An experimental verification on existence of air-drag force influencing yarn tension during rotor spinning

Abstract

Purpose Most researchers have neglected the effect air-drag force on yarn tension during rotor spinning. This paper aims to study the effect of rotor air-vacuum pressure in conjunction with opening roller speed and yarn linear density on the yarn tension generated during the rotor spinning, which has established their significant influences on both the mean and the peak tension.This is the first of one-of-a-kind experimental study being reported to demonstrate the influence of air-drag force on yarn tension during the rotor spinning under dynamic condition. Design/methodology/approach The dynamic measurements on yarn tension at the exit of the doffing tube were carried out by using an electronic capacitive yarn tension meter during rotor spinning. The derived experimental data were fitted into equations to construct the response equations and to work out the coefficients of multiple correlation between the data and the predicted equation for both the mean and the peak tension. Various surface plots were constructed by using those response surface equations, so as to study the effect of variables on yarn tension generated during the rotor spinning. Findings The study has established that the rotor vacuum is responsible in causing a change in yarn tension, it increases with the decrease in air-vacuum inside the rotor. The involvement of the opening roller speed in altering yarn tension during rotor spinning has been proved. As the opening roller speed changes, so does the air stream surrounding the opening roller speed with consequent alteration of the centrifugal force generated due to the rotation of the rotor. The centrifugal force and, hence, the yarn tension generated in the rotor will be simultaneously affected by both the rotor relative vacuum and the opening roller speed. Research limitations/implications This is a structured experimental study to verify the influence of air-drag force generated during rotor spinning on yarn tension. Very limited theoretical work has been carried out in this direction as reported in the introductory part of the paper. The result of the present study will encourage future researchers to revisit the theory on generation of air-drag force during rotor spinning and work out a new formula. Practical implications Next only to the conventional ring spinning system, the rotor spinning holds the second place in the share of global yarn production. Because of its advantage of lower cost of production and amenability to automation, the rotor spinning has gained acceptance in spun yarn production, particularly for spinning coarse and medium counts of yarns. Currently, it has acquired about 25 per cent share in the world’s spun yarn production. As many of the rotor machine variables significantly affect fibre configurations and, subsequently, the yarn properties by influencing the airflow characteristics inside the rotor unit, the study of yarn tension during rotor spinning and its analysis assumes a significance. Social implications Rotor spinning is a relatively new and faster method of conversion of discrete fibres into continuous staple yarn and, subsequently, various textiles and garments. Its yarn is distinct and a bit different compared to the conventional ring yarn. It has got wide acceptance in the market and fashion. As such, the spinning sector that converts fibres into yarns is an important industry world over, providing employment to many. Besides, being the basic operation in the fibre value chain, it supports many downstream activities, including human clothing and fashion. Thus, the research on rotor spinning, particularly the yarn engineering to produce better products will be helpful to strengthen and grow the textile value chain. Originality/value This is an original research study. The magnitude and the direction of the air drag on the yarn during rotor spinning is very difficult to assess. Thus, most researchers for the sake of simplicity in analysis have neglected its effect on yarn dynamics, but a few of them have taken note of it in their theoretical propositions. However, no experimental result has been reported so far in the literature, supporting the influence of such air-drag force on yarn tension in the rotor spinning. In fact, none of the above studies have considered the induced effect of centrifugal force caused because of the rotation of the opening roller on the airstream that flows from the transfer channel inlet into the rotor because of its partial vacuum, causing consequential effects on air-drag force and tension in the yarn inside the rotating rotor. This is the first of one-of-a-kind experimental study being reported to demonstrate the influence of air-drag force on yarn tension during the rotor spinning under dynamic condition.