UNIT-1 Rotor Spinning

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search began on a broad front at the end of the 1960s. The newer spinning systems developed since then include rotor spinning, air-jet spinning, friction spinning, vortex spinning, electrostatic spinning, core spinning, wrap spinning, twistless spinning and others.

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structures of yarn obtained from these systems are also different and vary in many aspects. The ring yarns have helical structure and even twist distribution, but sometimes there can be problem in ring spun yarn related to twist liveliness and migration of fibres inside yarn. For improving these aspect new structures came into picture, which are different from ring spun yarn structure and these structures will also behave differently in fabric stages
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TWIST DISTRIBUTION IN YARNS FROM DIFFERENT TECHNOLOGIES

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rotor spinning, electrostatic spinning, air-vortex spinning, friction spinning and disc spinning.
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Open end spinning is also known as break spinning or free fibre spinning. In this process the fibrous material is highly drafted to separate out the individual fibres. The individual fibres are subsequently collected onto the open end of the yarn. This is rotated to twist the fibre into the yarn structure to form a continuous strand of yarn. This is wound onto a bobbin to form the yarn package
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device for drafting the fibrous mass into individual fibres, a means of transporting the fibres to the yarn end, a device for collecting the separated fibres onto the yarn end in a manner that enables the correct yarn count to be obtained, a device for rotating the yarn end to insert twist into the collected fibres, and a means of winding the yarn on to the package.
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 lower

power consumption per unit quantity of yarn produced higher speed of twist insertion resulting in very high yarn delivery speed a significant resulting increase in productivity larger delivered package size elimination of some processes such as roving and winding more uniform yarns
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 Open

end yarns produce different characteristics in the end product. These yarns may be used to advantage in fabrics where uniformity and a smoother surface are of prime importance.

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 Open

end yarns are used in pile fabrics, apparel, household, industrial and technical applications. Uses include heavy weight satin and poplins, corduroy, velveteen, rain wear, denims, drills, sheets, pillow cases, bed spreads, printed fabrics, curtains, window blinds, upholstery, cleaning cloths, dress goods, underwear, rugs, carpet, blankets, terry towel and diapers.

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 headstock

(a ) and tailstock (b) the spinning and winding units (c), empty tube supply (d) 1 - 2 operating robots (e) on each side of the machine for cleaning, piecing and package change; package conveyor belt for transporting the full cross-wound packages to the end of the machine (f);
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 Rotor

spinning was initially developed with two main objectives:

To provide a more economical spinning system than conventional ring spinning through higher productivity, and To produce yarn of a quality that matches or surpasses that of the conventional ring spinning.

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a feed roller and feed plate a saw tooth or pin covered roller called an opening roller a tapered tube known as a fibre transport channel a shallow cup called as rotor (which includes a groove cut into the circumference at the maximum internal radius of the rotor referred to as the rotor groove) a flange tube facing the rotor base and co-axial to the rotor, termed the doffing tube a pair of delivery rollers that feed the spun yarn to the package build device

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 Preparation

of the sliver Fibre Opening Fibre transfer

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 The

need for the right quality of sliver determines whether one or two draw frame passages are required after carding for short staple fibres. Insufficient drawing passages results in an inferior yarn quality. Too many drawing passages decrease the feed sliver cohesion. Satisfactory yarn strength and consistency are usually obtained most economically from two draw frame passages.
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 The

basic purpose of the draw frame passages is to obtain a uniform and well blended sliver through the doubling action at the draw frame and, by the drafting action, to parallelize and straighten fibres particularly those with hooked ends whether leading, trailing and both ends. However, fibres with trailing hooks have less of a negative influence on rotor yarn strength and irregularity than on ring-spun yarns.
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 Fewer

doublings or a heavier feed sliver count gives poorer spinning results. Waste fibres, such as cotton comber noil or card flat strips, are typically as clean, fine and strong as the longer fibres from which they have been removed, but may be too short for roller drafting. A typical mean fibre length in these cases is 9 to 12 mm. In such circumstances, the rollers may be fed with auto-leveled card sliver in which a small percentage of longer fibre has been blended.
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The opening roller removes the fiber from the sliver as it is fed in, and, after two or three rotations, delivers them to the feed tube in which the airflow takes them to the rotor. The trash particles are extracted by centrifugal forces in the first 90 degree of the opening roller revolution. The majority of rotor machines use a 50-80 mm diameter steel opening roller (also known as an opener, beater roller or disintegrator) which functions in a manner similar to that of the taker-in roller on a carding machine.

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 It

is designed to be fed by sliver usually ranging from about 40-300 times thicker than the yarn count to be produced, depending on the machine design. If fibre feed is too slow, particularly with thick sliver, the result is a longer operating time for the opening roller, leading to fibre damage and excessive dust formation. If the fibre feed is too fast, it will spend less time in the opening roller and opening will be inadequate.
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 The

tooth shape (i.e. face angle and tooth tip configuration), surface roughness, frictional coefficient and opening roller speed are all critical for successful spinning. Basically the opening roller speed should be as low as possible. It is important to note, however, that too slow a speed tends to cause fibre lapping and irregularly spaced thick and thin places in the yarn.

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 On

the other hand, increased opening roller speed causes higher dust formation, higher fiber damage, reduction in yarn strength and breaking elongation. It can even cause fibre melting in the case of thermoplastic fibres.

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 This

needs to be balanced with the fact that a higher opening roller speed also results in better trash extraction, better sliver opening, a reduced wrapping tendency, improved yarn evenness and lower imperfection (thick and thin places, neps) in the yarn. The opening roller surface speed is usually selected from within the range 800-2500 m/min, depending on the type of fibre and the roller design
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higher opening speed may be required to provide increased opening force in the following circumstances:

increased feed sliver count, even when the feed rate in mass per unit time is constant increased fibre length the use of three-dimensional crimped fibre (compared with two-dimensional crimp) the use of finer fibres, because of the increased fibre surface area

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 The

card clothing used on the opening roller is usually of the rigid metallic type, varying from a face angle of about 65 and 18.5 points/cm 2 for cotton to 80 or 100 and 15 points/cm 2 for manmade fibres. Opening roller service life is considerably affected by the fiber material as well as by the dirt content in the fibre.

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 The

main wear points are the tooth face and tooth tip. Service life can be extended by the shape of the tooth (e.g. sickle shape, rounded tooth tip) and by tooth coating. Coated teeth show much lower levels of wear. Diamond-coated opening rollers have proved excellent in this respect.

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 Removal

of fibres from the opening roller is by controlled air flow, aided by centrifugal acceleration. The ratio of air speed to opener surface speed should be in the region of 1.5 to 4.0. The higher ratios result in a higher yarn tenacities because of the improved fibre orientation.

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After opening, the fibres are conveyed to the collecting surface of the rotor through a feed tube. Ideally the fibre should pass down the feed tube one at a time, but in practice the average number of fibres in the feed tube cross section can be as many as four. If too many fibres are fed along side each other, the rotor tends to accumulate tufts of fibres, thereby increasing yarn irregularity. The fibres passing along the feed tube are in a relaxed state. As a result fibre tensions are much more evenly distributed in yarn, causing less fibre migration than in ring spun yarns.

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