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    Weaving With Unsized Yarn

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    amarsalokhekarad
    This document summarizes research on size-free weaving of cotton fabrics using a high-speed weaving machine. The researchers produced cotton twill fabrics without traditional warp sizing, using rotor-spun yarn with good properties. They were able to weave over 100 yards of fabric without any yarn breaks, demonstrating the feasibility of size-free weaving. However, the fabrics showed small, fuzzy defects from yarn abrasion during weaving. Optimizing yarn structure and weaving parameters like pick density and weave type could help minimize defects and expand size-free weaving applications. Further research is needed to fully understand and improve the size-free weaving process.

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    Weaving With Unsized Yarn

    Uploaded by

    amarsalokhekarad
    381 views20 pages
    This document summarizes research on size-free weaving of cotton fabrics using a high-speed weaving machine. The researchers produced cotton twill fabrics without traditional warp sizing, using rotor-spun yarn with good properties. They were able to weave over 100 yards of fabric without any yarn breaks, demonstrating the feasibility of size-free weaving. However, the fabrics showed small, fuzzy defects from yarn abrasion during weaving. Optimizing yarn structure and weaving parameters like pick density and weave type could help minimize defects and expand size-free weaving applications. Further research is needed to fully understand and improve the size-free weaving process.

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    This document summarizes research on size-free weaving of cotton fabrics using a high-speed weaving machine. The researchers produced cotton twill fabrics without traditional warp sizing, using rotor-spun yarn with good properties. They were able to weave over 100 yards of fabric without any yarn breaks, demonstrating the feasibility of size-free weaving. However, the fabrics showed small, fuzzy defects from yarn abrasion during weaving. Optimizing yarn structure and weaving parameters like pick density and weave type could help minimize defects and expand size-free weaving applications. Further research is needed to fully understand and improve the size-free weaving process.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    381 views20 pages

    Weaving With Unsized Yarn

    Uploaded by

    amarsalokhekarad
    This document summarizes research on size-free weaving of cotton fabrics using a high-speed weaving machine. The researchers produced cotton twill fabrics without traditional warp sizing, using rotor-spun yarn with good properties. They were able to weave over 100 yards of fabric without any yarn breaks, demonstrating the feasibility of size-free weaving. However, the fabrics showed small, fuzzy defects from yarn abrasion during weaving. Optimizing yarn structure and weaving parameters like pick density and weave type could help minimize defects and expand size-free weaving applications. Further research is needed to fully understand and improve the size-free weaving process.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
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    The key takeaways are that size-less weaving on high-speed looms is feasible for some fabric types if yarn quality is high and weaving parameters are optimized. Further research is needed to minimize yarn abrasion and expand the scope of size-less weaving.

    The motivation behind this research is to eliminate the costly process of warp sizing by developing a yarn structure and weaving method that can be used without traditional sizing. A major challenge is abrasion of the yarn during weaving.

    The research approach involves producing yarn with desirable attributes for size-less weaving, developing a method to set yarn twist without sizing, modifying loom components to minimize abrasion, and manipulating weaving parameters to study their effects.

    SIZE-FREE WEAVING OF COTTON FABRICS ON A MODERN HIGH-SPEED WEAVING MACHINE: AN UPDATED PROGRESS REPORT

    Beltwide Cotton Conferences New Orleans, Louisiana, USA January 9-12, 2007

    Sawhney, A.P.S., Singh, K.V.*, Condon, B. and Pang, S.S.**


    Southern Regional Research Center, Agricultural Research Service, USDA, New Orleans, LA 70124 * Mechanical and Manufacturing Engineering Department, Miami University, Oxford, OH 45056 ** Department of Mechanical Engineering, Louisiana State University, Baton Rouge, LA 70803

    Outline
    Motivation of this research Research Approach Materials and Methods

    Summary of results and discussions


    Concluding remarks

    Future research plans


    Acknowledgements

    Motivation of this research


    Weaving is by far the largest market for the value-added utilization of cotton (~75% market share, worldwide)

    Textile Processes
    (Combed) Spinning Raw Cotton (Carded) Spinning Warping and Sizing Weaving Finishing

    Can we eliminate the costly process of warp sizing and the subsequent fabric desi

    Motivation of this research


    CHALLENGE: ABRASION OF YARN DURING WEAVING

    Research Approach
    Production of a yarn structure that has most of the

    most desirable attributes* for size-less weaving (* viz., low


    hairiness, high abrasion resistance, and excellent uniformity and consistency of other characteristics)

    Development of a method to set (stabilize) twist

    torque/liveliness of the yarn and prepare a loom beam for weaving without the traditional sizing. Modification of critical loom components, mainly the reed, to minimize abrasion of warp yarn in weaving. Manipulation of weaving parameters and conditions, including fabric construction, weaving speed, and machinery settings, to study their effects on the weaving performance and fabric quality.

    Materials and Methods


    Cotton (Acala) HVI Strength: 32.14 Rd 80.11; +b 8.89 gf/tex Leaf content 1.4 Elongation 11.7% Area: 0.44 UHML 1.193 Cut 9; Grade 11-2 Uniformity Ratio Maturity Ratio 0.906 84.3% % Short Fiber Index Fineness 163.7 mtex. 6.78
    Micronaire 4.092

    Materials and Methods


    YARN PRODUCTION
    The selected cotton was opened and cleaned (using

    Whitin hopper-feeder, Superior inclined cleaner, and Fiber Controls Corporation Vertical Fine Opener). Chute fed to a Crosrol Mark 4 single card; carded at about 60 lb per hour. The card sliver was drawn once with auto-leveling on a Hollingsworth 990SL DF. The drawn sliver was converted into laps with a modified Whitin Super Lapper.

    Materials and Methods


    YARN PRODUCTION
    The laps were combed using a Hollingsworth

    comber running at 200 nips per minute and removing 12% noils. The combed sliver was drawn once with autolevelling, using the same drawframe. A 30 tex (Ne 20/1) yarn was spun on a Schlafhorst Autocoro with the rotor speed of 110,000 rpm and twist multiplier of 140 ( TM 4.51 E); Corolab was set to remove major yarn imperfections.

    Materials and Methods


    YARN PREPARATION: BEAMING
    1. First (Zero) Treatment: No application of any heat &/or fluid.
    START OF BEAMING Split zone 1 57 Yards Split zone ~ 20 m Size Box 57 Yards Split zone ~ 20 m Size Box

    2. The yarn was sitting on the cylinders, while the latter were being heated from room temperature to 2200 F. 3. Second Treatment: cylinders at 2200 F.
    4. The yarn was sitting on the cylinders at 2200 F, while the water for yarn washing was being boiled in the (size) box.

    Materials and Methods


    YARN PREPARATION: BEAMING
    5. Third Treatment: The yarn was washed in boiling water and dried on heated cylinders at 2200 F. 6. The yarn was sitting on the heated cylinders, while a typical PVA size mix/formulation (as a control) was being prepared. 7. Fourth Treatment: The warp was slashed with the traditional size.
    4 Split zone ~ 20 m Size Box 57 Yards Split zone ~ 20 m Size Box Approx. 57 Yards

    5 6 7

    END OF BEAMING

    Materials and Methods


    WEAVING
    Machinery: A modern high-speed, flexible-rapier

    weaving machine, with maximum speed of 500 picks per minute (ppm), was used.
    Fabric Construction: -Twill with face down; ~61

    ends/inch (epi); and 20 50+ picks/inch (ppi).


    Evaluation of Weaving Performance: Was done by

    the number of machine stoppages due to a yarn breakage and/or failure and by the fabric quality (appearance, defects, hand, and other properties)

    Summary of results and discussions


    YARN PROPERTIES
    The 20/1 Ne (30-tex) rotor-spun yarn had

    excellent metrics. Single-Strand Mean Breaking Strength: 500 cN Count-Strength Product: 128 kN/tex Uster Unevenness CV Index: 12.8% (with very low numbers of imperfections). The yarn performed very well with no major failure during warping and beaming.

    Summary of results and discussions


    MECHANICAL WEAVING PERFORMANCE
    Very Good!! For the first time ever, ~ 100 yards of 100%-

    cotton twill fabrics of light construction were produced under mill-like conditions without sizing and, more importantly, with no warp yarn failure or breakage. The maximum weaving speed for a particular fabric construction (ppi) was 500 ppm and the

    Summary of results and discussions


    FABRIC QUALITY
    Unsatisfactory

    (mainly due to presence of tiny , fuzzy-ball-like defects on either face of the fabric)
    Progressive abrasion of yarn during weaving

    Fabric Defects: Ball formation

    Summary of results and discussions


    FABRIC QUALITY
    A preliminary inspection of the size-free woven

    fabrics (greige) indicates that the pick density of 40 ppi and the corresponding weaving speed of 400 ppm may be the optimum weaving conditions for obtaining a reasonable fabric quality with a few defects that probably can be tolerated only in certain fabric styles.

    Summary of results and discussions


    MECHANICAL PROPERTIES of SIZE-FREE WOVEN FABRICS

    Fabric Sample* 500 ppm/30 ppi

    Tensile (Breaking) Strength*** (MPa)


    23.870 2.82 (Warp) 15.857 2.21 (Weft) 30.628 5.10 (Warp) 15.810 4.40 (Weft) 34.565 2.893 (Warp) 27.745 1.951 (Weft)

    Tear Strength*** (MPa)


    0.996 0.10 (Warp) 0.996 0.329 (Weft) 1.260 0.071 (Warp) 1.038 0.24 (Weft) 1.566 0.23 (Warp) 1.118 0.221 (Weft)

    500 ppm/40 ppi


    500 ppm/50 ppi

    ***The tests were conducted in accordance with the ASTM D5035 standard for Breaking Force and Elongation of Textile Fabric and ASTM D2261 standard for Tearing strength of Fabrics by the Tongue (Single Rip) Procedure. *The fabric samples were corresponding to the fifth treatment (The yarn was washed in the boiling water and dried on the cylinders at 220 F.

    Summary of results and discussions


    The weaving speed does not seem to be as

    critical as the pick density and/or the weave type. (For example, the 50 ppi density at 400 ppm presented a rather difficult condition by way of producing a much higher frequency/number of fabric defects, compared to the pick density of 30 ppi at 400 and even 500 ppm).
    Plain weave, as expected, was very difficult

    even at 40 ppi and 400 ppm. The weave produced a fabric of totally unacceptable quality with numerous fuzzy-ball formations.

    Summary of results and discussions

    The presence of fabric defects generally was random, but it appeared that the frequency of defects was particularly greater on one side of the fabric width. However, occasionally, a couple of yards of fabric showed no defects at all. This indicated a possibility of eliminating these defects with further research on the yarn structure and quality and the weaving conditions. The ceramic-coated loom reed appeared to have generated fewer fabric defects, compared to the conventional reed.

    Conclusions
    Size-less weaving on a modern high-speed weaving

    machinery is feasible at least for some fabric types, where minor fabric defects may not be critical. The yarn quality must be superior and more consistent than that of a run-of-the-mill yarn. Ordinary heat setting of warp yarn may be adequate to set the yarns twist torque and enable size-free weaving. Further research on improvements of yarn structure and weaving parameters is essential to minimize yarn abrasion in weaving, which is critical to expand the scope and fundamental understanding of size-less weaving.

    Acknowledgements
    The authors greatly appreciate the ARS National

    Program Staff and the ARS- MSA and SRRC managements for providing the necessary resources to conduct this vital research
    They also acknowledge the input and cooperation of the

    National Cotton Council of America and Cotton Incorporated for providing the industrial prospects, research materials, and overall guidance As always, the significant input and cooperation of our technicians, especially Jim Sandberg and Jerome Jeanpierre, are also recognized.

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