Spinning Geometry of Ring Spinning Machine

Akash S. Bansode*

Abstract
The ring spinning machine will continue to be the most widely used spinning process in short
staple spinning .The spinning geometry is a critical aspect in the spinning process of staple yarn.
The spinning geometry influences the distribution of fiber tension in the spinning triangle, twist
insertion rate in the yarn, binding-in of fibers, the properties of spun yarns, tension in yarn and
the performance of the machine.
The spinning geometry represents the dimensions between the elements of the ring spinning
machine which are comes in the path of yarn formation and also the inclinations of elements as
well as inclination of the yarn with respect to the parts of the machine. Thus in this paper,
different aspects of spinning geometry, influence of the parts of the ring spinning machine on the
resultant yarn properties and performance of the ring spinning machine are discussed.
Key words: Ring spinning, spinning geometry, spinning triangle, fiber tension distribution,
balloon control ring, balloon height, deflection angle.

 Introduction

The invention of ring spinning machine was done by an American Mr. Thorp in 1828. In that
ring spinning machine the modification and implementation of Ring & Traveller elements done
by another American Mr. Jenk in 1830. At today’s scenario more than 170 years Ring Spinning
has undergone considerable modifications. Evolution of the ring spinning machine is not yet
completed.
The ring spinning machine will continue to be the most widely used spinning process in short
staple spinning because of it can be used universally, Produces yarn with optimum properties,
uncomplicated and easy to control, flexible with regard to volume (blend and batch sizes). In the
ring spinning machine the spinning geometry plays an important role regarding quality of yarn
and performance of machine. [1]
Definition
Fiber strand passes through the drafting arrangement, thread guide, balloon control ring and
traveller. These parts are arranged at various angles and distances relative to one another, which
give varying deflections and paths of travel for the yarn. The set of dimensions, guiding and
leading angles, of the machine elements with each other on ring frame machine which are
together referred as the spinning geometry. [2]

 Spinning Geometry

Spinning geometry is a geometrical representation of a ring frame machine elements with respect
to formation of yarn. Spinning geometry has a significant influence on the spinning operation
and the resulting yarn, primarily upon, tension conditions on fibers and yarn, binding-in of the
fiber, number of end breaks, yarn hairiness, yarn irregularity and generation of fly etc. Spinning
geometry is optimization decisive factor for machinery manufacturers. However, it has to be
borne in mind here that changing a spinning geometry parameter inevitably entails a change in
all other geometry parameters
It is therefore an absolutely essential set of parameters to be the machine builder. Within the
spinning geometry; the following aspects have to be considered. [2]

 The Spinning Triangle

 The Balloon Height
 Roller Overhang
 Drafting arrangement inclination
 Wrap of the yarn on the thread guide

A figure 1 shows a different angle and dimensions in the spinning geometry as follows [3]
 Figure.1- Spinning Geometry

 Spinning Triangle
The turns of twist in a yarn are generated at the traveller and travel against the direction of yarn
movement to the drafting arrangement. Twist must run back as close as possible to the nip line of
the rollers, but it never penetrates completely to the nip because, after leaving the rollers, the
fibers first have to be diverted inward and wrapped around each other. Accordingly, at the exit
from the rollers there is always a triangular bundle of fibers without twist, the so-called spinning
triangle. By far the most end breaks originate at this weak point, because the yarn tension in the
balloon cannot be transmitted almost without hindrance as far as the drafting arrangement,
whereas twist in the spinning triangle is zero-nor does it attain its full value in the adjoining yarn
section either, because of friction at the thread guide.

The length of the spinning triangle depends upon the spinning geometry and upon the twist level
in the yarn. As can be appreciated from the immediately foregoing remarks, a short triangle
represents a small weak point and hence fewer end breaks. As usual, however, advantages have
to be weighed against disadvantages.

If the spinning triangle is too short, then the fibers on the edge must be strongly deflected to bind
them in. This is not possible with all fibers. Some edge fibers escape the twist effect and are lost
as fly. Other may be bound-in, but at one end only; one fiber end them projects from the body of
the yarn, which is therefore hairy.

On the other hand, a long spinning triangle implies a long weak point and hence more ends
breaks. However, a resultant advantage is that the edge fibers are better bound into the edge
fibers are better bound into the yarn, which gives a smoother yarn and less fly. [2]

3.1 Spinning Triangle in Compact Ring Spinning:

In the enlarged view of ring spun yarn is examined, it is easy to see that the integration of many
fibres is poor, and they therefore make no contribution to yarn strength as shown in Figure 3. In
other words, if all fibres could be completely integrated in the yarn, both strength and elongation
could in turn be further enhanced. It is thus obvious that even ring-spun yarns are not yet ideal as
regards yarn structure. [5]
The development of the compact spinning process began with the desire to achieve a significant
improvement in yarn quality by influencing the spinning triangle Figure 3. The process is
focused on achieving higher yarn strength and a reduction of yarn hairiness, especially on
eliminating the longer hairs, which have a particularly bad influence on the further process. The
improvement achieved is shown in the Figure 3.
The Fig. 4(a) displays the fibre triangle at the exit of a conventional ring frame drafting system.
The twist imparted by the spindle cannot flow up to the clamping line. The outer fibres spread
out and are thus more highly tensioned than those on the inside. The Fig. 4(b) does not show a
spinning triangle. The yarn twist flows right up to the clamping line. The yarn is round and
smooth. To achieve tenacity comparable with conventional ring-spun yarns, a lower number of
turns per meter can be used, which enables higher productivity of the spinning machine, as well
as better elasticity and softer hand of different flat textile products. [5], [6], [7]

 The Inclination of Drafting Arrangement:

The angle of inclination of drafting arrangement (fig. 5) is one factor which determines
the height of the spinning triangle. The inclination of drafting arrangement is with respect
to the horizontal line of the machine. If the drafting arrangement is mounted with a
relatively low inclination, the angle of the wrap of

Figure.5 – Inclination of drafting arrangement to vertical

the fiber strand over curvature of the front bottom drafting roller is large; this will give a long
spinning angle, with its associated advantages and disadvantages
With a steeper inclination and large angle (α2), the deflection angle £2 is small and the spinning
triangle is short. The inclination of the drafting arrangement in modern ring spinning machines
now lies between 45° and 60°, very often 45°. [1], [2]

 Roller Overhang:

The top front roller almost never lies vertically above the associated bottom roller known as
Roller Overhang (fig. 6). Usually, the top roller is shifted about 2 to 4 mm forward. This gives
somewhat smoother running, because the weighting force exerts stabilizing component acting in
the running direction so that swinging of the top roller is avoided.

Furthermore, the angle of wrap is reduced and the spinning triangle is made shorter. The
overhang must not be made too large, however, as otherwise the distance from the exit opening
of the roller nip line, becomes too long resulting in poorer fiber guidance and increased yarn
irregularity. [2], [3]

 Inclination of Stretch Yarn to Vertical:

The yarn run through the thread guide with an inclination giving a deflection angle of
about 15º to 30º and a wrap angle (on modern machines of 0º to 50º). This variability
arises in part from the up and down movement of the lappets, balloon control rings and
ring rail. In addition, there is a very large difference in angle of wrap depending upon
whether the yarn in the balloon extends from the guide towards the machine or away
from the machine (to the left). The angles therefore never have the same size at any two
points around the guide. The thread guides also exert a braking effect on pulsation of the
balloon, which seldom rotates smoothly. It is usually required to absorb impacts and
vibration arising from the traveller and from air turbulence. A large deflection damps
these impacts and vibrations at the thread guide, so that they no longer penetrate fully to
the spinning triangle.
A smaller angle of wrap, therefore, implies more turns of twist in the spinning triangle and fewer
end breaks, but also higher yarn tension at that weak point. The latter effect can partly neutralize
the favorable effect of the higher twist level. Also, impacts and vibrations are better able to pass
through to the spinning triangle. If the twist density is raised at the nip line, them the spinning
triangle will also clearly become smaller with all the resulting advantageous and disadvantageous
effects.[2]

 The Balloon Height:

On the ring spinning machine, yarn take up capacity depends on, among other factors, the height
of the tube and air turbulence formed by the yarn rotating with traveller speed. However, this
height can only be varied within certain a tall balloon implies considerable tension differences
between winding of the cop base and winding at the top.
Also, a balloon in this from is unstable; it can collapse. The latter problem can be solved by use
of a balloon control ring. However, since the yarn rubs on this ring-and the higher the balloon,
the greater the degree of rubbing-use of control rings can lead to roughening of the yarn to a high
hairiness value, to increased generation of fly and to melt spots (with synthetic fibers).[1],[2], [3]
 Other Dimensions in Spinning Geometry[2], [3]:

 he lift Ik is about 20 mm shorter than the tube height Ik.

 The distance from the top edge of the tube to the thread guide should be at least 2 dh +5
mm.
 The basic setting of the length Ir (between the ring and the balloon control ring) can be
slightly less than half the length IB.
 The ratio (ring diameter)/ (tube height) =0.2-0.225.
  The ratio [tube diameter (top edge)]/[interior ring diameter] = 0.45-0.5

Conclusions:

In Ring Spinning, the Spinning Geometry plays a vital role regarding to the quality of yarn and
performance of machine. Spinning geometry has a significant influence on spinning operation
and the resulting yarn primarily on: Tension conditions, Binding-in of the fibers, Number of End
Breakages, Yarn Hairiness, Yarn Irregularity, and Generation of Fly. Turn the spinning width,
should be as close as possible to spinning triangle width to minimize high loss of fiber, minimize
hairiness in the yarn. In Compact Ring Spinning system, the width of spinning triangle get
reduces the integration of edge fibers in yarn cross section increases. The inclination of the
drafting arrangement in modern ring spinning machine now lies between 45° to 60°, very often
45° to get optimum spinning triangle. Roller overhang must not be too large

Balloon height lB (Fig. 82):

Every spinner is interested in producing large packages to increase their running time on
subsequent machines, at least as long as the large package does not influence productivity. As
cop size is a function of ring diameter and tube length (lK), choosing large dimensions in both
might be considered. However, this is not possible because the larger the ring diameter the lower
the production rate, and tube length depends on ring diameter. If the tube is too long, the balloon
becomes too high for its diameter and this implies considerable tension differences between
winding on the cop base and winding at the top. Even when using balloon checking rings, as is
mostly the case, a balloon of this shape is unstable. It might – and in fact often does – collapse,
leading to ends down.The ratio of ring diameter to tube length should be about 0.2 to 0.225.

Lift lH:
About 20 mm shorter than tube length lK.

Distance from top of tube to thread guide (lappet) (lF):

At least 2 x dH + 5 mm.

Basic setting lR (distance from ring to balloon checking ring):

Slightly less than half length lB.

Ratio of tube outside diameter at top to ring diameter:

About 0.45 to 0.5.
 Fig. 82 – Spinning geometry angles and dimensions

Spinning length E
This length E (Fig. 82) differs quite markedly depending on machine design. If it is very long, then a
second or even third balloon might emerge between lappet (F) and the front roller, in extreme cases
increasing the ends down rate. However, insufficient length is much more troublesome, because the
spinning length is a damping zone for all the shocks and disturbances coming from the balloon. If they
pass without reduction into the spinning triangle, they cause a considerable increase in ends down rates.
Here too, an optimum has to be found.

Fig. 82 – Spinning geometry angles and dimensions

Spinning angle γ

At the thread guide of the lappet, the yarn is deflected more or less according to the design of the
machine, mainly depending on angle γ (Fig. 82). This angle also has a major influence on the ends down
rate and yarn formation due to the twist insertion operation. Twist is inserted at the traveler by its rotation.
The twist must rise against the movement of the yarn up to the front rollers, where it has to tie in the
fibers. If deflection arc γ at the lappet is large (Fig. 82), a substantial part of the rising twist will be held
back at this point. The fiber mass at the critical point, i.e. the tying-in point of the spinning triangle,
therefore has less twist than ultimately the final yarn. This results firstly in more ends down, because yarn
strength between the drafting system and the lappet is simply inadequate owing to insufficient twist, and
secondly the twist retention impairs the tying-in of the fibers. The yarn receives its twist in two stages,
most of it at the spinning triangle and then an additional twist insertion in a yarn already formed between
traveler and lappet. This in turn is detrimental to the yarn properties.
Also important at this point is almost constant contact with the thread guide eyelet, i.e. the yarn should
always lie on the lappet wire. Alternate touching and lifting clear of the wire during one revolution of the
traveler causes tension peaks at the spinning triangle which again increase the ends down rate.

Fig. 82 – Spinning geometry angles and dimensions

Roller overhang
 Fig. 89 – Overhang (V) of the top front roller

The top front roller almost never lies vertically above the associated bottom roller. Usually, the top roller
is shifted about 2 to 4 mm (V, Fig. 89) forward. This gives somewhat smoother running, because the
weighting force exerts stabilizing effect acting in the running direction, thus preventing oscillation of the
top roller. Furthermore, the angle of wrap is reduced and the spinning triangle is made shorter. The
overhang must not be too large, however, otherwise the distance from the exit opening of the aprons to
the roller nip line becomes too long, resulting in poorer fiber guidance and increased irregularity.

ROLLER SETTINGS CRADLE LENGTH

For ring spinning

Like the roller settings in the draw frame and in the roving frame, the roller settings at the ring spinning
machine have to be adjusted according to the fibre length. As it was explained in the other processes that
use a 3-over-3 roller drawing system, there are two roller distances that have to be adjusted: the break
draft (B in Fig. 44), which has the function of pretensioning the fibres, and the main draft (A in Fig. 44),
which has the function of drawing the fibre material to the required yarn fineness.

As mentioned in the appropriate chapter of the roving production setting (chapter 5.8.1.1.), the optimum
setting of the break draft distance is not only influenced by the fibre length but also by the drafting
resistance of the fibre material. The higher the drafting resistance the higher the break draft roller setting
has to be chosen.

Examples for settings of the main and the break draft distance with different fibre materials can be found
in Table 18.

For different main draft field distances that are necessary when processing fibres with different lengths,
cradles with different cradle lengths are available (see Fig. 45). Examples for the right cradles with
different fibre lengths can be seen in Table 19.

If for economic reasons fibres have to be spun that exceed the specified length of the cradles in use (for
example fibres longer than 40 mm with the 36 mm cradle) the middle bottom roll can be moved
backwards up to 8 mm to accommodate the increased staple length. Then the middle top rolls with the
cradles and the back rollers have to be adjusted accordingly.
The spacer thickness (see Fig. 45) has to be adjusted according to the fineness of the fibre material. When
adjusting the spacer thickness, the higher bulkiness of the fibres has to be taken into account in order to
avoid over control of the fibres which leads to a higher ends-down rate and a high number of thick and
thin places in the yarn.

Fig. 44 – Roller settings in a ring spinning machine (A: main draft; B: break draft)

Table 18 – Examples of break draft and main draft field distances

Fig. 45 – Cradle length and cradle spacer

 Table 19 – Examples of cradle lengths according to the fibre length

Top roller pressures and top roller cots

Top roller( ) pressures may have to be raised in older drafting arrangements. They should not lie below
12 daN, on the front cylinders, possibly even as high as 15 daN.

In general it can be said that softer front top roller cots result in a better enclosure and guidance of the
fibres. But especially when running man-made fibres and blends, softer front roller cots have a higher
tendency to form laps and they wear out quickly. To avoid these disadvantages, harder cots should be
chosen. In addition, treatment of at least the delivery roller, as described in chapter 5.7.3., is
advantageous.

Recommended shore hardness of top roller cots when running man-made fibres are 65-75 ° for the feed
rollers and 75-85 ° for the delivery rollers. In the processing of blends, those cots should be selected
which provide a good yarn quality with a minimal lapping tendency

DRAFT DISTRIBUTION

The total draft in the drawings system of a ring spinning machine depends, of course, on the
relationship of the roving and the yarn fineness. To avoid process problems and yarn quality
losses, the total draft has to be set within practical limits which depend on the properties of the
used fibre material. In the end, the roving fineness has to be adjusted stepwise to the required
yarn fineness in order to avoid a drawing process outside the practical limits. In Fig. 46
recommendations for the roving fineness according to the required yarn fineness and to the used
fibre material can be found.

Once the total draft has been evaluated within the practical draft limits, it has to be divided into
the break draft and the main draft.

Like the total draft, the break draft has to be set within limits. On the one side, it has to be high
enough to fulfill the task of pretensioning the roving for an optimum drawing process in the main
draft zone. On the other side, the break draft has to be low enough to avoid stick-slip motion (see
Rieter Manual of Spinning – Volume 1) or to avoid overload of the drive system when
processing fibres with high draft resistance on long spinning machines. As general rules it can be
said that:

 with higher break drafts the break draft distance should be reduced to maintain yarn
quality
 with lower break drafts the break draft distance can be higher, which results in a less
sensitiveness to variations of fibre length, roving draft resistance and climatic conditions.

Examples for normal break drafts with processing different fibres and different draft levels can
be found in Table 20. The main draft has to be set after choosing an appropriate break draft
according to the required yarn fineness.
Fig. 46 – Recommendations for roving fineness depending on the required yarn fineness and on the fibre
material

Table 20 – Examples for normal break drafts with processing different fibres and different draft levels

TRAVELER SPEED

To be contd…….

ROLLER SETTING

For draw frame

The roller settings (distances between the roller pairs of a draft zone) have to be adjusted
according to the fiber lengths of the raw material. Settings which are too narrow cause fiber
damage while too wide settings increase the number of floating fibres and result in higher
unevenness of the sliver.

For polyester and polyamide fibres the following roller settings can be recommended (see
Fig. 36):

 break draft field: fibre cut length +20 %

 main draft field: fibre cut length +5 to 10 %.

Rather wider settings become necessary with:

 processing of low-pill fibres

 processing of high-strength fibres
 processing of fine fibres
 processing of fibres with considerable crimp
 processing of fibres with poor spin finish
 Use of low break drafts.

In the case of acrylic fibre, too narrow settings in the main drafting field can lead to cold draw
setting and thus to a higher shrinkage level in the end product. If fibres longer than 40 mm are to
be processed, it is advisable to remove all fibre-guiding elements, e.g. the pressure bars, from the
drafting arrangement. Examples of roller settings on a 4 over 3 roller drawing frame depending
on different raw materials are given in Table 11. These settings should only be used as a start-up
recommendation while optimum settings always have to be found out by experiment.

General settings for standard fibres (regarding pilling behavior, strength, crimp etc.) can be
found on the 5 over 3 roller drafting system in Fig. 37.

For special fibre types the settings have to be adjusted.

Fig. 36 – Roller settings in 4 over 3 drafting system

 Table 11 – Examples for Roller settings with different materials (4 over 3 roller)

Fig. 37 – 5-over-3 roller drafting system

TOP ROLLER PRESSURE;

The task of the top roller pressure is to ensure the clamping of the fibres which is needed for an optimal
drafting process. The roller loading of older draw frames must be set rather higher than for processing
cotton. Modern draw frames already use high pressures for all fibres so usually no change of the pressure
is required when different materials are used. Only if high drafting forces occur, higher top roller
pressures are required. This can be the case, for example, when heavy sliver weights or fibres with
high drafting resistance are drawn.
In Fig. 38 and Table 12 examples for regular and high top roller settings on Rieter draw frames are given.

In the case of high top roller settings an increased effective nip zone has to be taken into account and the
roller settings (see chapter 5.7.2.1.) have to be increased by 1-2 mm.

Fig. 38 – Top roller pressures on a 4-over-3 roller drafting system

Table 12 – Examples of top roller pressure settings on a 4-over-3-roller drafting system

DRAFT DISTRIBUTION

The total draft on a drawing frame is performed in two steps: the break draft and the main draft
(see Fig. 36). The task of the break draft is to prepare the fibres for the main draft by
introducing pretension into the sliver and by removing the fibre crimp. Usually the break draft
is between 1.28 and 1.7 and depends on several influencing factors. In general it can be said that
higher break drafts are needed with:

 earlier draw frame passages

 finer fibres
 longer fibres
 pill-free fibres
 High strength fibres.

In any case stick-slip motion has to be avoided (see Rieter Manual of Spinning – Volume 1).

Since the break draft depends on the material and the total draft is usually set by the processing
system, the main draft is given and has to be calculated by total draft divided by break draft.
For high quality products the main draft should however be limited to the following values:
  cotton/man-made fibre blends: 3.8
 viscose: 6.3
 acrylic (crimped): 5.2
 polyester (crimped): 6.0
 polyester (sewing thread): 3.7
 polypropylene: 6.1

Examples of draft arrangements for different materials and for draw frames of the first and
second draw frame passage are given in Table 13.

Table 13 – Examples of draft distributions with different materials