 1(b), where SB > SA > S1B
The yarn tenacity decreases to a point X and then increases as a decreases.
Extent of this decline depends on the relative value of SB, SA and S1B
When b is small, as the A fibres break, the very few B fibres cannot sustain
the large extra load applied to them, and they break too.
As a decreases, fewer A fibres to bear the load thus the tenacity of the
blended yarn decreases, and thre are still few B fibres to bear the still
substantial load increases when all the a fibres rupture .
However, at the point X, a has decreased and b increased to such an extent
that when A fibres break there are sufficient B fibres to bear the extra load
and they will survive until they reach their own breaking strain.
Therefore, as b increases to 100%, the tenacity of yarn increases.
Fig.2(a) and 2(b)
Fiig.3(a) and Fgig.3(b)
 Tensile strength of ring, rotor and air-jet yarns
(theoretical yarn strength is predicted from fibre properties)
 Tensile strength of ring, rotor and air-jet yarns
(theoretical yarn strength is predicted from yarn properties)
 F1 (first fibre)
F2 (second fibre)
strand axis F3 (third fibre)
F4 (fourth fibre)

Fn (nth fibre)

Ln

L4
L3
L2
Schematic view of evaluation of Fibre overlapping indices in yarns

•Start adding the total length as soon as first two fibres start overlapping
•Consider the area of overlapping up to which first fibre, which is overlapping, terminates
than put the values of L1 to Ln in the formula of FOI
•For remaining part repeat the exercise with same assumption
L2 is the simultaneous fibre overlapping length of first two fibres ( F1 & F2)
L3 is the simultaneous fibre overlapping length of first three fibres ( F1, F2 & F3)
Ln is the simultaneous fibre overlapping length of first n fibres( F1, F2, F3 & Fn)

for two fibres overlapping i=2, & for n simultaneous fibres overlapping i=n;

Total fibre overlapping by first two fibres =2xL2

Total fibre overlapping by first three fibres =2x(L2 –L3) +L3x3

=2L2 + L3

Total fibre overlapping by first four fibres =2x(L2 –L3) +(L3 –L4) x3 +4 x L4
= 2x L2 +L3 + L4
Total fibre overlapping by first n fibres =2x(L2 –L3) +(L3 –L4) x3 + 4 x (L4 – L5)
+........+ n-1(Ln – Ln-i) + n x Ln
= 2x L2 +L3 + L4 + .... + Ln

= L2 + L2 +L3 + L4 + .... + Ln
Total fibre length examined= n x Avg. fibre extent
n
Therefore, Fibre Overlapping Index = FOI  ( L2   Li) / n
i 2
x Average fibre Extent
‘FOI’ can ranges from 0 to 1 for no overlapping to total well straight and parallel fibres
overlaps (ideal case)
 Ring Yarn Ring Yarn
(Type I) (Type II) Rotor Yarn Air-jet Yarn
Fibre Extent (mm) 28.20 28.78 19.89 24.64
FPO (mm) 12.79 12.32 6.92 9.62
FOI 0.49 0.46 0.36 0.42
T H extent (mm) 1.11 1.29 2.39 1.17
T H Number 8.83 6.48 23.00 20.36
L H extent (mm) 1.48 1.80 3.06 1.65
L H Number 9.22 6.11 26.67 15.39
Av H extent (mm) 1.30 1.55 2.73 1.41
Total H Number 18.14 12.70 51.75 36.14

•Trailing Hook extent is smaller than leading hook extent in yarns

 Fibre
Ring yarn ( Type I) extent FPO FOI T H Ex T H N L H Ex L H N A H Ex To H N

Rank 3 2 2 3 3 3 2 3 3
%Vari.
EX 0.6 17.2 22.5 0.2 0.8 2.4 7.0 0.0 2.8
Lap Hank
F value 0.1 0.6 11.7 0.0 0.2 0.1 0.2 0.0 1.3

Rank 1 1 1 1 1 1 1 1 1
%Vari.
Card draft EX 58.9 21.2 52.7 51.9 61.1 53.8 33.2 52.0 71.0

F value 2.5 0.2 9.1 1.0 5.6 1.0 0.4 0.8 10.6
Rank 2 3 3 2 2 2 3 2 2
%Vari.
Draft/doublings EX 25.0 2.4 21.0 12.0 30.8 9.3 0.0 2.6 21.8

F value 3.2 0.1 10.9 0.7 8.5 0.5 0.0 0.1 9.7
R*R 0.84 0.41 0.96 0.64 0.93 0.66 0.40 0.55 0.96
 Ring Yarn (Type II) fibre extent FPO FOI T H Ex THN L H Ex LHN A H Ex ToH N
Rank 2 2 2 2 2 2 2 2 2
%Vari.
32.7 16.9 27.2 17.6 28.8 15.6 2.8 19.5 18.2
Lap Hank EX
F value 3.3 1.3 2.3 0.5 1.5 0.6 9.1 0.7 3.4

Rank 1 1 1 1 1 1 1 1 1
%Vari.
47.1 56.5 48.7 13.1 23.1 21.6 95.8 20.9 69.3
Card draft EX
F value 1.6 1.4 1.4 0.1 0.4 0.3 103.6 0.3 4.3

Rank 3 3 3 3 3 3 3 3 3
%Vari.
Draft/doubling 0.24 0.08 0.22 0.45 8.35 12.02 0.82 3.05 1.71
EX
s
F value 0.02 0.01 0.02 0.01 0.42 0.47 2.65 0.11 0.32

R*R 0.80 0.73 0.76 0.31 0.60 0.49 0.99 0.43 0.89
Rotor Fibre
yarn extent FPO FOI T H Ex T H N L H Ex L H N A H Ex To H N
Rank 2 1 2 3 2 3 3 3 3
%Vari.
Lap
EX 29.8 77.3 35.7 0.2 30.3 0.0 1.5 0.0 6.6
Hank
F value 3.5 24.5 13.0 0.5 2.6 0.0 0.3 0.0 2.7
Rank 1 2 1 1 1 1 1 1 1
Card %Vari.
draft EX 52.8 11.7 49.0 86.5 44.0 31.7 44.2 69.0 33.5
F value 2.1 1.2 6.0 56.8 1.3 0.4 2.7 1.5 4.6
Rank 3 3 3 2 3 2 2 2 2
Draft/
%Vari.
doubling
EX 0.4 4.7 9.8 12.2 2.4 10.5 43.2 0.8 55.1
s
F value 0.1 1.5 3.6 24.1 0.2 0.4 7.8 0.1 22.7
R*R 0.83 0.94 0.95 0.99 0.77 0.42 0.89 0.70 0.95
 Fibre
Airjet yarn extent FPO FOI T H Ex T H N L H Ex L H N A H Ex To H N
Rank 3 2 3 3 2 2 2 3 2
%Vari. EX 22.3 27.0 15.4 9.3 22.6 16.1 2.0 11.5 2.8
Lap Hank
F value 1.8 1.9 14.5 0.7 1.5 1.2 0.3 0.9 0.9
Rank 1 1 1 1 1 1 1 1 1
Card draft %Vari. EX 29.3 33.0 58.4 22.6 35.6 57.3 82.7 59.1 79.7
F value 0.8 0.8 18.2 0.6 0.8 1.4 3.6 1.5 8.2
Rank 2 3 2 2 3 3 3 2 3

Draft/doubling %Vari. EX 23.3 10.7 23.9 43.1 12.3 0.0 0.0 3.4 11.0
s
F value 1.9 0.7 22.3 3.5 0.8 0.0 0.0 0.3 3.4
R*R 0.75 0.71 0.98 0.75 0.70 0.73 0.85 0.74 0.94
 Regression Model of Fibre Orientation Parameters of Ring Yarn Type I ( in term of S/N ratio)
% ffect of R/F
Parameters Regression Model or S/F draft R*R
fibre extent 91.2 - 15227 Lh - 0.198 cdrft - 0.00020 d/d - 1.00 Ring draft 63.7 0.915
FPO 38.8 - 5347 Lh - 0.041 cdrft - 0.0085 d/d - 0.235 Ring draft 2.8 0.248
FOI - 64.7 + 12630 Lh + 0.202 cdrft - 0.0048 d/d + 0.981 Ring draft 29.2 0.807
T H Ex 332 - 84095 Lh - 0.996 cdrft - 0.0148 d/d - 5.50 Ring draft 44.3 0.711
THN 354 - 93545 Lh - 1.18 cdrft + 0.0100 d/d - 5.91 Ring draft 61.5 0.962
L H Ex - 36 + 7855 Lh + 0.099 cdrft - 0.0180 d/d + 0.62 Ring draft 2.6 0.204
LHN 18 - 11629 Lh - 0.090 cdrft - 0.0079 d/d - 0.58 Ring draft 2.8 0.178
A H Ex 137 - 34976 Lh - 0.417 cdrft - 0.0158 d/d - 2.28 Ring draft 23.3 0.31
To H N 190 - 54994 Lh - 0.665 cdrft - 0.0009 d/d - 3.41 Ring draft 55.8 0.806
Regression Model of Fibre Orientation Parameters of Ring Yarn Type II ( in term of S/N ratio)
fibre extent 62.4 - 9408 Lh - 0.0979 cdrft - 0.0085 d/d - 1.12 S/F draft 15.7 0.528
FPO 61.7 - 10840 Lh - 0.121 cdrft - 0.0079 d/d - 1.38 S/F draft 17.0 0.39
FOI - 2.3 - 1888 Lh - 0.0083 cdrft - 0.00154 d/d - 0.121 S/F draft 0.5 0.29
T H Ex - 125 + 23337 Lh + 0.413 cdrft + 0.020 d/d + 5.3 S/F draft 5.9 0.251
THN - 231 + 60156 Lh + 0.619 cdrft + 0.0109 d/d + 7.71 S/F draft 32.5 0.72
L H Ex - 45 + 1743 Lh + 0.162 cdrft + 0.082 d/d + 1.80 S/F draft 0.8 0.288
LHN - 290 + 67656 Lh + 0.871 cdrft + 0.0746 d/d + 9.82 S/F draft 59.3 0.852
A H Ex - 56 + 4324 Lh + 0.179 cdrft + 0.045 d/d + 2.17 S/F draft 1.5 0.24
To H N - 273 + 65472 Lh + 0.768 cdrft + 0.0442 d/d + 9.03 S/F draft 71.2 0.949
 Regression Model of Rotor Yarn (in term of S/N ratio)
Parameters Regression Model % variation R*R
explained
Rotor /A/J draft
fibre extent 24.5 - 347 Lh + 0.0003 cdrft - 0.00032 d/d + 0.0110 Rotor Draft 0.7 0.823
FPO 47.4 - 10234 Lh - 0.0827 cdrft + 0.00197 d/d - 0.0474 Rotor Draft 6.6 0.909
FOI 16.4 - 8192 Lh - 0.0616 cdrft + 0.00304 d/d - 0.0463 Rotor Draft 10.4 0.828
T H Ex - 114 + 26679 Lh + 0.307 cdrft + 0.0461 d/d + 0.207 Rotor Draft 49.6 0.948
THN - 35.9 + 3357 Lh + 0.018 cdrft + 0.0056 d/d + 0.0113 Rotor Draft 0.7 0.335
L H Ex - 66.4 + 14938 Lh + 0.165 cdrft - 0.0092 d/d + 0.113 Rotor Draft 9.5 0.283
LHN - 23.7 - 800 Lh - 0.020 cdrft - 0.0278 d/d - 0.0012 Rotor Draft 0.0 0.656
A H Ex - 95.5 + 20621 Lh + 0.233 cdrft + 0.0147 d/d + 0.159 Rotor Draft 29.1 0.532
To H N - 29.7 480 Lh - 0.0194 cdrft - - 0.0122 d/d - 0.0075 Rotor Draft 0.9 0.867
Regression Model of Air-jet Yarn Fibre Orientation Parameters (in term of S/N ratio)
fibre extent 8.4 + 4160 Lh + 0.0667 cdrft - 0.00293 d/d + 0.0393 A/J draft 22.6 0.706
FPO 4.3 + 2199 Lh + 0.0614 cdrft + 0.0120 d/d + 0.0296 A/J draft 5.3 0.715
FOE - 16.1 + 3369 Lh + 0.0562 cdrft + 0.00555 d/d + 0.0274 A/J draft 22.7 0.509
FOI 19.7 - 7685 Lh - 0.0770 cdrft + 0.00225 d/d - 0.0520 A/J draft 32.7 0.935
T H Ex 124 - 31954 Lh - 0.378 cdrft - 0.0820 d/d - 0.220 A/J draft 27.2 0.849
THN - 26 - 9521 Lh + 0.098 cdrft - 0.077 d/d + 0.035 A/J draft 0.1 0.385
L H Ex 101 - 20729 Lh - 0.386 cdrft - 0.0256 d/d - 0.201 A/J draft 13.4 0.599
LHN - 167 + 29181 Lh + 0.548 cdrft + 0.035 d/d + 0.253 A/J draft 5.4 0.501
A H Ex - 97 + 8447 Lh + 0.305 cdrft - 0.022 d/d + 0.134 A/J draft 1.6 0.346
To H N 92.0 - 22777 Lh - 0.340 cdrft - 0.0443 d/d - 0.185 A/J draft 32.3 0.831
 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

30
29.5
29
S/N ratio of fibre extent

28.5
28
27.5
27
26.5
26
25.5
25
0.001220.00144 88 101 114 127 6 by 6 8 by 8
Lap Hank Card draft Draft/Doublng

• A 101 or 114 card draft and corresponding medium ring or speed frame draft gives
the highest fibre extent in ring yarns
• The effect of Krpm in finisher sliver retains in rotor and air-jet yarns.
• A127 card draft and corresponding lower air-jet draft gives the highest fibre extent
and fibre-pair-overlap in air-jet yarn
 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

22
S/N ratio of fibre-pair-overlap

19

16
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

• Trends FPO in ring yarn are similar to Krpm in roving.

• Trends of FPO are similar to fibre extent in air-jet yarn.
 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn
-5.5
-6
-6.5
S/N ratio of FOI

-7
-7.5
-8
-8.5
-9
-9.5
-10
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

• FOI trends are opposite to the trends of fibre extent in ring yarn type I and same in ring
yarn type II
 S/N ratio Plot of Trailing Hook Extent
Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

1
0
S/N ratio of trailing hook extent

-1
-2
-3
-4
-5
-6
-7
-8
-9
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

-15
S/N ratio of number of trailing hooks

-18

-21

-24

-27

-30
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

•In ring yarn type I, trends is similar to fibre extent

 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

-2
S/N ratio of leading hook extent

-5

-8

-11
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

-14.5
S/N ratio of number of leading hooks

-17.5

-20.5

-23.5

-26.5

-29.5
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

•In ring yarn type II, trends is similar to fibre extent

 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

-2
S/N ratio of average hook extent

-4

-6

-8

-10

-12

-14

-16
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

• Trends of trailing, leading & total hook extent in rotor yarns are similar to trends of ρ
in forward, reverse and their averagein finisher sliver
 Ring yarn type I Ring yarn type II Rotor yarn Air-jet yarn

-21
S/N ratioof total number of hooks

-23

-25

-27

-29

-31

-33

-35
0.00122 0.00144 88 101 114 127 6 by 6 8 by 8

Lap Hank Card draft Draft/Doublng

• Hook removal is more in ring type II than ring Yarn Type I

• Total number of hooks in rotor yarns do not depend on rotor draft
1. Changes in FOI are best explained by changes in process
variables in all yarns
2. Effect of Krpm with change in lap hank & draft/doublings on
fibre overlapping indices is retained in rotor and A/J yarns.
3. No. of trailing hooks < no. of leading hooks if draft is changed at
R/F/ rotor, but > if draft is changed at S/F /A/J
4. Fibre extent improves, overlapping indices reduces and trailing
hooks extent and their number decreases in A/J if less
draft/doublings finisher sliver is fed
• Tension difference between fibres at different radial positions
in a twisted yarn is one of the factors that is responsible for
fibre migration.
• Fibre faces different tension conditions
• Fibres at core will have minimum tension because of shorter
path.
• But fibres on the surface will come to have maximum tension.
Hence fibres lying near the surface will try to migrate into
inner zones to lower its energy.
This will lead to a cyclic interchange of fibres between core
and surface.
Morton , TEXT. Res.J., (1956)
• The bundle of fibres as coming out from drafting system is in the
ribbon form is turned into the yarn and the fibres on one side of
the ribbon will go to the centre of the yarn while those on the
other side will appear on the surface
• Therefore flat ribbon can be twisted in two ways:
• Normal twisting of ribbon
• Wrapping mechanism of flat ribbon (hollow structure is
created in the core of the yarn)
Fibres lying on the surface will show maximum migration
tendencies while those in the core will migrate little and
occupy intermediate position in the yarn.
Hearle and Bose Text. Res. J. (1965)
• Fibre migration is the cyclic change in the
distance of elements of a fibre or filament
(along its length) from the axis of a yarn, which
occurs during production of yarn.
Fibre Related Factors
- Higher modulus fibre develops more tension, hence occupies the core
position in the yarn.
- In any spun yarn the tendency of fibres to coil up and pack
closely when twisted, depends on the following parameters :
(1/h-2/E)
where h is the torsional rigidity of fibre and E is its bending modulus

Greater the positive value of this parameter, the closer is the packing and
hence occupy the core of yarns.
The component with lower value of (1/h-2/E) will be displaced to the
surface.
In general, longer, finer and higher modulus fibres tend to migrate to the core
of the yarn
Cassie,A.B.D., J.Text. Inst.(1949)
• Yarn Related Factors
Two main factors influence fibre migration
1. Yarn twist
Rapid rise of migration with the increase of yarn twist.
Frequency of migration is strongly correlated to the
frequency of twist in the yarn.

2. Linear density of yarn

Higher is the linear density higher is the rate of migration.
Hearle & Gupta, Text. Res. J., (1965), Morton, Text.Res.J., (1956)
• Processing Related Factors
1. Type of Spinning System
2. Machine Geometry
3. Machine Settings
4. Machine Parameters
 Vertical Scale
Yarn Surface
Tracer Fibre

θ r

Horizontal Scale
Z

Schematic view of a tracer fibre under

projection microscope

8
Overall tendency of fibre to be away from the
yarn axis

1 Zn
Mean Fibre Position Y
zn  o
Y dz

 Y / n
Where n observations of Y were made over a
length Zn
 1/2
1 Zn 
RMS Deviation D  (Y  Y ) dz 
2

 zn 
o

1/2
 (Y  Y ) / n  2
• Mean migration intensity 1 2

1/2
Zn  dY 
I 
 zn
 0   dz 
 dz  

1/2
 (dY / dz ) / n  2
m m m
mWnWn  s  Wn Wn  s
Ts  1 1 1
1
  m    m 2  m  
2 2 2

 m
 mWn   Wn   mWn  s   Wn  s  
2

  1  1    1  1  

m N s
• Where.
 k  l / k
• Where k the wavelength of the kth coefficient, and l = the
extent length of the trace being analysed.
Yarn Extension 0% 4% 8% 12%

MFP 0.459 0.465 0.439 0.442

(13.94) (16.88) (15.09) (14.73)

RMSD 0.359 0.356 0.338 0.333

MMI 1.783 1.664 1.569 1.489

 Yarn Extension 0% 4% 8% 12%

Dia of Yarn (mm)Dy 0.230 0.166 0.161 0.156

(27.87) (3.19) (2.80)

Helix Dia (mm)DH 0.143 0.104 0.097 0.095

(27.35) (6.56) (2.27)

Ratio= Dy/DH 0.619 0.623 0.602 0.605

Influence of Process Parameters on Migration
Characteristics (DREF-2 Yarn)

15
 Microscope
Circular
Rod knob

Gears
Yarn
Light

Schematic diagram of setup for three-dimensional study

 Two-dimensional migration Three- dimensional migration
S. Ref. 1st sliver feeding 5th sliver feeding 1st sliver feeding 5th sliver feeding
no.
MFP RMS MMI MFP RMS MMI MFP RMS MMI MFP RMS MMI
OE1 0.765 0.239 5.32 0.154 0.122 2.68 0.813 0.296 5.830 0.172 0.122 2.673
OE2 0.787 0.256 4.92 0.139 0.109 2.05 0.828 0.282 5.610 0.158 0.115 2.223
OE3 0.775 0.252 4.80 0.174 0.135 2.75 0.836 0.287 5.364 0.192 0.137 2.754
OE4 0.781 0.262 5.46 0.145 0.115 2.37 0.838 0.286 6.028 0.158 0.113 2.301
OE5 0.816 0.238 5.11 0.139 0.108 1.78 0.853 0.268 5.277 0.153 0.109 1.771
OE6 0.807 0.262 4.85 0.131 0.107 2.00 0.847 0.290 5.262 0.147 0.113 2.131
OE7 0.742 0.260 5.81 0.168 0.128 2.70 0.795 0.279 6.429 0.182 0.131 2.754
OE8 0.758 0.222 5.12 0.156 0.110 2.59 0.805 0.240 5.723 0.166 0.107 2.546
OE9 0.776 0.256 4.75 0.090 0.092 1.51 0.836 0.315 5.259 0.105 0.095 1.570
OE10 0.760 0.224 4.12 0.121 0.099 1.89 0.829 0.258 4.720 0.139 0.104 1.898
OE11 0.736 0.254 6.24 0.202 0.134 3.51 0.770 0.265 6.650 0.213 0.132 3.388
OE12 0.749 0.251 5.20 0.128 0.099 2.50 0.795 0.267 5.936 0.140 0.101 2.565
OE13 0.769 0.224 3.99 0.123 0.092 2.01 0.810 0.261 4.695 0.135 0.092 2.098
OE14 0.790 0.249 4.60 0.123 0.090 1.83 0.827 0.273 5.209 0.137 0.094 1.900
OE15 0.760 0.215 4.23 0.145 0.097 2.19 0.846 0.256 4.927 0.160 0.100 2.235
Parameter Response Surface Equations R2
Two-dimensional migration parameters
1st sliver feeding position
MFP 0.760 - 0.022*X3 + 0.016*X1*X1 0.670
RMS 0.244 - 0.015*X1*X3 0.262
MMI 4.967 + 0.443*X3 0.301
5th sliver feeding position
MFP 0.133 + 0.022*X1 + 0.018*X1*X1 - 0.026*X2*X3 0.777
RMS 0.095 – 0.006*X1 + 0.008*X3 + 0.017*X1*X1 + 0.01*X2*X2 – 0.011*X2*X3 0.844
MMI/cm 2.16 + 0.515*X3 + 0.251*X2*X2 -0.347*X2*X3 0.782
Three-dimensional migration parameters
1st sliver feeding position
MFP 0.822 - 0.025*X3 0.658
RMS 0.262 - 0.007*X2 - 0.010*X3 + 0.009*X1*X1 + 0.016*X1*X2 + 0.015*X2*X3-– 0.015*X1*X3 0.864
MMI/cm 4.944 + 0.528*X3 + 0.398*X1*X1 + 0.366*X2*X2 + 0.331*X3*X3 0.753
5th sliver feeding position
MFP 0.147 - 0.009*X1 +0.020*X3 + 0.019*X1*X1 - 0.027*X2*X3 0.822
RMS 0.097 - 0.006*X1 + 0.006*X3 + 0.016*X1*X1 + 0.009*X2*X2 -0.010*X2*X3 - 0.007*X1*X3 0.875
MMI/cm 2.320 + 0.485*X3 - 0.288*X2*X3 0.721
• 3- dimensional study gives actual position of fibres in the yarn

• MFP, MMI and RMS deviation values are higher for 3-dimensional study
 Parameter Response surface Equations R2
MFP 0.822 – 0.025*X3 0.658

RMSD 0.262 – 0.007*X2 – 0.01*X3 + 0.009*X1*X1 + 0.864

0.016*X2*X2 + 0.015*X2*X3 – 0.015*X1*X3

MMI/cm 4.944 + 0.528*X3 +0.398*X1*X1 + 0.366*X2*X2 + 0.753

0.331*X3*X3
MFP (Trailing half) 0.874 – 0.032*X3 – 0.020*X2*X2 – 0.021*X3*X3 0.815
RMS deviation (Trailing half) 0.263 – 0.011*X2 + 0.016*X2*X2 + 0.016*X2*X3 0.518

MMI/cm (Trailing half) 5.228 – 0.429*X2 + 0.515*X3 + 0.447*X1*X1 + 0.773

0.358*X3*X3
MFP (Leading half) 0.785 + 0.015*X2 – 0.023*X3 + 0.026*X1*X1 0.688
RMSD (Leading half) 0.224 – 0.044*X1*X3 0.361
MMI (Leading half) 4.473 + 0.380*X3 + 0.349*X1*X1 + 0.552*X2*X2 0.726
20
 Parameter Response surface Equations R2

MFP 0.147 – 0.009*X1 +0.020*X3 + 0.019*X1*X1-0.027*X2*X3 0.822

RMSD 0.097 – 0.006*X1 + 0.006*X3 + 0.016*X1*X1 + 0.009*X2*X2 - 0.875

0.010*X2*X3 – 0.007*X1*X3

MMI/cm 2.320 + 0.485*X3 – 0.288*X2*X3 0.721

MFP (Trailing half) 0.142 – 0.014*X1 + 0.23*X3 – 0.020*X2*X3 0.740

RMSD (Trailing half) 0.087 – 0.008*X3 + 0.011*X1*X1 + 0.010*X2*X2 + 0.010*X3*X3 0.781

MMI/cm (Trailing half) 2.201 + 0.542*X3 – 0.263*X2*X3 0.753

MFP (Leading half) 0.158 + 0.015*X3 + 0.031*X1*X1 – 0.033*X2*X3 0.847

RMSD (Leading half) 0.095 – 0.008*X3 + 0.023*X1*X1 + 0.010*X2*X2 0.802

MMI/cm (Leading half) 2.27 + 0.390*X3 – 0.36*X2*X3 0.627

 MFP of OE friction yarn

• Fibres from 1st feeding position 1

feeding 1

MFP
0.5
have higher MFP, RMSD and MMI 0
feeding 5

• Trailing half of fibres have higher

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S. No

of MFP, RMSD and MMI for 1st

feeding positions bur reverse RMSD of OE friction yarn

trend for 5th feeding position 0.4

RMSD
feeding 1
0.2
feeding 5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S. No.

MMI of OE friction yarn

MMI/cm 10
feeding 1
5
feedind 5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S. No.
MFP for 1st sliver feeding position of OE friction yarns
 • MFP increases with the increase in suction air pressure upto 12% difference in drum
speed
• MFP increases with the increase in difference in drum speed up -20 mbar suction air
pressure
• MFP decreases with the increase in difference in drum speed beyond -20 mbar suction
air pressure
• MFP decreases with the increase in opening roller speed upto 12500 rpm and then
increases

1.0 1.0 1.0

1 20 9 18
0.2 0. 0.1
8 17 0.1 0.
0.
19
0. 6 17

Suction air pressure (mbar)

0.
Suction air pressure (mbar)

1
Suction air pressure (mbar)

0.

0.5 18 0.5 0.5

0.
5 16
0.
1 0.

0.0 0.0 0.0

0.

0. 0.
17

14 15
-0.5 -0.5 -0.5
0.

0.16
0.15
16 0. 0.
13 14
0.1 0. 0.
4 15 0. 13
12

-1.0 -1.0 -1.0

-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Differenceindrumspeed(rpm) Differenceindrumspeed(rpm) Differenceindrumspeed(rpm)

a) OR speed = 10000 rpm b) OR speed = 12000 rpm c) OR speed = 14000 rpm

Fig 6.4:MFP for 5th sliver feeding position of OE friction yarn

 • RMSD initially decreases and then increases with the difference in drum speed and
suction air pressure at 10000 rpm opening roller speed
• RMSD decrease with the increase in suction air pressure beyond 12000 rpm
• Minimum value of RMSD observed at 13160 rpm opening roller speed, 8.6 %
difference in drum speed and -23.5 mbar suction air pressure

1.0 1.0 1.0

0.28

0.2

0.275
0.2
0.2

85

0.270
0

90
80

Suction air pressure (mbar)

0. 28

Suction air pressure (mbar)

Suction air pressure (mbar)

0.5 0.5 0.258 0.5 0.26

0.27
0.290

0.0 0.2
70 0.0 0.0
0.295

0.26
5
-0.5 0.28
-0.5 -0.5

0.264
0.2

0. 2
0. 3
0. 2
0.2

0. 2
76
0. 2

70
00

0.2

0.
94
88

0.
0 64
0.26

0.
31
32
9
82

30
-1.0 -1.0 -1.0
-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Differenceindrumspeed(%) Differenceindrumspeed(%) Differenceindrumspeed(%)
a) OR speed = 10000 rpm b) OR speed = 12000 rpm c) OR speed = 14000 rpm

Fig. 6.5: RMSD for 1st sliver feeding position of OE friction yarn
 • Initially decreases and then increases with difference in drum speed
• Increases with suction air pressure upto 12000 rpm opening roller speed
• Initially decreases and then increases with the increase in opening roller speed
• Minimum value observed at 12000 rpm opening roller speed, 7.5 % difference in
drum speed and -15 mbar suction air pressure

1.0 1.0 1.0

5 30
13

12
40
5

0.1

08

04

0
16
0.
14

0.11 0.12
0.1
0.100

0.1

0.1
0.

0.1
0.

Suction air pressure (mbar)

Suction air pressure (mbar)

8
Suction air pressure (mbar)

0.1
0.12
0.5

06
5
0.5 0.5

16
0.1
14
12
0.104

0.1
0.1
0.1
20
0.0

10
0.0 0.0

0.1

08
0.0
96

0.1

10
08
0.1

0.1
15

0.1

12

0.1 14
-0.5

0.1

8
-0.5 -0.5

0.1

0.1 0.11
16
0.1 0.09
10 2

0.1 0
0.1

2
22
06

-1.0 -1.0 -1.0

-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Difference in drum speed (%) Difference in drum speed (%) Difference in drum speed (%)

a) OR speed = 10000 rpm b) OR speed = 12000 rpm c) OR speed = 14000 rpm

Fig 6.6: RMSD for 5th sliver feeding position of OE friction yarn
• Initially decreases upto 9 % difference in drum speed and then increases
• Marginally decreases upto -16 mbar suction air pressure and then increases

1.0 1.0 5.8

0 6.3 5.70 5
6.3 0 5
6.1
5 5.8
5.85 6.0 5.40

Suction air pressure (mbar)

5.5
Suction air pressure (mbar)

0 5
0.5 0.5 5.2
5
5.55 5.7
0 5.10

5.40 4.95
0.0 0.0
5.25

4.8
0

-0.5 -0.5

-1.0 -1.0
-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Difference in drum speed (%) Difference in drum speed (%)

a) OR speed = 10000, 14000 rpm b) OR speed = 12000 rpm

Fig 6.7: MMI for 1st sliver feeding position of OE friction yarn
• Increases with suction air pressure
• Increases with increase in difference in drum speed upto -20 mbar suction air
pressure
• Decreases with increase in difference in drum speed beyond -20 mbar suction
pressure
• Minimum MMI obtained at -15 bar suction air pressure and 5 % difference in
drum speed
1.0

2.4
2.2
Difference in drum speed (coded value)

6
2.
0.5
2.0

0.0

2.8
1.8

-0.5

-1.0
-1.0 -0.5 0.0 0.5 1.0
Suction air pressure (coded value)

Fig 6.8: MMI for 5th feeding position of OE friction yarn

 Migration Parameters of Core-Sheath Friction Yarns
for 1st feeding position
Comb. Overall fibre Trailing half of fibre Leading half of fibre
No. MFP RMS MMI MFP RMS MMI MFP RMS MMI
1 1.032 0.308 4.830 1.082 0.318 5.380 0.972 0.220 3.660
2 0.970 0.271 4.960 1.050 0.276 5.620 0.900 0.201 3.690
3 1.010 0.280 5.070 1.050 0.290 5.630 0.950 0.250 3.940
4 0.982 0.308 5.580 1.012 0.318 6.180 0.952 0.238 3.580
5 1.032 0.336 5.240 1.072 0.339 6.030 0.982 0.266 4.450
6 1.062 0.370 5.630 1.120 0.390 5.790 1.012 0.290 5.360
7 0.968 0.311 6.430 1.038 0.331 7.370 0.908 0.220 4.200
8 0.950 0.284 6.150 1.010 0.274 5.850 0.880 0.214 5.050
9 1.026 0.368 5.690 1.080 0.388 6.590 0.946 0.228 3.310
10 1.058 0.404 5.410 1.128 0.414 6.220 0.990 0.274 3.820
11 0.938 0.261 5.790 0.990 0.268 6.460 0.890 0.211 4.540
12 0.972 0.290 5.840 1.022 0.280 6.458 0.952 0.180 4.380
13 0.960 0.326 5.190 0.990 0.316 4.900 0.940 0.240 4.340
14 1.000 0.295 5.160 1.070 0.325 6.200 0.942 0.175 3.000
15 1.021 0.310 4.770 1.060 0.308 5.670 0.991 0.240 3.480
Migration Parameters of Core-Sheath Friction Yarns for
5th Sliver Feeding Position
Overall fibre Trailing half of fibre Leading half of fibre
Comb. MFP RMSD MMI MFP RMSD MMI MFP RMSD MMI
No.
1 0.640 0.174 3.320 0.645 0.161 3.270 0.636 0.158 3.180
2 0.626 0.180 3.390 0.628 0.166 3.580 0.624 0.154 2.770
3 0.635 0.198 3.230 0.642 0.178 3.440 0.629 0.156 2.640
4 0.628 0.183 3.160 0.629 0.145 3.190 0.626 0.159 2.900
5 0.648 0.195 3.190 0.663 0.191 3.160 0.633 0.159 2.880
6 0.638 0.181 2.992 0.642 0.185 2.840 0.625 0.175 2.960
7 0.624 0.166 3.410 0.633 0.157 3.570 0.617 0.153 2.960
8 0.592 0.167 3.383 0.596 0.159 3.500 0.587 0.151 3.030
9 0.632 0.177 2.716 0.636 0.160 2.660 0.629 0.152 2.610
10 0.634 0.165 2.478 0.639 0.151 2.450 0.628 0.148 2.390
11 0.618 0.161 3.300 0.624 0.157 3.560 0.614 0.139 2.760
12 0.612 0.144 3.250 0.621 0.141 3.260 0.608 0.125 2.920
13 0.633 0.182 2.980 0.631 0.173 2.900 0.636 0.164 2.900
14 0.627 0.184 3.112 0.629 0.188 3.130 0.618 0.164 2.650
15 0.640 0.159 2.760 0.655 0.152 2.710 0.645 0.141 2.460
Migration parameters of core-sheath friction yarns for 1st feeding position
Parameter Response surface Equations R2

MFP 0.999 – 0.044*X3 0.715

RMSD 0.300 – 0.042*X3 + 0.028*X3*X3 0.745

MMI/cm 5.080 + 0.28*X3 + 0.693*X3*X3 0.743

MFP (Trailing half) 1.052 – 0.042*X3 0.577

RMS (Trailing half) 0.307 – 0.047*X3 + 0.028*X3*X3 + 0.018*X1*X2 0.885

– 0.027*X1*X3

MMI/cm (Trailing half) 5.654 + 0.692*X3*X3 0.371

MFP (Leading half) 0.947 + 0.017*X2 – 0.038*X3 0.632

RMS (Leading half) 0.230 – 0.029*X3 0.462

MMI/cm (Leading half) 3.670 + 0.719*X3 0.328

31
Migration parameters of core-sheath friction yarns for 5th feeding position

Parameter Response surface Equations R2

MFP 0.633 – 0.008*X1 – 0.013*X3 – 0.008*X3*X3 – 0.874

0.006*X1*X3

RMSD 0.173 – 0.010*X3 + 0.012*X1*X1 – 0.010*X3*X3 0.627

MMI/cm 2.942 + 0.246*X3 + 0.317*X1*X1 0.800

MFP (Trailing half) 0.634 – 0.011*X1 – 0.013*X3 0.704

RMS (Trailing half) 0.172 – 0.009*X3 – 0.015*X2*X2 0.438

MMI/cm (Trailing half) 2.953 + 0.347*X3 + 0.366*X1*X1 0.794

MFP (Leading half) 0.631 – 0.007*X1 – 0.011*X3 – 0.013*X3*X3 0.731

RMSD (Leading half) 0.152 – 0.008*X3 + 0.010*X1*X1 – 0.009*X2*X2 0.620

MMI/cm (Leading half) 2.67 + 0.104*X3 + 0.245*X1*X1 + 0.167*X1*X2 0.640

 • Fibres from 1st feeding position have higher MFP, RMSD and MMI
• Trailing half of fibre have higher MFP, RMSD and MMI for both feeding
positions

MFP of core-sheath yarn RMSD of core-sheath yarn

1.5 0.6

RMSD
feeding 1 Feeding 1
MFP

1 0.4
0.5 Feeding 5 0.2 Feeding 5
0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S. No. S. No.

Fig 6.8a Fig 6.8b

MMI of core-sheath yarn

10
MMI/cm

feeding 1
5
feeding 5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S. No.

Fig 6.8c
• MFP for 1st feeding position decreases with the increase in suction pressure
• MFP for 5th sliver feeding position decreases with the increase in suction air
pressure and opening roller speed

1.050 1.000 0.6

08
0.6
08
0.6
12

Suction air pressure (mbar)

1.030 0.6
16
0.500 0.6
20

0.6
1.010 24
MFP

0.6
0.000 28

0.990
0.6
32

-0.500
0.970

0
0.64
0.6
36

0.950 -1.000
-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Suction air pressure (mbar) . Opening roller speed (rpm)

Fig 6.9a: MFP for 1st sliver feeding position Fig 6.9b: MFP for 5th sliver feeding position
1st sliver feeding position
• RMSD decreases with the increase in suction air pressure
5th sliver feeding position
• RMSD marginally increases upto -17.5 mbar suction air pressure and then
decreases
• RMSD decreases upto 12000 rpm opening roller speed and then increases

0.380 1.000
0.160

Suction air pressure (mbar)

0.164
0.360
0.500 0.168
RMS deviation

0.340 0.172

0.000
0.320

0.180

0.180

0.184
0.176

0.176
0.184
-0.500
0.300

0.280 -1.000
-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Suction air pressure (mbar) Opening roller speed (rpm)

Fig 6.10a: RMS deviation for 1st sliver feeding Fig 6.10b: RMS deviation for 5th sliver feeding
position position 35
1st sliver feeding position
• Decreases upto -19 mbar suction air pressure and then increases
5th sliver feeding position
• Increases with the increase in suction air pressure
• Initially decreases and then increases with increase in opening roller speed

6.240 1.000 3.

3.3

3.4
2

3.4

3.3

2
3.
3.1

Suction air pressure (mbar)

0.500
5.840
MMI (per cm)

3.0

0.000
2.9

5.440
-0.500 2.8

5.040 -1.000
-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Suction air pressure (mbar) Opening roller speed (rpm)

Fig. 6.11a: MMI for 1st sliver feeding position Fig 6.11bMMI for 5th sliver feeding position
• Three-dimensional analysis gives higher MFP, MMI and RMSD
• Fibres from 5th sliver feeding position shows lower MFP, RMSD and MMI for both yarns
Open-end friction yarns
• Trailing half of the fibre has higher MFP, RMSD and MMI for 1st sliver feeding position
but reverse trend for 5th feeding position
• MFP decreases at 1st feeding position and increases at 5th feeding position with suction
air pressure
• RMSD initially decreases and then increases with the increases in suction air pressure
• MMI in general increases with the increase in suction air pressure
Core-sheath friction yarns
• Trailing half of fibre has higher MFP, RMSD and MMI for both feeding positions
• MFP decreases with increase in suction air pressure and opening roller speed
• RMSD decreases with the increases in suction air pressure
• MMI initially decreases and then increases with the increase in suction air pressure
• Suction air pressure has major influence on migration parameters
 Yarn extension (%)

0% 4% 8% 12%
Packing density
0.457 0.825 0.842 0.840

Increase in packing density (%) 80.53 2.06 -0.24

0.230 0.166 0.161 0.156

Yarn diameter (mm)
(8.439) (9.444) (8.628) (8.158)

Decrease in yarn diameter (%) 27.82 3.19 2.80

 0.9
Average packing density of yarn

0.8

0.7

0.6

0.5

0.4

0.3
0% 2% 4% 6% 8% 10% 12%
Yarn extension(%)
 Zone Zone radius Packing density at different yarn extension levels
number (mm) 0% 4% 8% 12%
1 0.005 0.318 0.403 0.469 0.587
2 0.014 0.435 0.628 0.572 0.584
3 0.024 0.453 0.699 0.646 0.681
0.848
4 0.034 0.584 0.756 0.781
(0.83),0.44
0.043 0.657 0.775 0.841
5 0.831
[0.46] (14.81) ,0.52 (8.51),0.53
0.053
6 0.675 0.749 0.780 0.833
7 0.063 0.649 0.667 0.692 0.703
8 0.072 0.534 0.569 0.539 0.499
9 0.082 0.409 0.393 0.333 0.315
10 0.092 0.288 0.206 0.177 0.138
11 0.101 0.184 0.099 0.058 0.056
12 0.111 0.113 0.045 0.022 0.018
13 0.121 0.068 0.026 0.009 0.006
14 0.130 0.037 0.011 0.006 0.004
15 0.140 0.020 0.007 0.003 0.001
16 0.150 0.012 0.006 0.001 0.000
17 0.159 0.009 0.002 0.000
18 0.169 0.005 0.002 0.000
19 0.179 0.003 0.002 0.000
20 0.188 0.003 0.001
 Zone Yarn Extension

0% 4% 8% 12%

Core 0.592 0.722 0.757 0.730

(21.96) (4.85) (-3.57)

Intermediate 0.327 0.574 0.574 0.693

(75.54) (0) (20.73)

Surface 0.018 0.028 0.021 0.051

 Packing density

Yarn Extension
1st Seg 2ndSeg 3rdSeg 4th Seg 5th Seg 6th Seg 7thSeg 8thSeg 9thSeg 10thSeg

0% 0.042 0.041 0.042 0.043 0.043 0.043 0.044 0.045 0.045 0.044

4% 0.076 0.076 0.080 0.080 0.077 0.079 0.081 0.083 0.082 0.083

8% 0.078 0.080 0.082 0.084 0.082 0.081 0.083 0.083 0.083 0.085

12% 0.081 0.081 0.083 0.085 0.083 0.082 0.085 0.085 0.084 0.087
 At 0% At 4% At 8% At 12%
0.09

0.08
Partial packing density

0.07

0.06

0.05

0.04

0.03
0 1 2 3 4 5 6 7 8 9 10 11
Diff. segments of the fibres in yarn
 Diameter(mm)
Yarn 10thSe
1st Seg 2ndSeg 3rdSeg 4th Seg 5th Seg 6th Seg 7thSeg 8thSeg 9thSeg
Extension g

0% 0.236 0.235 0.233 0.230 0.231 0.230 0.227 0.227 0.227 0.228

4% 0.170 0.169 0.165 0.166 0.168 0.167 0.165 0.163 0.165 0.164

8% 0.165 0.162 0.160 0.159 0.161 0.162 0.160 0.160 0.160 0.159

12% 0.160 0.158 0.156 0.155 0.157 0.158 0.155 0.155 0.157 0.154
 At 0% At 4% At 8% At 12%

0.25

0.24

0.23

0.22
Diameter of yarn(mm)

0.21

0.2

0.19

0.18

0.17

0.16

0.15
0 1 2 3 4 5 6 7 8 9 10
Different segments of fibres in yarn
 Yarn segments

Yarn extension

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th

0% 9.037 8.376 7.924 7.655 8.357 7.203 8.564 8.427 8.654 9.019

4% 10.120 8.944 7.908 8.419 8.677 9.428 9.151 9.689 9.750 10.994

8% 9.515 8.292 7.773 7.706 9.014 8.329 8.509 8.242 8.513 9.391

12% 7.756 7.602 7.984 8.567 8.820 7.975 7.142 8.539 8.054 8.360
 At 0% At 4% At 8% At 12%

11.5
11
Within segment C.V. %

10.5
10
9.5
9
8.5
8
7.5
7
0 2 4 6 8 10
Different segments of fibres in yarn
Fibre Orientation
in Sliver and
Roving
Measurement of Fibre
Orientation
Indirect Method
Direct Method
 Lindsley’s Methodology

Lindsley proposed a methodology to study fiber

orientation in sliver and roving following indirect
method.
Used apparatus is shown here.
Ba
ck
wa
rd

Q D
er
Sliv
Fo
rw
ard

C. H. Lindsley, Textile Research Journal 21, 39-46, 1951.

Scheme of Lindsley Technique

Figure 1: Hypothetical sliver

Figure 2: Sliver is gripped by a set of top and

bottom plates (bottom plates are invisible).
Scheme of Lindsley Technique
(Contd.)

Figure 3: At first, comb out the fibers protruding from the edge of the
right-hand side plates and discard them. As a result, green color
fibers are discarded.
Scheme of Lindsley Technique
(Contd.)

Figure 4: Then, cut the fibers protruding from the edge of the right-
hand side plates and weighed the blue colored cut fibers (W)
 Scheme of Lindsley Technique
(Contd.)

Figure 5: Remove the right-hand side plates and comb the fibers, as a
result, the blue-colored fibers will be combed out. Take the weight of the
combed-out fibers (C).
 Scheme of Lindsley Technique
(Contd.)

Figure 6: Put the plates back to their original position and cut the fibers
protruding from the right-hand side of the plates (blue and red colored cut
fibers). Take the weight of the cut fibers (E).
Scheme of Lindsley Technique

Figure 7: Once again remove the right-hand side plates and cut the fibers
protruding from them (blue and red colored fibers). Take the weight of the
cut fibers (N).
Lindsley’s Fibre Orientation
Coefficients

Lindsley proposed three indices

Cutting Ratio = E/N
Combing Ratio = C/(E+N)
Orientation Index = 1- E/N

Lindsley fails to give an explanation of the physical

significance of these coefficients.
Leon’teva fibre
orientation coefficient

Modified coefficient of
relative fibre parallelisation
The ratio of the weight of the combed out fibres to
that of the whole of the clamped fibre tuft before
combing is represented by C/(C+N+E)

Therefore, when C/(C+N+E) decreases, Kp increases.

But, the equation of Kp reveals that even with the

increase in value of E, the value of Kp increase

Modified coefficient of relative fibre prallelisation

Kmp = [1- (C+E)/(C+N+E)]*100
Limitations of Indirect
Method
No information about
- Number of hooks
- Types of hook
- Extent of hooks
Immature fibres (cotton) generates more hooks but
reduce weight of immature fibres is not taken
into consideration.

But takes less time to study the fibre orientation.

 Fibre Orientation in Sliver
Type of Value of Coefficient
sliver Value of 𝜌 Value of Kp
Forward Backward Mean Forward Backwa Mean
rd
Carded 9.297 16.409 12.853 57.463 62.368 59.915
1st Drawn 7.948 6.370 7.159 73.177 69.759 71.468
2nd 3.086 3.686 3.636 76.307 77.632 76.969
Drawn
Fibre Orientation in Rotor
Groove

Type of Value of Coefficient

sliver Value of 𝜌 Value of Kp
Forward Backward Mean Forward Backwa Mean
rd
Carded 15.577 16.755 16.166 45.789 47.41 46.599
1st Drawn 10.987 9.864 10.425 51.123 49.638 50.405
2nd 5.811 6.688 6.239 53.648 54.598 54.033
Drawn
Summary:
Fibre Orientation Coefficients
 Cutting ratio E/N
 Combing ratio C/(E + N)
 Orientation index 1-E/N
 Proportion of curved fibre ends (P) E/(E + N) * 100
 Coefficient of relative fibre parallelization [1-C/(C + N + E)] * 100
(Kp)
 Modified coefficient of relative fibre
parallelization (Kp) [1-(C + E)/(C + N + E)]*100
 Projected mean length (inch) 2*(Wf + Wr)/(Cf+Cr+Nf+Nr+Ef+Er)+M

C= Weight of combed out portion N=Weight of the material after

combing and cutting under the
E=Weight of projected portion from the edge side plate
of the side plate
W=Weight of the material
t=Width of the clamp in inch(2”) clamped by the edge plate
after initial combing
 ll

𝑡𝑎𝑛β = 2π𝑅𝑧
𝑙 = ( √1 + (2πRz)2 )/z
• Yarn assumed to be circular in cross section.
• Compose of series of concentric cylinders of differing
radius.
• Each fiber follows a uniform helical path around one of
the concentric cylinder. So that its distance from the
yarn axis remain constant.
• Helical angle gradually increases.
• No. of twist/length remain constant in all the layers.
• The density of fibre in yarn remain constant throughout
the model.
• Yarn consists of large no. of filaments.
•
 2  r dr .  cos B
dn 
F
n dn  d 2  r dr .  p  1
0 0
F 1    dZ 
2

d  d  dr   p 1
 0 
F 1    dZ 
2

Sec 2 B 1  tan 2 B
1
1    dZ 
2
cos 2 B
1
cos B 
1    dZ 
2
If total length of fibre in unit length of yarn = L
Volume of fibre in unit length of yarn of diameter d

= πd2 µp /4

F . L = πd2 µp /4

L = πd2 µp /4F

Length of fibre in unit length of yarn in element = Ln

Consider length of fibre before twisting the yarn - a
L
ao 
n
After twist the length of yarn = a =1

 d 2 p 2  FT 2
ao  
4 F  p
 1    dT   1
2

  dT 
2

ao 

2 1    dT   1
2

If S is the retration in yarn

a
S 1 
ao


  dT   2
2
 1    dT   1
2

  dT 
2

1    dT   1
2


1    dT   1
2

S  tan 2 B 2 
Volume of unit length of the ideal yarn = πR2
Mass of the yarn = πR2/vy
Where vy specific volume of the yarn (cm3 /g)
Yarn count = T = mass of 1 km
= (πR2/vy ) x 105 tex
After rearrangement
R = (vy T/ π 105 )1/2
tanβ = 2 πRz
tanβ = 0.0112 vy1/2 z T1/2
 Diameter
Yarn Measured
Fibre calculated
Sample Spinning linear yarn Deviation,
type using
code technology density diameter, (%)
Peirce formula,
( tex ) (µm)
(µm)
C01 Cotton Ring 24.60 261.32 186.65 28.57
C02 Cotton Compact 24.60 226.63 186.65 17.64
V01 Viscose Ring 27.43 261.21 197.02 24.57
V02 Viscose Rotor 25.11 258.22 188.54 26.98
V03 Viscose Airjet 24.60 175.08 186.65 -6.61
V04 Viscose Ring 31.65 224.29 211.16 5.85
V05 Viscose Rotor 30.55 228.07 207.97 8.81
V06 Viscose Airjet 28.15 169.48 199.96 -17.98
V07 Viscose DREF II 32.59 199.23 214.32 -7.57
If the ratio of volume of fibre in unit length of yarn to the total
volume of yarn of that particular length is defined as
{ μp=(Packing Density) }
•
•
•
d is yarn diameter in micron,
k is spinning technology coefficient (only
spinning technology dependent )
q and c are exponents
T yarn fineness in tex
Z is twist per meter
Fibre type k q c

Cotton 135 0.6416 -0.2613

Viscose 251 0.6342 -0.3763

Polyester 161 0.6650 -0.2790

Fibre k1 q c
Cotton 86.7 0.6416 -0.403
Viscose 28.6 0.6342 -0.372
Polyeste
49.5 0.6650 -0.357
r

Technology k2
Ring 222
Rotor 256
Compact 174
DREF II 248
 Deviation from
Calculated yarn diameter,
measured diameter,
Measured µm
Spinni Yarn %
Fibre Yarn yarn
Sample ng linear
type twist, yarn
code techn density,
t/m diameter,
ology tex By By By
µm By By By
Peirce Peirce Eqn.
Eqn. 11 Eqn. 12 Eqn. 11
formula formula 12

C03 Cotton Ring 41.01 859 254.84 239.06 250.33 244.7 6.19 1.77 3.98

C04 Cotton Ring 30.60 882 207.99 206.50 206.03 216.3 0.72 0.94 -4.00

C05 Cotton Ring 24.40 857 196.78 184.40 179.51 200.1 6.29 8.77 -1.69

C06 Cotton Ring 24.60 515 222.97 185.15 206.14 226.6 16.96 7.55 -1.63

C07 Cotton Ring 24.60 651 210.24 185.15 193.90 214.0 11.93 7.77 -1.79

C08 Cotton Ring 24.60 1021 186.26 185.15 172.38 192.9 0.60 7.45 -3.56
 Deviation from
Calculated yarn diameter,
measured diameter,
(µm)
Measured (%)
Spinni Yarn Yarn
Fibre yarn
Sample ng linear twist
type yarn
code techn density
diameter,
ology (tex) (t/m)
(µm) By By By
By By By
Peirce Peirce Eqn.
Eqn. 11 Eqn. 12 Eqn. 11
formula formula 12

V08 Viscose Ring 18.87 741 146.28 162.16 134.54 151.0 -10.86 8.02 -3.23

V09 Viscose Ring 18.51 1170 128.82 160.61 111.92 130.6 -24.67 13.12 -1.38

V10 Viscose Ring 18.23 1090 126.46 159.39 113.84 132.4 -26.04 9.98 -4.70

V11 Viscose Ring 16.54 635 140.62 151.82 131.16 147.9 -7.96 6.73 -5.18

V12 Viscose Ring 16.49 793 127.68 151.59 120.40 138.2 -18.73 5.70 -8.24
 Deviation from
Calculated yarn diameter,
measured diameter,
(µm)
Measured ( %)
Spinni Yarn
Fibre Yarn yarn
Sample ng linear
type twist yarn
code techn density
(t/m diameter,
ology (tex)
(µm) By By By
By By By
Peirce Peirce Eqn.
Eqn. 11 Eqn. 12 Eqn. 11
formula formula 12

P01 Polyester Ring 15.62 868 168.03 147.54 151.63 172.8 12.20 9.76 -2.84

P02 Polyester Ring 14.13 837 159.46 140.32 143.29 166.4 12.00 10.14 -4.35

P03 Polyester Ring 19.11 859 189.89 163.19 173.89 191.1 14.06 8.42 -0.64

P04 Polyester Ring 19.11 1046 174.30 163.19 164.59 181.5 6.38 5.57 -4.13

P05 Polyester Ring 19.82 1179 169.72 166.19 163.10 172.8 12.20 3.90 -2.84
 Calculated yarn Deviation from
Measured diameter, measured diameter,
Yarn
Fibre Yarn yarn µm %
Sample Spinning linear
type twist, yarn
code technology density,
t/m diameter, By Peirce By By Peirce By
tex
µm formula Eqn. 12 formula Eqn. 12

T01 Cotton Ring 43.42 502 293.53 245.98 290.3 16.20 1.10
T02 Cotton Rotor 48.40 792 315.62 259.71 296.1 17.71 6.18
T03 Viscose Ring 12.43 986 105.54 131.61 113.1 -24.70 -7.16

T04 Polyester Ring 29.23 513 264.56 201.82 275.2 23.71 -4.02

T05 Viscose Ring 31.75 782 194.29 210.34 195.5 -8.26 -0.62

T06 Polyester DREF II 46.50 1398 318.03 254.56 289.6 19.96 8.94

T07 Viscose Rotor 34.74 561 252.00 220.03 259.2 12.69 -2.86

T08 Polyester Ring 19.62 794 180.00 165.35 197.7 8.14 -9.83

T09 Polyester Rotor 20.50 1150 191.00 169.02 203.6 11.51 -6.60

183.34
T10 Cotton Compact 24.12 681 190.27 183.5 3.64 3.56
 Calculated yarn Deviation from
diameter, measured diameter,
Measure
Yarn µm %
d yarn
Fibre linear Yarn
Sample Spinning yarn
type density twist,
code technology diameter
, t/m
,
tex By By
µm By By
Peirce Peirce
Eqn. 12 Eqn. 12
formula formula

PV01 P/V blend Ring 16.18 822 132.36 150.16 139.0 -13.45 -5.02

PV02 P/V blend Ring 13.21 800 122.56 135.68 126.7 -10.70 -3.38

PV03 P/V blend Ring 19.11 801 146.04 163.19 152.4 -11.74 -4.35

PV04 P/V blend Ring 19.62 948 142.43 165.35 146.9 -16.09 -3.14

PV05 P/V blend Ring 22.62 1136 141.48 177.54 149.8 -25.49 -5.88
 Calculated yarn Deviation from
Measure diameter, measured diameter,
Yarn µm %
d yarn
Fibre linear Yarn
Sample Spinning yarn
type density twist,
code technology diameter
, t/m
, By By
tex By By
µm Peirce Peirce
Eqn. 12 Eqn. 12
formula formula

PV06 P/V blend Ring 14.73 831 132.36 143.27 141.0 -8.24 -6.53

PV07 P/V blend Ring 16.27 809 144.68 150.57 149.2 -4.07 -3.12

PV08 P/V blend Ring 19.82 831 152.77 166.19 163.6 -8.79 -7.09

PV09 P/V blend Ring 18.81 964 141.21 161.90 152.6 -14.65 -8.07

PV10 P/V blend Ring 17.42 1064 137.62 155.81 142.9 -13.21 -3.84
 Calculated yarn Deviation from
diameter, measured diameter,
Measure µm %
Yarn
d yarn
Fibre linear Yarn
Sample Spinning yarn
type density twist,
code technology diameter
, t/m
,
tex By By
µm By By
Peirce Peirce
Eqn. 12 Eqn. 12
formula formula

PV11 P/V blend Ring 16.13 818 156.51 149.93 163.1 4.21 -4.21

PV12 P/V blend Ring 17.12 780 162.24 154.46 170.0 4.80 -4.78

PV13 P/V blend Ring 19.75 809 177.59 165.90 180.6 6.58 -1.69

PV14 P/V blend Ring 19.42 926 165.18 164.51 172.6 0.41 -4.49

PV15 P/V blend Ring 20.02 1186 151.12 167.03 163.9 -10.53 -8.46
Polyester/Viscose,
k1 q c
%

00/100 28.6 0.6342 -0.372

20/80 29.3 0.6364 -0.369
45/55 33.2 0.6411 -0.364

70/30 42.4 0.6492 -0.360

100/00 49.5 0.6650 -0.357
The probability, p, of the fibre being incorporated into the yarn, depends on
the ratio of sum of the elemental length li to actual fibre length Lf, so
P = .∑ li/Lf
Thus, if ∑ li = Lf, P = 1
Then the full length of the fibre will be spun in.
If ∑ Li = 0, P = 0
Then fibre resides on the yarn surface, e.g., totally as a wrapper fibre or hair.
If part of the fibre length is spun in and the rest protrudes from the yarn or
forms a wrapper
Then li < Lf, and 1 > P > 0
For the yarn length Li in the figure
Li = ∑ li cos a
Where a = the angle between the elemental length and yarn axis
This can be repeated for Lj, Lm and so forth, so

Kfi = ∑Ln/L
Where n = I, j, m etc.
kfi =( Lo – ∑xn)/L

Where ∑xn = the fibre length projecting out of

the yarn body
• Kf = [∑Li/n]/L
• Kf = Lo/L
• Where Li = individual fibre extent
• Lo = arithmetic mean of the projected length of individual fibres
along the yarn axis
• N = number of observation
• L = fibre length
CONFIGURATION OF FIBRES IN RING YARN
CONFIGURATION OF FIBRES IN ROTOR YARN
CONFIGURATION OF FIBRES IN AIR- JET YARN
CONFIGURATION OF FIBRES IN OE-FRICTION YARN
Fibre Configuration in Ring yarn: Fibre Hook
Leading Hook

Percentage:11 %
Hook Extent:1.3 mm
Mean Fibre Extent: 25.5 mm

Trailing Hook

Percentage:17 %
Hook Extent:1.9 mm
Mean Fibre Extent:25.5 mm
 Fibre Configuration in Ring yarn: Fibre Hook

ddle Hook

Percentage: 0.25 %
Mean Fibre Extent:28 mm
Fibre Type of Spinnin Leading Trailing Straight Other Yarn Breakin
length yarn g-in Hooks Hooks Fibres types of Tenacty g
(mm) coefficie (%) (%) (%) Hooks (g/tex) Elongati
nt (Kf) (%) on (%)

38 Ring 0.83 7 7 77 9 11.41 9.97

OE 0.69 26 8 44 22 10.15 10.57
Rotor
44 Ring 0.81 6 12 73 9 12.47 10.24
OE 0.62 21 7 36 36 9.45 10.79
Rotor
51 Ring 0.81 8 8 72 12 14.08 10.14
OE 0.57 22 7 30 41 8.79 11.02
Rotor
Yarns Mean fibre Spinning-in- Helix Number Yarn Leading Hook Trailing Hook Double Hook
extent coefficient angle of fibres diameter
(mm) (o) in yarn % Extent % Extent % Extent
(µm)
cross- (mm) (mm) (mm)
section

30.2 0.69 17.2 178.2 209 9.8 1.3 14.2 1.9 4.0 3.5
Ring (9.2) (9.3)
Spun

20.4 0.46 25.1 157.6 220 20.1 4.2 10.5 3.1 6.3 7.5
Rotor (10.4) (10.1)
spun

33.3 0.76 11.5 162.1 182 7.8 1.2 10.2 1.4 1.6 3.1
Air-jet (8.3) (8.0)
spun

13.7 0.31 30.3 156.8 245 32.3 8.5 25.9 5.6 14.5 13.4
OE- (16.1) (17.3)
frictio
n
spun

Chapter-4
There are four different possibilities of fibre
configuration in the sliver.
1. All fibres in the sliver are straight
2. All fibres in the sliver have leading hooks
3. All fibres in the sliver have trailing hooks
4. All fibres in the sl;iver have both sides hooks
The deposition of fibres on rotor groove can be divided into
following three categories.
1. Category 1
Fibre is just emerging out from transport tube and is being
picked up by yarn tail.
2. Category 2
Fibre is partially in side the transport tube and partially on
the rotor groove.
3. Category 3
Fibre is fully imbedded on rotor groove.
• 1. All Fibres are Straight

Fibre Configuration Fibre picking Fibre in yarn

Cat.1

Cat.2

Cat.3
• 1. All Fibres are leading hook

Fibre Configuration Fibre picking Fibre in yarn

Cat.1

Cat.2

Cat.3
• 1. All Fibres are trailing hook

Fibre Configuration Fibre picking Fibre in yarn

Cat.1

Cat.2

Cat.3
• 1. All Fibres are both end hooked

Fibre Configuration Fibre picking Fibre in yarn

Cat.1

Cat.2

Cat.3
 Fibre Configuration in Air-jet yarn: Sheath Fibre

Percentage:3 %
Mean Fibre Extent: 15 mm

Uniform
Wrapping Angle
 Fibre Configuration in Air-jet yarn: Sheath Fibre

Varying
Wrapping Angle
 Fibre Configuration in Air-jet yarn: Hook Fibre

Leading Hook
Core

Trailing Hook
Core
Percentage:16%
Hook extent:1.6
Mean Fibre Extent: 28 mm
 Fibre Configuration in Air-jet yarn: Core Fibre

Core Fibre
Fibre Configuration in Air-jet yarn: Loop & Entanglement

Entanglement

Loop
 Fibre Configuration in Air-jet yarn:Fibre Buckling

Buckling

Percentage: 0.5%
Mean Fibre Extent: 25 mm
Fibre Configuration in
Ring-spun Yarn
 Fibre Configuration in Ring yarn: Cylindrical Helix

Cylindrical Helix

Percentage:66.5 %
Mean Fibre Extent: 33 mm
 Fibre Configuration in Ring yarn: Fibre Hook
Leading Hook

Percentage:11 %
Hook Extent:1.3 mm
Mean Fibre Extent: 25.5 mm

Trailing Hook

Percentage:17 %
Hook Extent:1.9 mm
Mean Fibre Extent:25.5 mm
 Fibre Configuration in Ring yarn: Fibre Hook

Middle Hook

Percentage: 0.25 %
Mean Fibre Extent:28 mm
 Fibre Configuration in Ring yarn: Wrapped Fibre

Wrapped Fibre

Percentage:0.25 %
Mean Fibre Extent: 4 mm
 Fibre Configuration in Ring yarn: Fibre Hook

Middle Hook

Percentage: 0.25 %
Mean Fibre Extent:28 mm
 Fibre Configuration in Ring yarn: Entanglement

Fibre Entanglement
Fibre Configuration in
DREF 2 Yarn
Fibre Configuration in Dref-2 Yarn: Entanglement & Loop

Fibre Loop &

Entanglement

Percentage:
Mean Fibre Extent:
 Fibre Configuration in Dref-2 Yarn: Layer Effect

Fibres at Different
Layers
 Fibre Configuration in Dref-2 Yarn: Layer Effect

Core Fibre

Percentage:3%
Mean Fibre
Extent:24 mm

Sheath Fibre

Percentage:3%
Mean Fibre
Extent:21 mm
 Fibre Configuration in Dref-2 Yarn: Fibre Hook

Leading Hook

Percentage:29%
Hook Extent:8.5 mm
Mean Fibre Extent:15.25 mm

Trailing Hook

Percentage:26 %
Hook Extent:5.6 mm
Mean Fibre Extent: 16.85 mm
 Fibre Configuration in Dref-2 Yarn: Fibre Hook

Fibre Buckling

Percentage:8%
Mean Fibre Extent: 12 mm
Fibre Configuration in
Rotor Yarn
 Fibre Configuration in Rotor Yarn: Core Fibre

Core Fibre

Percentage:36 %
Mean Fibre Extent:26 mm
Fibre Configuration in Rotor Yarn: Sheath Fibre

Mechanism of Wrapper Formation

 Fibre Configuration in Rotor Yarn: Sheath Fibre

Tight Wrap

Percentage:4%
Mean Fibre
Extent:0.45 mm
 Fibre Configuration in Rotor Yarn: Sheath Fibre

Tight & Loose

Wrap
combination

Percentage:7 %
Mean Fibre Extent: 3 mm
 Fibre Configuration in Rotor Yarn: Sheath Fibre

Loose Wrap

Percentage:4%
Mean Fibre Extent: 5 mm
 Fibre Configuration in Rotor Yarn: Hook Fibre

Leading Hook

Percentage:23 %
Hook Extent:2.4 mm
Mean Fibre Extent: 23 mm

Trailing Hook
Percentage:17%
Hook Extent:2.8 mm
Mean Fibre
Extent:22.5 mm
Fibre Configuration in Rotor Yarn: Loop & Entanglement

Entanglement

Percentage:
Mean Fibre Extent:

Loop

Percentage:
Mean Fibre Extent:
 Fibre Configuration in Rotor Yarn: Fibre Buckling

Buckling

Percentage:1 %
Mean Fibre Extent: 26 mm
Spinning Systems and Fibre
Orientation in Yarn
Art of Yarn Spinning
OE Rotor Spin Box
Yarn Twist in OE Rotor
Spinning
Opening and Cleaning
Opening Roller
Fibre deposition on rotor surface
and yarn peeling off
OE Rotor Geometry
Type Rotor Grooves
Rotor Groove Geometry
Types of Navels
Working Principle Rotor
Spinning
Wrapper fibre formation
Formation of Wrapper
fibre
Air-jet Spinning Machine
Murata Jet Spinner (Dual
Nozzle)
Distribution of twist during yarn
formation (MJS)
MVS Drafting
Ring, rotor and vortex yarns structure
Fibre Orientation in Carded
Web

Tracer fibre content – 0.5 % Tracer fibre content – 0.3%

CONFIGURATION OF FIBRES IN RING YARN
CONFIGURATION OF FIBRES IN ROTOR YARN
CONFIGURATION OF FIBRES IN AIR- JET YARN
3-D path of fibre at 0% and 4% yarn extension
Internal Yarn Structure

Cross sectional images of yarn A

Internal Yarn Structure

Cross sectional images of yarn B

 Radial packing density
of yarns
0.7

0.6

0.5
Packing Density
0.4

0.3

0.2

0.1

Yarn Radius, mm

Yarn F Yarn B Yarn G

Radial Packing Density of
Yarns
Air jet Spinning Winding
Transverse
Com4 Jet Piecing
Ideal Packing Density
 Open Packing
Fibres lie in layers between
successive concentric circles
 Close Packing
Fibres fit into hexagonal packing
One fibre in the core
Two Fibres in the core
Three Fibres in the Core
Four Fibres in the Core
Five Fibres in the Core
Ideal Packing Density in layer structure

Total number of fibre in yarn cross-section

N = 1 + 3 A (A + 1) For C = 1
N = (A + 1)(3A + C) For C = 2, 3, 4, 5 and 6
Where N = total number of fibres in yarn cross-section
A = number of layers

Total number of fibres in particular layer

B = 6A For C = 1
B = 6A + c for C = 2, 3, 4, 5 and 6
Where B = a particular layer
Total number of voids in the yarn cross-section

n = 6 A2 For C = 1
n = 6A2 + 2AC + C -2 For C = 2, 3, 4, 5 and 6
where n = number of voids in the yarn cross-section
Maximum Packing Density

Area of fibres = πrf 2 /2

Area of triangle = rf2 √
Packing density = Area of fibres/area of the
triangle
Packing density = (πrf 2 /2)/ (√ rf2)
= π/2√
= 0.907
Minimum Packing Density

Area of fibres = πrf 2 /2

Area of triangle = √ rf2
Packing density = Area of fibres/area of the
triangle
Packing density = (πrf 2 /2)/ ( √ rf2)
= π/8√
= 0.227
Packing Density (general)

Area of fibres = πrf2 /2

Area of triangle = (c + 2rf )(a + 2rf )sin𝛼
Packing density = πrf2 /(c + 2rf )(a + 2rf )sin𝛼

sin𝜶 = [√{2(a + 2rf )(c + 2rf )}2 – {(a + 2rf )2 + (c + 2rf )2 – (b + 2rf )2 }2 ] / 2[(c + 2rf )(a + 2rf )]

Packing Density = 2πrf2 /[√{2(a + 2rf )(c + 2rf )}2 – {(a + 2rf )2 + (c + 2rf )2 – (b + 2rf )2 }2]
Distance between fibres Packing
density
a = 0, b = 0, c = 0 0.907
a = ≤ rf /3, b = ≤ rf /2, c = ≤ rf 0.8792
a = ≤ rf /2, b = ≤ rf , c = ≤ rf /2 0.5308
a = ≤ rf , b = ≤ rf , c = ≤ rf 0.403
a = ≤3 rf /2, b = ≤ 3rf /2, c = ≤ rf 0.3308
a = ≤ 2rf , b = ≤3 rf /2, c = ≤ rf 0.3091
a = ≤ 2rf , b = ≤ 2rf , c = ≤ 2rf 0.227
Cross- section of yarn
 Packing density

0
0.1
0.2
0.3
0.4
0.5
0.6
0.7

0.0073
0.0219
0.0365
0.0511
0.0657
0.0803
0.0949
Radial Packing Density

0.1095
0.1241
0.1387
Yarn Radius, mm
0.1533
0.1679
0.1825
0.1971
0.2117
Yarn B
Yarn C
Yarn A
STRUCTURAL
MECHANICS OF
YARN
 Actual number of fibre in yarn cross-section
 Total area of fibre in yarn cross-section - Se  ne 
 Centre of gravity of yarn cross-section Se
 Packing density of fibre in yarn.
If si * is the average area of fibre
Then total area of fibre in yarn cross-section

S = s * x n
e i e
Six
Where ne experimental number of fibre in yarn cross
section  Se 
Se  Si*  ne
Total area of fibre in yarn cross-section can also be
calculated by following equation
𝑇
ST =
𝜌
𝑇– Yarn fineness T
ST 
𝜌 – specific density of fibre

If s – is the area of single fibre.
t
s 
s=

𝜌

Where t – fineness of fibre

Total area of fibre in yarn cross- section
ST = s x n e

But for real yarn

ST ≠ s x ne

But ST > s x ne
ST > s x ne
𝒕
> x ne
𝝆 𝝆

> ne
𝒕

nT > ne
𝒏𝒆
if = Kn
𝒏

Kn < 1→ ?
 HELICAL MODEL OF YARN

s < s’
s’ =
𝑐𝑜 𝛽𝑖
Where tan𝛽𝑖 = 2πri z
z = twist in yarn
 Se = s’ x ne

Se ≠ s’ x ne

But ST > Se

𝒆
If = Ks

Ks < 1→ ?
s’ < s*
where s* - area of fibre in actual
yarn

𝜷𝑯 < 𝜷𝑨

s* > s’ → MIGRATION
 Number of fibre in rotor and
ring spun yarns
Yarn no. 1 2 3 4 5 6 7 8

Material Viscose Viscose Viscose Viscose Polyester Polyester Polyester Polyester

Fibre 40 40 34 34 38 38 32 32
Length
(mm)
Fibre 1.6 1.6 1.45 1.45 1.7 1.7 1.7 1.7
Fineness
(dtex)
Yarn type RING Rotor -1 Rotor -1 Rotor-2 Rotor -1 Rotor -1 Rotor -1 Rotor -1

Yarn 19.6 19.2 34.6 37.8 21.5 20.5 20.1 35.5

count
(tex)
Yarn 669 784 561 407 747 1158 812 784
Twist
(m-1 )
Kn 0.96 0.81 0.82 0.83 0.79 0.80 0.79 0.82
 Structural mechanics of double roving feed and
single roving feed yarn

Roving Yarn Packin Yarn Yarn

𝟎
Spacin count nT ne Kn 𝜽 ST Se Ks g diamet diamet
g (Ne) densit er er
mm mm2 mm2 y optical graph
(mm) (mm)
6 29.41 176.45 164.23 0.931 21.40 0.0251 0.0236 0.941 0.5402 0.236 0.241

8 29.53 177.18 157.67 0.889 27.25 0.0253 0.0242 0.959 0.5725 0.232 0.236

10 29.47 177.86 154.12 0.871 29.42 0.0252 0.0228 0.906 0.5490 0.230 0.232

Single 29.56 177.36 168.66 0.951 18.10 0.0253 0.0244 0.964 0.5205 0.244 0.249
yarn