UNIT-3 Friction 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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process is included in the open-end group because the fiber strand (draw frame sliver) must be opened completely into individual fibers and then reassembled to a new strand (yarn).
formation of a new strand is carried out by using suction to bring the individual fibers into engagement with the rotating open end of the yarn, e.g. by perforated drums with an internal vacuum.
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high delivery speeds; low yarn production costs (lower than those of ring spinning); elimination of rewinding; low end breakage rates; yarn character similar to that of ring-spun yarn; no wrapping fibers; optically good mass evenness (well suited to knitted goods); better and softer handle than that of rotor-spun yarn; smooth yarn appearance.

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yarn strength; high tendency to snarl; higher number of fibers needed in yarn crosssection; difficulty of keeping spinning conditions constant; high air consumption; increasing unevenness and imperfections with increasing spinning speed, and further reduction in yarn strength.
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spinning was first developed when Fehrer produced the DREF friction spinning system in 1973. In this machine, the preopened fibres were made to fall onto a perforated cylindrical drum, the rotation of which imparted twist to the fibre assembly. Due to problems in controlling the flow, slippage occured between the fibre assembly and the perforated roller, which reduced the twist efficiency.

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Later the DREF-II friction spinning machine was developed to overcome this problem. This machine incorporates a specially designed inlet system which provides the required draft. These drafted slivers are opened into individual fibres by a rotating carding drum (opening roller) covered with saw-tooth wires. The individual fibres are stripped from the carding drum by centrifugal force supported by an air stream from a blower. The fibres are then transported by additional rollers to two perforated friction drums. The mechanical friction on the surface of the drums twists the fibres. Suction through the perforation of the drum assists the twisting process and helps in the removal of dust and dirt.
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Friction spinning technology works on the principle of friction twisting. Figure 1 shows the working principle of friction spinning. In this system, the preopened fibres are fed onto a moving, perforated collecting drum underneath which there is suction device. The fibres are fed between this and a second rotating drum. Twisting occurs due to the frictional forces between the drums and the fibre assembly. The process is also known as mechanical-aerodynamic spinning due to the fact that the spinning effect is produced by the movement of two spinning bodies (friction drums) assisted by air suction. Due to its versatility and high output speed of up to 300 m/min, the friction spinning system is considered suitable for producing yarns in the coarse count range, i.e. greater than 20sNe.
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The DREF-III friction spinning machine was introduced into the market in 1981. This machine was developed to improve yarn quality, extend the yarn count up to 18s Ne and produce multi-component yarns. The DREF-III uses a core-sheath type friction arrangement as shown in Figure 2. In this machine an attempt is made to improve the quality of yarn by aligning the majority of fibres in the direction of yarn axis. The remaining fibres are wrapped round the core fibres to form a sheath. The sheath fibres are wrapped round the core fibres by the false twist generated by the rotating action of drums. Two drafting units are used in this system, one for the core fibres and other for the sheath fibres. This system produces a variety of core-sheath type structures and multi-component yarns using different core and sheath fibres in the count range of 1-18sNe with delivery speeds as high as 300 m/min. Figure 2 : DREF-III friction spinning system

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or more carded slivers are passed to the main opening roller (2) (i.e., a drum clothed with sawteeth) after leaving a drafting arrangement (1). While the drafting arrangement has only a slight drafting effect, the saw tooth roller opens the strand into individual fibers.
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fibers separated in this way are lifted off the roller by a blower (3) and form a cloud (7), descending toward two perforated drums (4). One suction stream (5) per drum draws the fibers into the convergent region between the drums.
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The open end of the yarn (6) projects into this zone and is also sucked toward the perforated drums. Since these rotate, the yarn also rotates in the convergent region. The newly arriving fibers contact the rotating yarn and are thereby caught and twisted in.

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is only necessary to withdraw the yarn continuously to twist fibers newly arriving in the convergent region into a yarn. Dref-2000 is suited for production of coarse yarns

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Spinning positions per machine 6 - 64 Delivery speed Raw material Count range Feedstock Yarn packages Yarn type Yarn characteristics Fields of use 250 m/min wool, bast fibers, synthetic fibers, secondary fibers Ne 0.3 - 14.5; 2 000 - 40 tex card sliver up to 8 kg normal OE yarn woolen-spun character, round, even home textiles, carpets, blankets, recycling products, technical products spinning of waste, elimination of process stages recycling, production of fancy yarn, core-spun yarn

Advantages Special features

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The DRE F-2000 friction-spinning machine employs the classic DRE F-2 system. This machine can produce S- and Z-twisted yarn without mechanical alterations to the machine by the operator. Yarns of 41 tex can be produced at production speeds of 250 m/min (Ishtiaque et al., 2003a). DRE F-2000 friction spinning machines are utilized for recycling textile wastes as well as the spinning of technical and other yarns. T he DREF-3000 friction spinning machine, the latest model of the machine, is utilized especially for the production of multi-component yarns (hybrid yams) of count 33666 tex with production speeds of up to 250 m/min. This machine has a filament guide and is capable of operating with several yarn cores, which are axially fed to the spinning drums. These core yarns are then provided with a fibre sheath and are positioned precisely in the middle of the yarn.
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 Platt

Saco Lowells (PSL) Master spinner is also a true open-end (OE) friction spinning system. It differs from the DREF-II in respect of fibre feed and the construction of the friction drums. The principle of operation of this machine is shown in Figure. A drawframe sliver (1) runs from a can into an opening assembly. This consists of a feed roller and an opening roller (2), and opens the fiber strand in the same way as the opening device in rotor spinning.
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The separated fibers pass through a specially shaped fiber channel (3), carried by an air flow from a vacuum inside the suction roller (4) into the converging region between the two friction rollers. One of these rollers is perforated to act as a suction roller, whereas the second roller is solid(5). A yarn (6) is formed in the convergent zone. A secondary suction duct at the end of transfer duct helps to give fibre orientation, and therefore to keep the fibres parallel to the yarn axis, resulting in improved fibre orientation and fibre extent in the final yarn. In the twisting assembly, one friction drum is perforated and includes a suction slot while the other is a solid roller which provides effective friction transfer. Unlike the DREF system, the spinning assembly is enclosed and so makes more efficient use of the air flow generated. However, these machines have not been successful in the longer run, mainly for two reasons: inadequate yarn strength, i.e. low utilization of the fiber properties, and inconsistency of the spinning results

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The separated fibers pass through a specially shaped fiber channel (3), carried by an air flow from a vacuum inside the suction roller (4) into the converging region between the two friction rollers. One of these rollers is perforated to act as a suction roller, whereas the second roller is solid(5). A yarn (6) is formed in the convergent zone. A secondary suction duct at the end of transfer duct helps to give fibre orientation, and therefore to keep the fibres parallel to the yarn axis, resulting in improved fibre orientation and fibre extent in the final yarn. In the twisting assembly, one friction drum is perforated and includes a suction slot while the other is a solid roller which provides effective friction transfer. Unlike the DREF system, the spinning assembly is enclosed and so makes more efficient use of the air flow generated. However, these machines have not been successful in the longer run, mainly for two reasons: inadequate yarn strength, i.e. low utilization of the fiber properties, and inconsistency of the spinning results

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