Air Vortex Spinning

(1)

Air Vortex Spinning

Prof.Dr.S.Kathirrvelu

Professor-(Text.Tech)

EiTEX, BDU

1/! 1/! " #Sc (T#)-T$S-%&S " #Sc (T#)-T$S-%&S

(2)

Vortex Spinning Vortex Spinning

&ortex s'ii techolo* +as itrouce * #urata #achier* &ortex s'ii techolo* +as itrouce * #urata #achier* t. a'a i 100. This techolo* is est ex'laie as a t. a'a i 100. This techolo* is est ex'laie as a evelo'2et of air-3et s'ii, 2a4i use of air 3ets for *ar evelo'2et of air-3et s'ii, 2a4i use of air 3ets for *ar t+isti. The 2ai features of #urata vortex s'ii (#&S) are t+isti. The 2ai features of #urata vortex s'ii (#&S) are %ilit* to 'rouce *ar at

%ilit* to 'rouce *ar at 400 m/min.400 m/min. +hich is al2ost+hich is al2ost 2020 times greater than ring spinning

times greater than ring spinning fra2e 'rouctio .fra2e 'rouctio . 1.

1. o+ 2ao+ 2aiteace costsiteace costs, a full* , a full* auto2ate 'ieauto2ate 'ieci s*ste2 ci s*ste2 aa eli2iatio of rovi fra2e.

eli2iatio of rovi fra2e. .

. The *ar The *ar a the faric 'ra the faric 'ro'erties of #&S *aro'erties of #&S *ar are cl are clai2e *ai2e * the 2aufacture

the 2aufacturer to r to e co2'arale to those e co2'arale to those of ri s'u *ar.of ri s'u *ar.



" #Sc (T#)-T$S-%&S

(3)

"

"##SS ((TT##)) TT$$SS %%&&SS 55

&$6TEX *ar is 2ae * the 7&$6TEX s'ii 2achie7 &$6TEX *ar is 2ae * the 7&$6TEX s'ii 2achie7 of #urata #achier* (#U6%TE8). The &$6TEX s'ii of #urata #achier* (#U6%TE8). The &$6TEX s'ii 2achie s'is *ars i a ui9ue +a* usi a air vortex 2achie s'is *ars i a ui9ue +a* usi a air vortex +hich +as evelo'e a is 2aufacture ol* * #urata +hich +as evelo'e a is 2aufacture ol* * #urata

(4)

: : " #Sc (T#)-T$S-%&S " #Sc (T#)-T$S-%&S Principle of operation Principle of operation

The basic principle of operation is shown in

The basic principle of operation is shown in Figurs 1Figurs 1 and and 22. The. The sliver is fed to

sliver is fed to 4-over-4 (or a four-pair) drafting unit4-over-4 (or a four-pair) drafting unit. As the. As the fibers come out of the front rollers, they are sucked into the fibers come out of the front rollers, they are sucked into the spiral-shaped opening of the

shaped opening of the air jet nozzleair jet nozzle. The nozzle provides a. The nozzle provides a swirling air current which twists the fibres . A guide needle within swirling air current which twists the fibres . A guide needle within the nozzle controls the movement of the fibres towards a

the nozzle controls the movement of the fibres towards a hollowhollow spindle.

spindle. After the fibers have passed through the nozzle, theyAfter the fibers have passed through the nozzle, they twine over the hollow spindle. The leading ends of the fiber bundle twine over the hollow spindle. The leading ends of the fiber bundle are drawn into the hollow spindle by the fibers of the preceding are drawn into the hollow spindle by the fibers of the preceding portion of the fiber bundle being twisted into a spun yarn. The portion of the fiber bundle being twisted into a spun yarn. The finished yarn is then wound onto a package.

(5)

;

" #Sc (T#)-T$S-%&S

Figure 1 :

Figure 1 : FFeed material eed material PassagePassage Through the machine

(6)

<

" #Sc (T#)-T$S-%&S

Figure 2: xpansion o! "#re Figure 2: xpansion o! "#re edges due to $hirling !orce o! the edges due to $hirling !orce o! the %et air stream

(7)

"

"##SS ((TT##)) TT$$SS %%&&SS 

The

The rafti rafti uit uit isis

alsoa ver*

i2'ortat ele2et i2'ortat ele2et i %ir-3et s'ii. i %ir-3et s'ii. &igh dra!ts

&igh dra!ts havehave to e 'erfor2e, to e 'erfor2e, +ith

+ith goodgood e'enness

e'enness of theof the =er >o+ a =er >o+ a excellent

excellent orientation

orientation of theof the =ers, at ver* hih =ers, at ver* hih 'rouctio s'ees. 'rouctio s'ees. Both su''liers Both su''liers have e9ui''e the have e9ui''e the

(8)

%s a co2'ariso +ith the aove-escrie +ra''i

2echais2 +ith tae2 3ets, it is useful to cosier

the e@ectiveess of +ra''i +ith ol* oe 3et. " this

situatio, the At+isti actio of the 3et is ot

ulli=e, a the core is therefore At+iste. The

ee =ers +ill, as escrie aove, +ra' the core

+ith a Airectioal helix. Bei that the core t+isti

is o+ i the sa2e irectio as the +ra''i actio,

so2e ee =er 2a* eco2e cauht a t+iste ito

the core, there* reuci the u2er of the2

availale to +ra' the core.

"

(9)

$e a''roach to icreasi the u2er of ee

=ers is to icrease the leth of the s'ii

triale so that the t+ist isertio 'oit is farther

fro2 the i' lie of the frot rollers. This results

i ee =ers havi to travel farther to+ar the

t+ist isertio 'oit at the a'ex of the s'ii

triale. The e@ect of oi this ca e

e2ostrate i covetioal ri s'ii *

'artiall* restricti the t+ist >o+ to+ar the i'

lie of the frot rafti rollers. The result is a

""##SS ((TT##)) TT$$SS %%&&SS 00

(10)

"

(11)

?iure <.0 is a iara2 of the sile-3et esi of the

#urata &ortex s*ste2, +hich is a sile air-3et

s'ii s*ste2. 8o2'are +ith the tae2 3et

s*ste2, it icor'orates a 2oi=e 3et ilet. ittle

techical ifor2atio is availale o the +or4i

'rici'le.

#uch ie'eet research has *et to e oe to ai

a

etaile

uerstai

of

the

+ra''i

a

etaile

uerstai

of

the

+ra''i

2echais2 of the &ortex s*ste2. o+ever, it is

'ossile that a 'artial loc4i of the t+ist >o+ 2a*

"

(12)

1

" #Sc (T#)-T$S-%&S

$e 'role2 +ith the vortex s*ste2 is

sii=cat =re loss uri the *ar for2atio.

This

This is

is rela

relate

te to

to the

the 'role2

'role2 of

of variatios

variatios i

i

ar 9ualit +hich are ot etectale *

covetioal eveess testers a so2eti2es

ol* ieti=e * +ea4 'oits i the =ishe

faric. The 'ath follo+e * the =re i the

currets create * the air 3ets 'la* a crucial

role i ar 9ualit. #ost structural efects are

cause * the e>ectio of =res i the air 3et

(13)

•

Both eliver* s'ee a *ar cout are sii=cat

factors for *ar eveess a i2'erfectios. %

icrease i eliver* s'ee results i eterioratio of

*ar eveess. This is the result of ecreasi

eFciec* of the air 3et strea2 at hiher eliver* s'ees

ecause there is less ti2e for the +ra''er =res to

+ra' arou the 'arallel core 'ro'erl. This 'articularl

a@ects =er *ars a 2eas that vortex s'ii is

est suite for coarser raes of *ar. Gole 'ressure

also has a sii=cat e@ect o *ar 'ro'erties.

15

" #Sc (T#)-T$S-%&S

(14)

The structure of vorte !arn co"pared to other

!arns

Vortex yarn has a two-part structure a core surrounded

by wrapper fibres. The number of wrapper fibres

compared to the fibre core is higher compared to the air

!et spinning.

!et spinning. "uring yarn

"uring yarn formation

formation,

, the leading

the leading ends of

ends of

the fibres are directed towards the yarn core and the

trailing ends wrap around the core fibres. #uch a

structure provides the necessary fibre orientation and,

at the same time, the re$uired yarn strength.

1:

" #Sc (T#)-T$S-%&S

(15)

This

This 'articular

'articular structure

structure of

of the

the %ir

%ir-vorte

-vortex

x s'u

s'u *ars

*ars

i>ueces the *ar 'ro'erties, of course. These

'ro'erties are 2ail* eter2ie *  'ara2etersH

1. 1. the 'e

the 'errce

cetae of +

tae of +ra''

ra''i =

i =ers

ersII

.

. the t

the t+ist l

+ist level o

evel of the

f the +ra''i

+ra''i =er

 =ers.

s.

The

The 'ercetae

'ercetae of

of +ra''i

+ra''i =ers

=ers ca

ca e

e i>uece

i>uece

* the

s'ii raft a * the istace  (?i. 5;), a it

is also

a fuctio of the *ar cout.

"

(16)

Spinning no((le

The

The s'ii

s'ii ole

ole is

is asicall*

asicall* the

the *ar

*ar for2

for2atio

atio

ele2et, i.e. the heart of the %ir-3et s'ii 'rocess.

8o2'resse air at u' to !.< #'a eters the actual

s'ii cha2er throuh : s2all ores, thus creati

a ver* stro air vortex (see ?i. 5<). %t the outlets of

the ores, this air vortex has a rotatio s'ee of u' to

1 !!! !!! r'2. The vortex 'erfor2s  fuctios

throuh this hih s'eeH

1. 1. e

eera

eratio

tio o

 of a

f a vac

vacuu2

uu2 a

a

 the

therre

e* a

* a

 air

air >o+

>o+

throuh the =er fee chaelI

"

(17)

"

(18)

"

(19)

10

" #Sc (T#)-T$S-%&S

% hiher 'ressure ca i2'rove streth

ecause +ra''er =res +ra' 2ore tihtl*

arou the core. o+ever, it ca also lea to

2ore lost =res. This creates 'otetial +ea4

'oits a icreases ueveess i the *ar.

% lo+ 'ressure leas to i2'rove eveess

thouh streth is reuce. The istace

et+ee the frot roller i' 'oit a the ti'

of the s'ile (

of the s'ile (indicated #) * in "gure 2

indicated #) * in "gure 2))

also a@ects *ar structure. The reater the

(20)

•

• " &ortex *ars, the cetre of the *ar is ot t+iste. T+isti" &ortex *ars, the cetre of the *ar is ot t+iste. T+isti

occurs at the outer sies of the *ar, as sho+ i

occurs at the outer sies of the *ar, as sho+ i Figures +Figures + and 4

and 4. ?ires at the cetre of the *ar re2ai loose +hile those. ?ires at the cetre of the *ar re2ai loose +hile those at the outer sie are full* t+iste. " ri s'u *ar, t+ist is at the outer sie are full* t+iste. " ri s'u *ar, t+ist is ive to the etire *ar fro2 the cetre to the surface of the ive to the etire *ar fro2 the cetre to the surface of the *ar (

*ar (Figures , and -Figures , and -). The *ar thic4ess i vortex *ars is). The *ar thic4ess i vortex *ars is ueve. T+isti is cocetrate at the thier sectios, +hile ueve. T+isti is cocetrate at the thier sectios, +hile t+isti is loose at the thic4er sectio, leai to reater *ar t+isti is loose at the thic4er sectio, leai to reater *ar hairiess. " the case of rotor *ar all the =res are t+iste hairiess. " the case of rotor *ar all the =res are t+iste fro2 the cetre to the outer sie

fro2 the cetre to the outer sie Figures  and ). T+isti isFigures  and ). T+isti is 2ore ueve for =res ear the surface of the *ar. Tale 1 2ore ueve for =res ear the surface of the *ar. Tale 1 'rovies a co2'ariso et+ee the

'rovies a co2'ariso et+ee the three t*'es of *ars.three t*'es of *ars.

!

" #Sc (T#)-T$S-%&S

(21)

1

" #Sc (T#)-T$S-%&S

Figure + :

Figure + : VVortex )arn cross ortex )arn cross sectionsection

Figure 4 : icrograph o! 'ortex )arn structure Figure 4 : icrograph o! 'ortex )arn structure

(22)



" #Sc (T#)-T$S-%&S

Figure , : 3rosssection o! the

Figure , : 3rosssection o! the ring )arnring )arn

Figure - : icrograph o! ring )arn structure Figure - : icrograph o! ring )arn structure

(23)

5

" #Sc (T#)-T$S-%&S

Figure  : icrograph o! rotor )arn structure Figure  : icrograph o! rotor )arn structure

Figure . : 3ross section o! the rotor )arn Figure . : 3ross section o! the rotor )arn

(24)

: : " #Sc (T#)-T$S-%&S " #Sc (T#)-T$S-%&S

P

Pr

ro

op

pe

er

rt

t!

!

#

#i

in

ng

g

$

$a

ar

rn

n

#

#o

ot

to

or

r

$arn

%orte

$arn

%arallelization and

&ibre orientation

'

'a

ax

x

'

'iin

n

(

(a

aiirriin

ne

es

ss

s

'

'a

ax

x

'

'iin

n

%

%iilllliin

ng

g

'

'a

ax

x

'

'iin

n

#

#ttrre

en

ng

gtth

h

'

'a

ax

x

'

'iin

n

)

)n

ne

ev

ve

en

nn

ne

es

ss

s

'

'a

ax

x

'

'iin

n

#

#u

urrffa

ac

ce

e s

sm

mo

oo

otth

hn

ne

es

ss

s

'

'a

ax

x

'

'iin

n

*

*o

orre

e

ffiib

brre

es

s

'

'a

ax

x

'

'iin

n

+

+e

ep

ps

s a

an

nd

d T

Th

hiic

ck

k p

plla

ac

ce

es

s

'

'iin

n

'

'a

ax

x



u

ullk

kiin

ne

es

ss

s

'

'iin

n

'

'a

ax

x

Ta&le 1' o"parison in !arn characteristics

(25)

; ; " #Sc (T#)-T$S-%&S " #Sc (T#)-T$S-%&S Figure  ' *ifference in Figure  ' *ifference in twist distri&ution in twist distri&ution in vorte+ rotor and ring vorte+ rotor and ring !arns

(26)

The overall avataes of vorte

The overall avataes of vortex *ar over the ri a rox *ar over the ri a rotor *arstor *ars are H

are H

- Better resistace to 'illi a arasioH this ives loer-lasti - Better resistace to 'illi a arasioH this ives loer-lasti

faric 'erfor2ace throuh a reater u2er of +ashi c*cles. faric 'erfor2ace throuh a reater u2er of +ashi c*cles. - ess hairiessH this reuces 'otetial 'role2s i faric - ess hairiessH this reuces 'otetial 'role2s i faric

'rouctio a ives a s2ooth a''earace to the faric. 'rouctio a ives a s2ooth a''earace to the faric.

- ess shri4aeH uli4e ri s'u *ar, the structure of vortex - ess shri4aeH uli4e ri s'u *ar, the structure of vortex

*ars 2eas the* are less 'roe to shri4 *ars 2eas the* are less 'roe to shri4

- #oisture asor'tio a r*iH the looser structure of =res at - #oisture asor'tio a r*iH the looser structure of =res at the cere of vortex *ars 2eas that the* asor 2oisture a the cere of vortex *ars 2eas that the* asor 2oisture a r* 9uic4l*

r* 9uic4l*

"

(27)

"

(28)

"

"##SS ((TT##)) TT$$SS %%&&SS CC

The aove =

The aove =ure shoure sho+s verticall* the tihtess of t+isti, a +s verticall* the tihtess of t+isti, a A- A-t+ist a S-A-t+ist iicate the irectios of A-t+isti ceteri o t+ist a S-t+ist iicate the irectios of t+isti ceteri o !L. The horiotal axis i the ra'h sho+s the istace fro2 the !L. The horiotal axis i the ra'h sho+s the istace fro2 the ceter i a cross sectio of the *ar. The i2ae chart of each ceter i a cross sectio of the *ar. The i2ae chart of each t*'e of *ar sho+s the *ar-t+isti structure see fro2 the sie. t*'e of *ar sho+s the *ar-t+isti structure see fro2 the sie.

(29)

" "##SS ((TT##)) TT$$SS %%&&SS 00 T T+ist +ist isis 'ro2iet 'ro2iet to+ar the to+ar the outsie of the outsie of the *ar, +hile at *ar, +hile at the ceter of the ceter of the *ar, =ers the *ar, =ers are 'arallel.

are 'arallel.

There

There is is oo ut+iste 'art. ut+iste 'art. T

T+ist +ist of of so2eso2e eree is 'reset eree is 'reset i the etire *ar i the etire *ar fro2 the ceter fro2 the ceter to the surface. " to the surface. " areas of ueve areas of ueve *ar thic4ess, *ar thic4ess, the t+ist +ill e the t+ist +ill e hih at the hih at the thier sectios, thier sectios, a lo+ at the a lo+ at the thic4er sectios thic4er sectios #icrora'h of the *ar structure

(30)

"

"##SS ((TT##)) TT$$SS %%&&SS 55!!

%ll =ers are t+iste fro2 the ceter to %ll =ers are t+iste fro2 the ceter to the outer sie. ?or =ers ear the surface the outer sie. ?or =ers ear the surface of the *ar, t+isti is ueve. So2e of the *ar, t+isti is ueve. So2e =ers are t+iste i the o''osite irectio =ers are t+iste i the o''osite irectio of the 2ai ule.

of the 2ai ule.

#icrora'h of the *ar structure #icrora'h of the *ar structure

(31)

"

(32)

"

(33)

"

(34)

"

(35)

T%GK M

T%GK M$U &E6

$U &E6M #U8

M #U8

5;

" #Sc (T#)-T$S-%&S