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]. Vortex-spun yarn has a ⦠The highest ratio of wild fibers in MVS yarns was observed in the wrapping fibers instead of the core fibers. Rieter has developed Rieter J10, J20 and J26 model spinning machines working with the same principle with Murata vortex spinning system. The airflow is a main parameter for the control of spinning and twisting [1–3]. In addition, they stated that there aren’t major changes in tenacity and breaking elongation values of fine count vortex spun yarns [21]. Core Spun MVS Yarn (Courtesy of Muratec) Covering fibers Basal and Oxenham investigated some process parameters including the nozzle pressure. Along with an increasing “θ” value, the axial velocity increases, and the tangential velocity decreases. Figure 8 shows a MVS spinning unit. Deterioration of fiber values led to higher fiber loss in spinning, lower yarn tenacity, high hairiness, high number of imperfections and bad spinning efficiency. They explained this with relation to the change in yarn bulk and hairiness, since higher cotton content results in a larger yarn diameter and more hairiness [25]. It provides up to 30 times the speed of ring spinning. 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. 6.7 The structure of vortex yarn compared to other yarns ... and is now an almost fully automated process of yarn spinning. During the yarn formation, as the twist propagation is prevented by the guide member, most of the fibers do not receive the false twist. Hence, a yarn similar to MJS yarn with parallel core fibers mostly but fewer open-ended fibers was observed. They used variance analysis for determining the differences between the properties of the vortex yarn and the air-jet spun yarn. The results showed that the twisted strength acting on the yarn by the vortex is also affected by the distance from the inlet of the nozzle block to the inlet of the hollow spindle. After coming out of the front rollers, the fibers move to the air-jet nozzle. In, the vortex spinning system, as shown in (Figure 1), the, spinning part is composed of an air-jet nozzle and a, hollow spindle with a yarn passage through it. The major goals of spinning is to produce the quality yarn from raw material, then remove the process faults followed by winding the short length bobbins on Cones. It was introduced in the 1980s. Open-End rotor spinning is another most commonly accepted unconventional short-staple yarn spinning technology. Eldessouki et al. They adopted the classification by Chasmawala et al. Carding process is called the heart of yarn spinning where fibers are opened and cleaned up to individual fiber level which decides the quality of final product. There are some little innovations compared to the previous models. A revolutionary idea, âspin yarn with the vortex flow of compressed airâ created VORTEX, a new concept in staple yarn. However, there are many parameters influencing this twisting system consequently the vortex yarn. Hence, there occurs the tight wrapping with higher twist which means less hairy yarns. Yarns produced by this VORTEX spinning have features different from those produced by other spinning methods. These are double sided machines with 100 spinning units with delivery speed up to 500 m/min. All forementioned fiber groups were observed in vortex spun yarn; however, belly-band fibers were hardly seen. The most studies reveal that coarser vortex spun yarns have better tenacity as well as the yarn evenness and the number of imperfections. The VORTEX® spinning, which only Muratec has successfully implemented, is creating a new wave in the world of fashion. Although the fibers are oriented to be twisted with the pressured air effect, the twisting motion tends to flow upward toward the front rollers of the drafting unit; here, the guide member protruding from the fiber bundle passage prevents this upward during the yarn formation. But it is also added that when the distance is too short, both ends of fibers are tightly held, and there occurs fewer fibers with open trailing ends. As a way of fascinated yarn production, there were many attempts for the air-jet spinning innovations such as “Dupont” in 1956, “Rotofil” in 1971, “Toyada” in 1983, “Toray” in 1985, etc. So the edge fibers move to second nozzle in an untwisted form. This result is attributed to encirclement of the core fibers by the wrapper fibers. In the vortex system, drafted fibers are introduced into a spindle orifice by an air vortex. 24,25 However, the limits of fine count yarn spinning in the vortex spinning system have not yet been identified. This provided the wrapping fibers whirling around the yarn core with the greater force. Under the action of air flow, the fiber strips are fed into the vortex tube at high speed from the cotton conveying pipe. Therefore, the starting state of the spinning process has an important influence on the stability of the vortex spinning process. pneumatic method which consists of passing a drafted strand of fibers through one or two fluid nozzles located between the front roller of a drafting system and a take up a device The researches added that the selection of jet orifice angle which should be comprised of several factors also affected the flow characteristics. Wild fibers: These fiber groups randomly protrude from the main yarn body in any direction. However, the core fibers are directed to second nozzle in a twisted form. Another study was conducted by Zou et al. [19] also concluded that spindle wear was a major problem as it negatively affects MVS yarn properties. The delivery speed, nozzle pressure and yarn count were the main variables on the Murata vortex spinning system. The yarns spun on two spinning units pass through the same yarn cleaning and waxing unit and are wound on the same package. The nozzle pressure increment led to the higher axial and tangential velocity in the nozzle which resulted better tensile properties of 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. At the time of the second nozzle leaving, the core fibers are unwrapped and the edge fibers are twisted in the opposite direction. This technology is best explained as a. development of air-jet spinning, making use of air jets for yarn. The interaction of a high nozzle angle and short front roller to the spindle provided better evenness. The explanation for that was the possibility of the fibers having much more place to arrange themselves in larger spindle diameters. Tracer fiber configuration in MVS yarns [5]. VORTEX is a high-quality yarn with a rich combination of functional and fashionable features. Generally, coarser yarns yielded better yarn properties in terms of yarn evenness, imperfection values, hairiness and tensile properties [20]. Although Murata Machinery claims, the yarn tenacity results improve as the yarn gets finer. 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]. Air-jet spinning is also known as Vortex or fasciated yarn spinning. also claimed that the finer MVS yarns have less proportion of core fibers than the coarser ones. While entering and passing through the ⦠Figure 8 displays the vortex and air-jet spun yarn together. 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. 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. Hence for the whole understanding of the system, each factor has to be investigated in detail. The needle holder has a substantially central, longitudinal axis and a guide surface that twists relative to the longitudinal axis, ). Yarn formation zone in vortex spinning [10]. Figure 14 displays scanning electron microscope pictures for the longitudinal view of Rieter, Murata vortex and Open-End rotor spinning. This frictional force contributes to draw the yarn from the spinning chamber with the roller rotating [28]. In a sense, vortex spinning is the real rotor spinning. The company introduced its first air-jet spinning machine, Murata Jet Spinner, MJS 801, at the American Textile Machinery Exhibition in 1982 (ATME ’82). 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. The success of Murata vortex spinning (MVS) system which is the newest system after all studies of air-jet systems has been much acceptable especially for the spinning ability of 100% cotton in high speeds (500 m/min) and the yarn structure resembling ring yarn structure rather than rotor yarns. By making research easy to access, and puts the academic needs of the researchers before the business interests of publishers. Murata has developed MVS 810, MVS 81T, MVS 851, MVS 861 and lastly the MVS 870 model spinning machines. VORTEX, a new type of yarn. The nozzle design parameters’ effect to the flow characteristics and its reflection to the yarn was mostly discussed. Belly band fibers are observed in the upright position with respect to the yarn central axis. The structure of MVS yarns has been classified into four main categories: tight wrappings, long wrappings, irregular wrappings and unwrapped. Figure 3. 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. 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. SPINNING PROCESS. There are also some studies related to comparison of air-jet spun yarns and vortex yarns. Spindle wear mainly occurred in the tip zone and the whole surface of the spindle. Comparison of yarn formation in MVS and MJS yarn spinning system [9]. These studies reveal that the nozzle air pressure directly influences the fiber configuration and the yarn structure. They determined the ratio between the fiber guidance element and the yarn delivery speed depending on the yarn count. The main features of Murata vortex spinning (MVS) are. Since fiber separation occurs everywhere in the outer periphery of the fiber bundle, a higher number of wrapper fibers are obtained with jet-spun yarns. In that case, yarn evenness and the imperfection results were more pleasing because of the minimum risk of losing control of fibers. However, the upper portions of some fibers separated from the nip point of the front rollers are kept open. With the insertion of the twist, the fibers are packed together, to-form a continuous yarn with special structure and, properties. Higher breaking elongation and work to break values were observed at the intermediate level of 2.5 with the highest total draft of 267. The swirling air has been used frequently for twisting the fibers instead of using mechanical parts in the recent years. 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. 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. Murata Machine has also developed a new vortex spinning model MVS 870 at ITMA 2011 Barcelona. In recent years, computational fluid dynamic approaches have been used to investigate the airflow characteristics in the vortex spinning nozzle [30–32]. Barium Activity Number (BAN) | Mercerization Test ... Slitter Machine | Object and Function of the Slitt... Vortex Spinning Process | Principle of Vortex Spin... Compactor Machine | Function of Compactor Machine ... Stenter Machine | Function of Stenter Machine | Wo... Shout Out at Felt | Manufacturing Process of Felt, Mechanism of Dye Fixation Processes in Fabric. Combine Singeing and Desizing of Woven Fabrics. reported that the changes in nozzle pressure influenced the tightness of wrapping fibers along the yarn strand as well as the amount of wrapping and the proportion of unwrapped sections. In the vortex spinning system, the twist insertion system is composed of an air-jet nozzle and a hollow spindle with a yarn passage through it. Description of each classification depending fiber arrangement is explained below [7]: Core fibers: These fibers may be straight or inclined. Even today, ring spinning makes the widest range of yarn counts with the highest strength. In the vortex system, drafted fibers are introduced into a spindle orifice by an air vortex. The spinning system ensures uniform winding tension with a tension ruler with minimum energy consumption [3, 4]. Figure 3 displays a detail view about the schematic diagram of the nozzle block of vortex spinning machine. In this system, the second nozzle creates false twist on the fiber bundle coming out of front roller. The conventional ring spinning, which, uses revolutionary mechanical part to insert twist into, the yarn, is currently the most widely used spinning, technique. This was explained as a risk for the leading end of the fibers to be more easily pulled out from the vortex spun yarn and for the fiber loss and more thin places in the yarn [18]. 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. They concluded that a large spindle diameter resulted in high hairiness, as well as low unevenness and tenacity values. In the 1990s, a new technology appeared on the market: air-jet spinning, the so-called Vortex ⦠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. 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. The wear of the spindle increased with an increasing working period. It is a process in which the input material to the spinning system is highly drafted, ideally to the individual fiber state. Initially only the man-made fibers could be used as the raw material; later, it was improved for cotton yarn spinning as well. The standard k-Ɛ turbulence model was used to study the air stream field of the main nozzle, and the standard wall-function approach was introduced to deal with flow near the walls. Maschweg 1 - 7. Ideal yarn structures of ring spun, Open-End rotor and MVS yarn were illustrated in Figure 6 [22]. Ortlek et al. Ring spinning is one of the most common spinning methods in the world. On the other hand, when the trailing ends of the fibers which have left the front rollers move to a position where they receive the powerfully whirling force of the nozzle, they are separated from the fiber bundle, extend outwardly and twine over the spindle. "VORTEX® spinning" is a technology which uses an air vortex to spin out the yarn. The system is stated to be suitable for processing man-made fibers and their blends with cotton; however, it was not capable of spinning 100% cotton or rich blends of cotton yarn [3]. The rotation of the strand causes the fibers to adopt helical forms and increase the number of turns of twist. In another investigation, Leitner et al. Erdumlu and Ozipek investigated the effects of draft ratios on the properties of vortex spun in their study. Licensee IntechOpen. It can be emphasized that there was no twist in the core fibers of the vortex yarns which was a significant feature. investigated the spinning limits for the vortex spinning. Contact our London head office or media team here. Spinning is the most important and the initial step in fabric manufacturing. [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. Schematic model of nozzle block and projection of the nozzle with jet orifices at section respectively is shown in Figure 10. According to the microscopic examinations, Soe et al. 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. There are also some investigations verifying the nozzle angle’s effect on the swirling air during vortex yarn formation. There are many studies concerning the effect of nozzle pressure to the vortex spun yarn. 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. Basal and Oxenham also suggested that the nozzle angle had significant impact on yarn hairiness and evenness. No wrapper fibers were observed in the ring spun yarn structure. 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. Each system has its limitations and advantages in terms of technical feasibility and economic viability. As the number of fibers in the cross section increases, the yarn break ratio during spinning also the yarn faults will be in a decreasing tendency. Tyagi et al. Open Access is an initiative that aims to make scientific research freely available to all. 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. But these methods had little commercial success. Hollow spindle spinning is a technology developed as a one-stage process for production of fancy yarns. 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. Of late, it’s being highly evaluated because its capable of producing polyester products requiring luxurious luster, Vortex spinning systems provide yarn with different structures and properties. D-49419 Wagenfeld / GERMANY . The preceding parts which will be core fibers later are drawn into the vortex spun yarn trail. 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. 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. it can drop it cone's automatically and can splice yarn automatically.
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