Frictional force is generated between yarn and roller by winding a preset amount of yarn onto the friction roller. also concluded that coarser yarns have higher tenacity and breaking elongation. A friction roller is adopted instead of the nip roller in the mechanism which draws the yarn from the spinning nozzle. The ratio of wrapping fibers to core fibers is a very decisive factor for the yarn fineness. The brush-like, open yarn end grasps the fibers brought into contact with it and continuously binds them into a yarn with the aid of the continual rolling movement. vortex yarns have tenacity advantages over air jet yarns, particularly at high cotton contents. After fibers have left the guide member, the whirling force of the air jet separates fibers from the bundle. They explained this with the high short fiber content of cotton slivers. Soe also studied the structure of MVS Yarns and made a comparison with ring and Open-End yarns. At constant air speed, the delivery speed should be reduced [15]. He summarized the results as dry seed cotton and hot air in the ginning increased the short fiber ratio and neps and reduced the fiber tensile. Deterioration of fiber values led to higher fiber loss in spinning, lower yarn tenacity, high hairiness, high number of imperfections and bad spinning efficiency. The researchers declared that the best yarn tenacity was obtained when the jet orifice angle was 70°, the jet orifice diameter was 0.4 mm, and the distance between the nozzle inlet and the hollow spindle was 14 mm [33]. Gizem Karakan Günaydin and Ali Serkan Soydan (March 1st 2017). Figure 14 displays scanning electron microscope pictures for the longitudinal view of Rieter, Murata vortex and Open-End rotor spinning. The researchers focus on the yarn formation area. In the twist insertion process of spinning a staple yarn, a strand of fibers is held on one end while the strand, length is made to rotate on its axis. MVS 861 spinning machine: (a) the general view of the machine, (b) the yarn spinning unit. So the yarn is mostly composed of the parallel fibers as in the air-jet yarns [4]. Ortlek and Ulku investigated some process parameters in their study, and they observed that increasing the delivery speed causes more hairiness and leads to deterioration for the tensile properties of vortex yarns. It is emphasized that the percentage of straight, hooked (trailing) and hooked (both ends) is very close to each other and higher than the leading hooked, entangled and looped fibers in vortex spun yarns (Table 1). Core fibers’ orientation has a big impact on the stress-strain behavior of the yarn. Along with an increasing “θ” value, the axial velocity increases, and the tangential velocity decreases. Scanning electron microscope pictures for the longitudinal view of Rieter, Murata vortex and Open-End spinning [29]. 2) Prevention of fiber slippage usually by twist insertion, although there are new methods invented now. Airflows have been increasingly used in transporting, drawing, separating and deforming solid structures for the advantages with respect to high efficiency and economic benefits. With the insertion of the twist, the fibers are packed together, to-form a continuous yarn with special structure and, properties. The number of jet orifices and the diameters of orifice directly affect the vortex magnitude. The results revealed that a high delivery speed deteriorated the physical properties of the yarns in terms of yarn evenness, thin places and tenacity. Murata vortex spinning (MVS) based on the air jet spinning technol- ogy has become more and more popular because of high produc- tion speed. Description of each classification depending fiber arrangement is explained below [7]: Core fibers: These fibers may be straight or inclined. The four air jets in the twist element create a whirlwind air-jet stream. They concluded that while working with high levels of the total draft using a heavy sliver, the better yarn evenness and thin place values are obtained as the intermediate draft gets lower. The individual fibers are subsequently collected onto the tail end of a seed yarn that is rotated to twist the fibers into the yarn structure and thereby form a new length of yarn. There are some studies examining the vortex and air-jet yarns made from different fibers. There might be some degree of inclination with respect to the yarn central axis. VORTEX, a new type of yarn. Login to your personal dashboard for more detailed statistics on your publications. The fiber arrangements of the RS, OERS and MVS yarns, including the MVS yarn with the tracer fibers were observed carefully. Textile Study in Europe: Everybody see dreams to study in European country. Even today, ring spinning makes the widest range of yarn counts with the highest strength. has been boosted further with the development of compact spinning, resulting in much less yarn hairiness thanks to its reduced, or compact, spinning triangle. The nozzle design parameters’ effect to the flow characteristics and its reflection to the yarn was mostly discussed. The wrapping effects of different types of fibers were obtained by the numerical simulation and compared with the view of vortex yarn structure under the scanning electron microscope [34]. In the study because of the high velocity and high Reynolds number in the nozzle, airflow is accepted as a turbulent flow. They obtained the relationship between the velocity and the radius of the main nozzle. Core Spun MVS Yarn (Courtesy of Muratec) Covering fibers In a sense, vortex spinning is the real rotor spinning. They used FLUENT to simulate the flow fields of air vortex spinning machine. The fiber bundle passage consists of a nozzle block and a needle holder. Publishing on IntechOpen allows authors to earn citations and find new collaborators, meaning more people see your work not only from your own field of study, but from other related fields too. Ability to produce yarn at 400 m/min. Because of ring spinning, providing all fibers to be spun into a wide range of yarn count with the lowest rate of yarn faults with the best quality, this spinning technology is still the most widely used one in the market. Murata vortex spinning (MVS) is based on the already existing air-jet spinning technology by Murata but essentially differs in principle from the MJS method because of the geometry of the air-jet twisting device used (US Patent 5,528, 895, 25 June 1996). Additionally, as the yarn delivery speed increased, hairiness also increased for both levels of intermediate draft [16]. MVS spinning system uses only one air jet instead of two as in the air-jet spinning system. Murata Machinery Ltd. also suggests that the short front roller to the spindle is favorable for less fiber waste. which is related to theoretical analysis of vortex yarn formation. They concluded that increase in nozzle distance causes an increase in long regular wrappings and number of wrapper fibers due to increase in the amount of fibers with Open-End configuration, while decrease in tight regular wrappings. Gordon made a survey related to the short fiber content and neps on Murata vortex spinning. According to the experimental results, yarn evenness, imperfections, tensile properties and hairiness were all affected significantly from the parameters. This paper studied the fiber movement in vortex spinning based on the flexible fiber finite element model, according to the theoretical mechanical analysis of the vortex spun yarn forming process. The finished yarn is wound on a package after its defects have been removed. D-49419 Wagenfeld / GERMANY . Recent refinements in spinning technologies have yielded significant improvement in yarn quality; however, the mechanism for these changes is not fully understood. Since the leading ends of all fibers are moved forward around the guide member and drawn into the spindle by the preceding portion of fiber bundle being formed into a yarn, they present partial twist and are less affected by the air flow inside the spindle. The air stream drifts the loose fiber ends around the yarn core. Loops may also be observed along the yarn axis and these groups are also classified as wild fiber groups. Twist insertion starts as the fiber bundle receives the force of the compressed air at the inlet of the spindle. The studies on vortex spun yarn related to spindle diameters claim that the tightness of wrapping on vortex spun yarn is significantly affected by the spindle diameter. The even yarns with fewer imperfections and lower hairiness are obtained. The tracer fibers were grouped according to their configuration. Jasimuddin Mandal Dyeing manager, PC Colour Soft Fabric Pvt. Moreover, the yarns with higher proportion of cotton content are more hairy on account of the higher bending and torsional rigidity of cotton fiber, and flexural rigidity and abrasion resistance are considerably higher in yarns with higher polyester content [24]. It was observed that increasing the nozzle pressure led to the increment of the axial and tangential velocity The fiber bundling receiving higher twist with the pressured air caused the yarn becoming much stronger but stiffer [10]. A basic air-jet spinning system is shown in Figure 9.12. There will be more wrapping fibers when the fiber is longer which results as a stronger yarn [22]. One of the decisive features from the other air-spun systems is the profiting from the minimal fiber fly. As the distance between the front roller nip point and the inlet of the hollow spindle increased, it was observed that the open trailing ends’ critical angular velocity decreased which mean the length decreasement of fiber embodies into the vortex. Murata has developed MVS 810, MVS 81T, MVS 851, MVS 861 and lastly the MVS 870 model spinning machines. In addition, a 3rd passage draw frame sliver with a yarn count of 3.19 ktex was spun into yarns of 14.76 tex using two different delivery speeds: 350 and 400 m/min. Since the internal airflow field inside the nozzle is very complex, there aren’t many studies on investigating the dynamic behavior of the fiber experimentally. The Murata vortex spinning based on the air jet spinning technology used for a wider range of fiber length. They determined the ratio between the fiber guidance element and the yarn delivery speed depending on the yarn count. The tensile characteristics increased as the nozzle distance increased. Comparison Table of Different Textile Fiber Proper... Moth Proofing Finishing Process of Fabric. The machine contains a three-roll drafting system and is equipped with two air-jet nozzles that create air vortices rotating in opposite directions. The invention discloses full melange yarns produced by vortex spinning and a process of producing the full melange yarns, which belong to the technical field of textiles. The spatial configuration and the influenced factors were analyzed. The formed yarn is then delivered out of, the nozzle through the yarn passage of the hollow, spindle with the drag of the delivery rollers and fed to, the winding part. Schematic model of nozzle block and projection of the nozzle with jet orifices at section respectively is shown in Figure 10. The most featuring characteristic of, the vortex spinning is that it is capable of spinning, 100% cotton fibers at very high speed (450m/min), and the produced yarn has a structure much similar to, In the MVS system a sliver is fed directly to a 4-line drafting unit. Working Procedure of Sample Dyeing (Knit Dyeing Se... Main Parts of Air Jet Loom for Weft Insertion, Water Proofing Finishing of Textile Fabric. When the fibers leave the front roller of the drafting device, they are drawn into a fiber bundle passage by air suction created by the nozzle. It is also used for the production of wrap yarns, which are bi-component yarns, made of a core of parallel fibres, bound together by a wrapper or binder that is usually a filament yarn. Generally, fibers with higher strength should be used for spinning air-jet and vortex yarns. On the other hand, less fiber loss with high yarn quality and better spinning efficiency was obtained from the cotton fibers stored in higher moisture and treated with less heat in ginning [26]. That’s why vortex spun yarns present much more wrapper fibers than air jet spun yarns, and their yarn structure is similar to ring yarns represents an idealized structure of vortex spun yarn. SEM images of spindle wear versus spindle working period for different spindle diameters were shown in Figure 11. This provided the wrapping fibers whirling around the yarn core with the greater force. The radial velocity influenced by the “θ” value has an expanding effect on the fiber bundle. All forementioned fiber groups were observed in vortex spun yarn; however, belly-band fibers were hardly seen. The researcher captured the images of the tracer fibers which were transferred to a computer later. In their study, they observed that the increment of the nozzle pressure resulted in high level of tight wrapping ratio. Zeng and Yu [30] made a research about developing a computational fluid dynamic (CFD) to simulate the airflow patterns inside the nozzle of an air-jet spinning machine. This system is claimed to be capable of producing 100% carded cotton yarns which have a ring spun-like appearance and higher tenacity due to higher number of wrapping fibers when compared with the previous air-jet spinning systems [3]. Figure 7 displays the yarn formation in MVS and MJS yarn spinning system. They used variance analysis for determining the differences between the properties of the vortex yarn and the air-jet spun yarn. The trial of MJS yarn production of pure cotton and the polyester/cotton blend with 83% of cotton ratio was not successful. They also added that there is not an apparent tendency of cotton or polyester fibers to become either wrapper or core fibers in blended yarns [9]. Figure 2 displays the general view of the MVS 861 machine and the yarn spinning unit. The fiber separation occurs everywhere in the outer periphery of the fiber bundle. But they emphasized that after a certain nozzle pressure, there might be some deteriorations for the yarn. [citation needed] Other systems include air-jet and open-end spinning, a technique where the staple fiber is blown by air into a rotor and attaches to the tail of formed yarn that is continually being drawn out of the chamber.Other methods of break spinning use needles and electrostatic forces. In that case, yarn evenness and the imperfection results were more pleasing because of the minimum risk of losing control of fibers. Available from: Buldan Vocational Training School, Pamukkale University, Denizli, Turkey, Department of Textile Engineering, Faculty of Engineering, Pamukkale University, Denizli, Turkey. Zou et al. Kuppers et al. How? Air-jet spinning passes through the air-jet nozzle to make the strands rotate at a speed of about 2500 r/min and undergo vortex torsion, so that the exposed free fiber ends on the surface of the yarn wrap the yarn body to form a wrapped yarn, as shown in Figure 1. Before the sliver from the drawframe is supplied to the air-jet spinner, combing is often used, as it is imperative to get rid of any dust or trash that could obstruct the spinning jets. In VORTEX spinning, one end of each fiber is anchored in the center of the yarn such that the center of the yarn is always without twist. Ortlek et al. The structure of VORTEX yarn optimizes the inherent characteristics of its base material. There are many studies concerning the effect of nozzle pressure to the vortex spun yarn. Only when the yarn drawing-in is successfully finished can the stable process of vortex spinning be achieved easily; otherwise, the stretched fibers will block the nozzle inlet and cause yarn breakage. vortex is a machine that can make synthetic types yarn at the near of zero twist. It is thought that the possibilities of fine count vortex yarn production with newly developed fibers such as microfibers at higher speeds are good to be investigated further for softer fabric handle. It was explained with the belief that the increment of the nozzle angle and pressure caused the fibers being integrated more tightly into the yarn structure [10]. Basal and Oxenham investigated the difference between the properties and structure of the MVS and MJS produced with different blends of cotton and black polyester. There is an air vortex between the front roller and the first nozzle which removes the twist and causes the edge fibers to be separated from the fiber bundle. Combine Singeing and Desizing of Woven Fabrics. The air-jet spinning methods have been developed since it is possible to eliminate the movable elements as the spindle and the traveler in ring spinning or the centrifuge in rotor spinning. They explained this with the result of less time for the wrapper fibers wrapping the parallel core fibers properly. Although the developments aimed to produce 100% cotton yarns, the acceptable quality was provided with polyester/cotton blended yarns in terms of yarn strength. The researchers made a solution of coupling between the fiber and airflow together with the fiber-wall contact. Erdumlu and Ozipek investigated the effects of draft ratios on the properties of vortex spun in their study. Subsequently, Murata introduced the MVS 851 spinning machine. Yarn formation in Rieter air-jet spinning machine [27]. [19] investigated the effects of various spindle diameters and the spindle working period on the properties of 100% viscose MVS yarns. This air-jet device includes a nozzle block with injectors for the generation of swirl flow, a needle holder, a hollow spindle and a guide member. They added that increasing ratio of the regenerated cellulosic fiber content has also contributes positively for the tenacity, breaking elongation values, roundness [23]. The company introduced its first air-jet spinning machine, Murata Jet Spinner, MJS 801, at the American Textile Machinery Exhibition in 1982 (ATME ’82). The twisting motion tends to propagate from the spindle toward the front rollers. Added to that in short distance between the front roller nip point and the spindle ensures less hairiness and leaner appearance [10]. Our team is growing all the time, so we’re always on the lookout for smart people who want to help us reshape the world of scientific publishing. One of the distinctive features of the system from the Murata vortex spinning system is the connection of sliver condensers, nozzle and the yarn quality sensor with the traversing device. Kılıç and Okur investigated the properties of cotton Tencel® and cotton ProModal® blended yarns in count of 30 Ne spun in different spinning systems (conventional ring, compact and vortex spinning system). The design of the nozzle as well as the airflow characteristics has a significant influence on the yarn character. Hence, the proportion of tight wrappings increased. Also airflow-fiber-nozzle interactions at the yarn formation area have to be analyzed carefully for the quality improvement of vortex yarn spinning. When it comes to spindle working period, Ortlek et al. twisting. But unlike the Murata vortex spinning system, it is not possible to produce core-spun yarns in Rieter air-jet spinning [27]. The high-speed whirled air current arises in the vortex chamber into where the pressured air is injected. Figure 4 displays the yarn formation in Murata vortex spinning system. Fibers that whirl around the hollow, spindle tip attach to the core fibers by wrapping onto, them and yarn with a similarly real-twisted structure, is formed. Related to the fiber composition, they concluded that higher cotton content is very effective improving absorbency and thermal insulation properties but decreases the air permeability. DETAILS ABOUT POLYESTER FIBERS Sohel Hossain B.Sc in Textile Engineering The People's University of Bangladesh Email: smasud39@gmail.co... An Overview of the Chemical Sector in Bangladesh Md. The fibres coming from the front drafting rollers are held together and twisted with the action of the high speed air flow inside the nozzle. This technology is best explained as a. development of air-jet spinning, making use of air jets for yarn. By this way, sliver/yarn is moved slowly over the defined range. These are double sided machines with 100 spinning units with delivery speed up to 500 m/min. Ideal yarn structures of ring spun, Open-End and MVS yarn, respectively [7]. Subsequently, these fibers are spirally wound, around the fiber core and formed into a vortex spun yarn as they are drawn into the spindle, Figure 2. Certainly, the conventional ring spinning technique is currently the most widely used, accounting for an estimated 90% of the world market spinning machines [1]. Needle holder with the guide member. The latest concept in air-jet spinning developed by Murata Machinery Ltd. is known as the vortex spinning system which uses a modified single air nozzle. Combing Longer and uniform fiber length gives better yarn quality combing process removes the short fibers thus ensuring that the yarn produced from combed cotton will be better in quality. 24,25 However, the limits of fine count yarn spinning in the vortex spinning system have not yet been identified. Yarn formation zone in vortex spinning [10]. Yarn formation in Murata vortex spinning system [4]. Hence, a yarn similar to MJS yarn with parallel core fibers mostly but fewer open-ended fibers was observed. The wild fibers increment leads to a more hairy yarn. investigated the spinning limits for the vortex spinning. The core fibers were helically embedded into the yarn. Studying the yarn formation with the swirling air concept arouse of interest of the researchers for a long time because it appears to be easy to understand as a spinning principle. After the departure of trailing ends from the nip point, they pass through the spiral fiber passage, and they twine over the hollow stationary spindle due to the whirling force of air-jet stream and become the wrapping fibers [5]. Several fiber properties govern the successful application of the air-jet process in vortex spinning system. VORTEX III 870 which was released in 2011 achieved a maximum speed of 500m/min. The investigators approve the simulation results with the yarn formation theory [32]. Figure 3 displays a detail view about the schematic diagram of the nozzle block of vortex spinning machine. But a reduction in yarn tenacity was observed at very high nozzle distances [13]. concluded that the highest proportion of core fibers were observed in ring spun yarn while MVS (Murata vortex spinning) yarn had the minimum ratio of oriented core fibers. Pei and Yu [32] discussed the principle of yarn formation mechanism in vortex spinning system by developing a three-dimensional CFD model to simulate the airflow characteristics inside the air nozzle. So the edge fibers move to second nozzle in an untwisted form. Vortex spinning has become a modern alternative method to ring and rotor spinning. Darling Downs cotton was used as the raw material for the bales. There are also some investigations verifying the nozzle angle’s effect on the swirling air during vortex yarn formation. SEM images of spindle wear versus spindle working period for different spindle diameters [19]. It is based on the Open-End spinning principle. However, there are many parameters influencing this twisting system consequently the vortex yarn. The airflow characteristics depending on the nozzle pressure reflect to the ratio of the wrapping fibers to the core fibers which cause many changes in yarn properties. This chapter is distributed under the terms of the Creative Commons Attribution 3.0 License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. Twist Insertion Process of Vortex Spinning: In the twist insertion process of spinning a staple yarn, a strand of fibers is held on one end while the strand length is made to rotate on its axis. At the end of the study, they concluded that the nozzle design was a very significant factor for the vortex formation hence the yarn quality. Some researchers have pointed out that the dynamic behavior of the fiber in the airflow field inside the nozzle plays an important role in the twist insertion process of vortex spinning. Each system has its limitations and advantages in terms of technical feasibility and economic viability. It’s based on principles of collaboration, unobstructed discovery, and, most importantly, scientific progression. And for further researches in order to improve vortex yarn quality, CFD can be used for optimizing the nozzle design [30]. Vortex Spinning Process | Principle of Vortex Spinning System, History of Sri Lanka Textile and Apparel Industry, SWOT Analysis for the Apparel Industry of Sri Lanka, The Strategies View of Industrial Engineering and Its Discussion, Physical and Chemical Properties of Silk Fiber, List of Top Textile Universities/Colleges in Europe For Higher Study/Education in Textile Engineering, Study on Air Permeability and Porosity of Fabric, Report on Changing Market Dynamics in the Global Textiles and Apparel Market, An Overview of the Textile Chemical Sector in Bangladesh, Different Types of Shedding Mechanism in Weaving Process. Help us write another book on this subject and reach those readers. The conventional ring spinning, which, uses revolutionary mechanical part to insert twist into, the yarn, is currently the most widely used spinning, technique. Wrapper-wild fibers: These fibers wrap around the core fibers in a different direction from the regular wrapping fibers. We share our knowledge and peer-reveiwed research papers with libraries, scientific and engineering societies, and also work with corporate R&D departments and government entities. Eldessouki et al. They declared that the fiber spatial configuration in vortex spun yarn was affected by the distance between the front roller nip point and the hollow spindle. Compared to commonly used ring yarns, the vortex yarn is less hairy, which leads to less fabric pilling and high abrasion resistance, high moisture absorption, color fastness, fast drying characteristics.
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