THE OPTIMIZATION OF OPEN END SPINNING

WITH RESPECT TO ENERGY CONSUMPTION

A THESIS
Presented to
The Faculty of the
Division of Graduate Studies
By
Stuart Syen

In Partial Fulfillment
of the Requirements for the Degree
Master of Science in Textiles

Georgia Institute of Technology

October, 1976
THE OPTIMIZATION OF OPEN END SPINNING WITH

RESPECT TO ENERGY CONSUMPTION

Appcovedi.

David IT Brookstein, Chairman

/ : ^
,.David^>R. Gentry SJ

~Ml Dejm^y^'i^ston^ J ^

Date Approved by Chairman y (PC^Z/fc?

 11

ACKNOWLEDGMENTS

I would like to express my deepest appreciation to my

thesis advisor and friend, Dr. David S. Brookstein, whose
guidance and encouragement made this thesis possible.
Special thanks also should go to Dr. David R. Gentry
for his advice during the early part of my studies at Georgia
Tech and for serving on my reading committee.
Dr. Milos Konopasek rendered invaluable assistance

with the computer work for which I am especially grateful.

Special mention should go to Mr. Mat Sikorski for his
help in connecting the power measuring equipment, Mr. Fay
Smith for keeping the spinning frame running, and Mr. Jim
Maxwell of Coats and Clark for supplying the necessary sliver
and performing evenness tests on the yarn.
 Ill

TABLE OF CONTENTS

Page
ACKNOWLEDGMENTS ii
LIST OF TABLES v
LIST OF ILLUSTRATIONS vii
SUMMARY ix
Chapter
I. INTRODUCTION 1
1.1.Statement of the Problem
1.2.Review of Literature
I.2.a. Energy Consumption in Open End
Spinning
I.2.b. Effect of Combing Roller Speed
on Open End Spun Yarn
I.2.C. Effect of Combing Roller Wire
Design on Open End Spun Yarn
I.2.d. Effect of Twist and Rotor Speed
on Open End Yarn
II. EXPERIMENTAL PROCEDURE AND INVESTIGATIONS . . . . 14
11.1.Scope of Experimental Investigation
11.2.Equipment for Experimental Investigation
11.2.a. Laboratory Open End Spinning
Frame
II.2.b. Energy Measuring Equipment
11.2.c. Sliver
II.2.d. Testing Equipment
11.3. Experimental Procedure
II.3.a. Spinning at Different Test
Conditions
II.3.b. Measuring Energy Consumption
II.3.c. Testing the Yarn
III. RESULTS AND DISCUSSION 20
III.l. Comparison of Laboratory Open End Spun
Yarn with Mill Open End Spun Yarn
 IV

Chapter Page
111.2. Yarn Strength
III.2.a. The Effect of Combing Roller
Speed on Yarn Strength
III.2.b. The Effect of Twist Multiple
on Yarn Strength
III.2.C, The Effect of Yarn Linear
Density on Tenacity
111.3. Yarn Elongation
III.3.a. The Effect of Combing Roller
Speed on Yarn Elongation
III.3.b. The Effect of Twist Multiple
on Yarn Elongation
111. 4. Yarn Energy to Break
III.4.a. The Effect of Combing Roller
Speed on Yarn Energy to Break
III.4.b. The Effect of Twist Multiple
on Yarn Energy to Break
III. 5. Yarn Uniformity
III.5.a. The Effect of Combing Roller
Speed on Yarn Uniformity
Ill.S.b. The Effect of Twist Multiple
on Yarn Uniformity
III.5.C. Yarn Evenness and Strength
III.6. Optimization of Open End Yarn Properties
with Respect to Energy Consumption
IV. CONCLUSIONS 56
V. RECOMMENDATIONS 58
Appendix
A. YARN TEST RESULTS 59
B. ENERGY CONSUMPTION MEASUREMENTS 68
C. QAS PROGRAM 70
D. ISO-GRAPHS FOR ENERGY CONSUMPTION AND YARN
PROPERTIES 72
BIBLIOGRAPHY 84
 LIST OF TABLES

Table Page
1. Breakdown of Energy Costs in Ring Spinning. . . . 7
2. Breakdown of Energy Costs in Open End Spinning. . 8
3. Investigated Parameters and the Number of Test
Conditions Used to Investigate the Effect of
the Four Parameters 14
4. Sliver Specifications 16
5. Strength and Uniformity of Mill and Laboratory
Yarn 20
6. The General Model for Energy Consumption and
Yarn Properties 42
7. Model of Energy Consumption and Yarn Properties
for 42 Tex Cotton 43
8. The Optimization Problem for 42 Tex Cotton. . . . 44
9. Yarn Tensile Strength for 32 Tex Cotton 60
10. Percent Elongation for 32 Tex Cotton 60
11. Energy to Break for 32 Tex Cotton 61
12. %CV for 32 Tex Cotton 61
13. Yarn Tensile Strength for 42 Tex Cotton 62
14. Percent Elongation for 42 Tex Cotton 62
15. Energy to Break for 42 Tex Cotton 63
16. ICV for 42 Tex Cotton 63
17. Yarn Tensile Strength for 32 Tex Cotton/Polyester 64
18. Percent Elongation for 32 Tex Cotton/Polyester. . 64
19. Energy to Break for 32 Tex Cotton/Polyester . . . 65
 VI

Table Page
20. %CY for 32 Tex Cotton/Polyester 65
21. Yarn Tensile Strength for 42 Tex Cotton/Polyester. 66
22. Percent Elongation for 42 Tex Cotton/Polyester . . 66
23. Energy to Break for 42 Tex Cotton/Polyester. . . . 67
24. %CV for 42 Tex Cotton/Polyester 67
25. Energy Consumption for Open End Spinning 69
 Vll

LIST OF ILLUSTRATIONS

Figure Page
1. Open End Spinning Head 3
2. Power Input for Spinning Operations Using
Ring Frames 9
3. Power Input for Spinning Operations Using
Open End Frames 9
4. Effect of Combing Roller on Yarn Strength . . . . 22
5. Effect of Twist Multiple on Yarn Strength . . . . 25
6. Structure of Ring and Open End Spun Yarn 27
7. Effect of Combing Roller Speed on Yarn
Elongation 30

8. Effect of Twist Multiple on Yarn Elongation . . . 32

9. Effect of Combing Roller Speed on Yarn Energy

to Break 34
10. Effect of Twist Multiple on Yarn Energy to Break. 36

11. Effect of Combing Roller Speed on Yarn Uniformity 37

12. Effect of Twist Multiple on Yarn Uniformity . . . 39

13. Strength-Energy Iso-Curves for 42 Tex Cotton. . . 46
14. Elongation-Energy Iso-Curves for 42 Tex Cotton. . 47
15. Energy to Break-Energy Iso-Curves for 42 Tex
Cotton , 48
16. Uniformity-Energy Iso-Curves for 42 Tex Cotton. . 49

17. Solution Space for 42 Tex Cotton 50

18. Flowchart for Minimizing Energy Consumption
Considering Strength, Elongation, Energy to
Break and Energy Consumption 52
 Vlll

Figure Page
19. Minimization of Energy Consumption with Respect
to Strength Elongation and Energy to Break. . . . 53
20. Minimization of Energy Consumption with Respect
to Uniformity 55
21. Strength-Energy Iso-Curves for 42 Tex Cotton/
Polyester 73
22. Elongation-Energy Iso-Curves for 42 Tex Cotton
Polyester 74
23. Energy to Break-Energy Iso-Curves for 42 Tex
Cotton/Polyester 75
24. Uniformity-Energy Iso-Curves for 42 Tex
Cotton/Polyester 76

25. Strength-Energy Iso-Curves for 32 Tex Cotton. . . 77

26. Elongation-Energy Iso Curves for 32 Tex Cotton. . 78

27. Energy to Break-Energy Iso-Curves for 32 Tex

Cotton 79
28. Uniformity-Energy Iso-Curves for 32 Tex Cotton. . 80

29. Strength-Energy Iso-Curves for 32 Tex Cotton/

Polyester 81
30. Elongation-Energy Iso-Curves for 32 Tex Cotton/
Polyester 82
31. Energy to Break Energy Iso-Curves for 32 Tex
Cotton/Polyester 83
 IX

SUMMARY

This research is concerned with optimizing energy

consumption during open end spinning without adversely
affecting yarn quality or rate of production. The method
of optimization consists of testing yarn, spun at levels of
rotor and combing roller speeds, to determine the effect of
machine parameters on yarn properties.
It can be concluded that a given level of strength,

elongation, energy to break or uniformity can be achieved at

different combinations of combing roller and rotor speed.
Since lower speeds result in lower energy consumption, the
properties of open end spun yarn can be optimized with respect
to energy consumption by finding the lowest combing roller
and rotor speed combination that produce acceptable strength,
elongation, energy to break and uniformity.
 CHAPTER I

INTRODUCTION

I.l. Statement of the Problem

Until the early 1970's, the United States was fortunate
to have relatively abundant and inexpensive energy. As a
result, technological advances in the textile industry had
been aimed toward increasing the utilization of labor and
capital. Accordingly, power consumption was of no major
concern, for it was less expensive per unit of production
than capital or labor; however, energy is now more expensive.
Current trends indicate that it will become even more
expensive and the possibility for power interruption will
exist.
The textile industry is a labor intensive industry.
In attempting to reduce the cost of labor per unit production
of goods, technical developments in the textile industry
have been focused towards increasing output per man and
machine-hour and these developments have led to increased
speeds for existing processes as well as the development of
new technologies.
Open end spinning was developed with a view toward
increasing the productivity of the yarn spinning process
beyond the limiting speeds of ring spinning. The process
was developed at a time when fuels used to produce electrical
energy were relatively abundant and inexpensive. At the time
of development, the increased productivity per man and
machine-hour justified the increased rate of energy consump-
tion; however, today the cost of electrical energy has
risen dramatically and it remains to reevaluate manufacturing
processes to determine if they can be run at reduced levels
of power consumption without significantly impairing the
quality of finished goods.
Until recently, energy consumption has not received
serious attention from the designers of open end spinning
systems. An examination of a laboratory open end spinning
frame suggests that a study of the material-machine inter-
actions occurring at those stations in the spinning system
that are primary users of energy but whose contributions to
the process do not affect the rate of productivity may lead
to recommendations that would serve to reduce the speeds of
these components and accordingly system energy consumption.
Open end spinning systems consist primarily of six
sequential operations (Figure 1). They are the following:
1. Fiber Separation--the continuity of fiber flow
is broken by separating tufts of fibers from the feed sliver
at the combing roller.
2. Fiber Transport--the fibers flow in an air channel
from the combing station to the spinning chamber.
3. Fiber Condensation on the Spinning Surface--
3. FIBER CONDENSATION 4. REMOVAL OF FIBER ASSEMBLY
ON THE SPINNING SURFACE FROM COLLECTING SURFACE

'3
5. TWIST
INSERTION
6^INDING

2. FIBER
TRANSPORT

1. FIBE:R
SEPARATION

Figure 1. Open End Spinning Head

centrifugal forces cause fibers to move from their central
entry point at the rotor to the groove on the circumference
of the rotor.
4. The Removal of the Fiber Assembly from the
Collecting Surface--fibers are pulled off the collecting
surface and out of the rotor by the tail of the preceding
formed yarn.
5. Twist Insertion--the revolving spinning chamber,
twisting the tail of the yarn while it is restrained at the
take up roll, results in real twist.
6. Winding--for open end spinning, winding is a
separate process taking place after the yarn is removed from
the spinning chamber.
Energy is likely to be consumed mostly during fiber
separation, twist insertion, and winding. Changes in the
speeds of these operations alter the energy consumption of
the open end frame; however, they do not necessarily change
the productivity. For example, altering the degree of fiber
separation or the amount of twist at a given winding speed
does not affect the output of the unit; changing the winding
speed directly affects output. Accordingly, energy economies
may be achieved by changing the speed of those operations
which are primary users of energy but do not affect the unit
rate of output of the process. No economy can be achieved
by reducing the speed of the winding roller because the
energy reduction is accompanied by a reduction in unit rate
o£ output. Hence, optimization o£ the open end spinning
process with respect to power consumption, requires determi-
nation of the effects of the degrees of both fiber separation
and fiber twisting on system power consumption and yarn
quality.
The objectives of this study are:
1. To determine the effects of modifying the amount
of fiber separation and twist on yarn strength, elongation,
energy to break, uniformity and energy consumption per gram
of yarn produced.
2. To develop an empirical model which can be used
to predict the above parameters.
3. To develop a methodology for determining the
minimum energy consumption, per gram of yarn, required to
produce a yarn of given strength, elongation, energy to
break or uniformity.
Summarizing, this study indicates how energy consump-
tion can be reduced by reducing the speeds of the combing
roller and rotor. These are significant in view of the fact
that spinning consumes more energy per gram of yarn produced
than any other process in yarn manufacturing.

1.2. Review of Literature

I.2.a. Energy Consumption In Open End Spinning
Spinning represents approximately 68 percent of yarn
manufacturing costs. Over 60 percent of the power required
in yarn manufacturing is consumed during spinning and 75
percent of this is consumed by spinning machinery. The
remaining 25 percent is consumed by lighting and air condi-
tioning. Therefore, a reduction in power consumption during
spinning would yield significant savings in yarn manufacturing
costs (Tables 1 and 2; Figures 2 and 3).
Previous studies of energy consumption for open end
spinning only consider the rotor as a variable. The following
empirical relationship for energy consumption of the rotor
IS reported:

Pw a(N
^ s ^•^) ^ s ^'^)^
-^ (R

P = power consumption
N = speed of rotation
Rs = chamber radius

An example of the difference in power consumption at two

specific rotor speeds is shown:

Pw2^ = 2.57 Pwl

T

P ^ = power consumption at 45,000 rpm

P ^ = power consumption at 30,000 rpm
The above relationship clearly shows that the power require-
ments are more than double for a 50 percent increase in rotor
speed.
 Table 1. Breakdown of Energy Cost in Ring Spinning
Energy price: 0.13 sFr/kWh
Cost Headings Breakdown of energy costs

sFr/kg °^ sFr/kg

1 Energy 0.193 11.6 1 Opening RooinO.025 13.1

2 Wages 0.463 27.8 2 Carding 0.029 15.0
3 Waste 0.297 17.8 3 Drawframes 0.011 5.9
4 Operating 0.054 3.3 4 Roving 0.013 7.0
materials frames
5 Capital 0.658 39.5 5 Ring frames 0.114 59.0
Total 1.665 100.0 Total 0.192 100.0
Table 2. Breakdown of Energy Cost in Open End Spinning

Energy price: 0.13 sFr/kWh

Cost headings Breakdown of energy costs
1

sFr/kg % sFr/kg

1 Energy 0.2279 14.2 1 Opening 0.0254 11.1

room
2 Wages 0.2427 15.1 2 Carding 0.0293 12.9
3 Waste 0.2846 17.7 3 DrawframesO.0167 7.3
4 Operating 0.1031 6.4 4 OE Spinner0.1565 68.7
materials
5 Capital 0.7492 46.6
Total 1.6075 100.0 Total 0.2279 100.0
 1 Air Conditioning 52 kW
2 Lighting 23 kW
3 Machinery 260 kW
Total 3ir TW
Figure 2. Power Input for Spinning Operators Using
Ring Frames^

1 Air Conditioning 66 kW
2 Lighting 22 kW
3 Machinery 3 06 kW
Total 394 kW

Figure 3. Power Input for Spinning Operations

Using Open End Frames^
 10

I.2.b. Effect of the Combing Roller Speed on Open End Spun

Yarn
An important parameter in open end spinning is the
combing roller speed. Empirical data indicates that as the
rate of combing is increased, a greater separation force is
3
exerted on the fibers. This reduces entanglement of fibers
in the rotor producing a yarn with less thick places, thin
places and other defects. However, increased separation
force damages a great percentage of fibers causing reduced
3
yarn strength. Combing roller speed also affects the
stability of the open end system, and reducing combing
roller speed results in more end breaks during spinning.
Yarn tenacity, irregularity and the number of imperfec
tions are affected by both the combing roller speed and the
type of sliver; therefore strength, tenacity, irregularity
and the number of imperfections can be used to measure the
effectiveness of combing. Increasing combing roller speeds
reduces the number of imperfections with only slight reduc-
tions in the yarn strength of 100 percent cotton. 4 A strong
correlation between combing roller speed and yarn strength
is not found in 100 percent cotton; however, a positive
correlation is found between strength and combing roller
3
speed for rayon.
I.2.C. The Effect of Combing Roller Wire Design
Two parameters of the combing roller design can be
varied by the manufacturer. They are the wire angle and the
 11

number of wires per inch. As the wire angle is increased,

the rate of combing is reduced. As the number of wires per
3
inch is increased, the rate of combing is increased. An
increase in the combing rate caused by combing roller design,
3
decreases yarn tenacity and improves uniformity. It is
recognized that the combing roller design has a significant
effect on yarn properties; however, this research is only
concerned with combing roller speed because energy consumption
is directly related to speed.
I.2.d. Effect of Twist and Rotor Speed on Open End Yarn
The effect of increasing the rotor speed can be
divided into contributing forces. One force is the effect
of the increased twist caused by increased rotor speed. The
second force is the effect of changes in the static pressure
within the rotor. Increasing the twist, improves yarn
strength, elongation and energy to break. As twist increases,
the helix angle of the fibers increase resulting in a
subsequent impairment of fiber contribution to yarn
strength.
When the fiber contribution to yarn strength, elonga-
tion and energy to break is impaired to the point where the
increased contact between the fibers no longer contributes
enough to balance this impairment, a loss in yarn physical
properties results. The effect of changes in static pressure
are not clearly understood; however, there is an optimum
static pressure for each fiber and deviations from it result
 12

in losses in all yarn physical properties.

The twist versus yarn-tenacity relationship for open
end spun yarn is similar to that of ring spun yarn. However,

open end yarns with the same nominal twist multiple as ring
4
spun yarns are generally 10-30 percent weaker. Real twist

is unknown for open end yarns because the twist efficiency,

the amount of machine twist translated into actual yarn

twist, changes with variations in fiber, sliver linear

2
density, feed rate and rotor speed. Twist efficiency
decreases with increases in machine twist because increasing

the machine twist increases the number of doublings in the

rotor and results in a greater amount of fibers in the yarn

cross section and an increased reaction to the turning moment
2
of the fibers. The turning moment is different for each
type of fiber; therefore, the twist efficiency will also
2
change for each fiber or blend. Losses in twist due to
2
efficiency are on the order of 10-30 percent.

Previous studies indicate that increased rotor speeds

result in poorer cotton yarn physical properties. This is

attributed to an alteration of the static pressure within

the rotor. For example, cotton has the lowest tenacity,

the largest number of imperfections and the highest short

term irregularity at highest rotor speeds. Decreased

opening is one possible explanation for this decrease in

yarn properties. Decreased opening occurs because the

higher feed rates that are used with higher rotor speeds
 13

result in a decreased amount of combing roller wire points

per fiber. As the number of wire points per fiber are reduced,
fiber separation is reduced and less opening occurs. Increas-
ing the combing roller speed could increase opening to the
desired level; however, it would also increase fiber breakage.
Therefore, since the combing roller speed cannot be increased
to balance out the opening lost at higher feed rates, there
is a higher frequency of thick, thin and weak spots which
result in a higher ends down rate during spinning. Higher
end breakage rates are compounded by the fact that piecing
up is more difficult at higher rotor speeds.
 14

CHAPTER II

EXPERIMENTAL PROCEDURE AND INVESTIGATION

II.1. Scope of Experimental Investigation

A total of four parameters involving 48 different
test conditions were examined to determine the effect of the
material-machine interactions on yarn tensile strength,
elongation, energy to break and irregularity. Energy consump
tion was evaluated by measuring the power used during each
test condition. Table 3 lists the parameters studied and
Appendix A lists all experiments with the corresponding
results.

Table 3. Investigated Parameters and the Number of

Test Conditions Used to Investigate the
Effect of the Four Parameters

Parameter Description No. of Conditions

No. ^
1 Effect of combing roller speed 3-5
2 Effect of twist multiple 3
3 Effect of fiber type 2
4 Effect of linear density 2
 15

II.2. Equipment for Experimental Investigation

II.2.a. Laboratory Open End Spinning Frame
A laboratory open end spinning machine with standard
Toyoda BD-200 spinning heads, built at Georgia Tech, was
used for spinning all of the yarns for this investigation.
This machine is designed so that one can independently alter
the combing roller speed, rotor speed and take up roller
speed. The combing roller drive is fitted with a variable
speed motor and controller. The rotor and take-up drives
are belt and gear driven with constant speed motors. Accord-
ingly, the rotor and take up roller speeds can be altered by
changing gears or pulleys. This device is unique in that
combing roller speeds can be altered quickly and without
affecting the operation of the other components of the
process .
II.2.b. Energy Measuring Equipment
The energy consumption of the laboratory open end
spinning frame used for this research is measured by metering
the amount of power drawn by the two lines which supply
electricity to the open end spinning frame. Since these two
lines do not deliver the same voltage, they have to be
measured separately. The 110 volt line which supplies power
to the combing roller was metered with an indicating wattmeter
The 220 volt line which supplies power to the rotor and take
up drives is also metered with an indicating wattmeter;
however, a shunt transformer was placed between this line and
 16

the meter to reduce the current through the meter. This

enabled measurement o£ the power without overloading the
meter. A safety switch was also employed to divert current
around the meters when power measurements are not needed.
II.2 .c. Sliver
Yarn was spun from the three slivers whose properties
are listed in Table 4. The 52 grain sliver obtained
from the Russell Corporation was used to determine if the
laboratory open end spinning frame was producing yarn of
comparable quality to that from a standard production
machine. The Russell Corporation currently spins yarn from
it on a commercial BD-200 spinning frame. Hence, the
measured properties of the yarn spun from this sliver on the
laboratory open end spinning frame can be compared with
those same properties of the yarn spun on conventional
equipment. The remaining two slivers, obtained from Coats
and Clark Incorporated, were used for the remaining tests.

Table 4. Sliver Specifications

Linear Staple Length Fiber Supplied by

Density

52 grain 1-1/16 inch cotton Russell Corporation

65 grain 1-1/16 inch cotton Coats and Clark
65 grain 1-1/16 inch/ 65% polyester/ Coats and Clark
1-1/2 inch 35% cotton
 17

II.2.d. Testing Equipment

A Uster constant rate of load single end strength
tester was used to obtain comparison results with the Russell
Corporation for the 52 grain sliver. The Uster was employed
because the Russell Corporation performs their yarn tests on
it. Accurate comparisons can be made between the Georgia
Tech laboratory open end spun yarn and that of the Russell
Corporation since the sliver and the testing procedure are
the same.
Testing for the majority o£ the experimental work was
accomplished on an Instron constant rate of extension tensile
tester and a Uster evenness tester. Strength, elongation
and energy to break were measured on the Instron. Evenness
and the number of imperfections per unit length were measured
on the Uster. Evenness was measured in U (Uster) percent
and converted to %CV (coefficient of variation) by multi-
plying it by a factor of 1.25.

II.5. Experimental Procedure

The objectives of the experimental program were to
measure the strength, elongation, energy to break, uniformity
and power consumption for each of the yarns produced under
the 48 different test conditions. Physical yarn properties
were then related to energy consumption.
II.5.a. Spinning at Different Test Conditions
To spin at a particular set of machine parameters,
the feed roll speed was first set at the speed which provides
the proper draft for the particular linear density of yarn
to be spun. Once the adjustments for yarn linear density
were made, the twist multiple was set by attaching the
proper combination of pulleys which give the proper rotor
speed for the amount of twist required. The real twist of
open end spun yarn is not known for twisting is not 100
percent efficient. The twist is frequently stated as the
ratio of rotor speed to take up speed. This is labeled
machine or nominal twist. The real twist is lower than the
machine twist because of twist slippage at the rotor surface.
The rotor is in effect a friction twisting system and the
torsional rigidity of the fibers inside it is great enough
compared to the coefficient of friction between the fibers
and the turbine wall to produce slippage; therefore, less
than one turn of twist will be inserted for each rotor
revolution. The loss of twist is on the order of 10-30
2
percent. The last parameter set was combing roller speed,
This was individually controlled and the speed of the combing
roller was set at 1000 rpm increments around Toyoda's
recommended speed of 8000 rpm using a General Radio Strobo-
j^
tach. The same combing roller is used throughout this
research. At no time is the take up speed changed. This is
kept constant to minimize changes in output.
II.3.b. Measuring Energy Consumption
The energy consumption for each test condition was
 19

measured using a watt meter. The watt readings were then

normalized to killowatt hours per killogram of yarn produced
(Appendix B).
II.5.c. Testing the Yarn
Ten single end breaks for each yarn were made on the
Instron to determine strength, elongation and energy to break.
Each specimen was 6 inches in length. The jaw speed of the
Instron was set at 2 inches per minute to give a breaking
time of 20 ± 2 seconds as recommended in ASTM D-1682. A
linear stress - strain relationship was used to determine energy

to break since the majority of Instron test charts show a

linear stress-strain response. The values of energy to break
were calculated by taking one half of the load multipled by
the elongation. It is then normalized to gram-centimeters
per tex.
Irregularity and imperfections per unit length were
measured using a Uster evenness tester. Two five minute
Uster tests, one at 8 yards per minute and the other at 100
yards per minute, were run at each experimental condition.
The U% obtained was converted to %CV by multiplying it by a
factor of 1.25. A spectrogram showing the amount of periodic
defect was also obtained for each test.
 20

CHAPTER III

RESULTS AND DISCUSSION

III.1. Comparison of Laboratory Open End Spun Yarn

with Mill Open End Spun Yarn
The strength and uniformity of yarn spun on a commer-
cial BD-200 open end spinning frame and of identical yarn
spun on the laboratory unit used for this research are
listed in Table 5. A justifiable comparison between the two
yarns can be made because the sliver and the machine settings
used to spin the laboratory yarn were the same as those
used to spin the mill yarn. The sliver used to spin the
laboratory yarn for this comparison was obtained from the
same mill whose yarn it was compared to. This sliver was
selected at random and received no special preparation.

Table 5. Strength and Uniformity of Mill

and Laboratory Yarn
Laboratory Commercial
Yarn Yarn
Breaking Load 300 gr 300-350 gr
%CV
12% 15%
Yarn specifications: 18 cc, TM 4.8, rotor speed
36000 rpm, combing roller speed 7000 rpm
 21

Examination of the results in Table 5 reveals that

the breaking load o£ the laboratory yarn is within the range
of the commercial yarn and the ICV is lower for the same
count of laboratory yarn. The results in Table 5 indicate
that the laboratory open end spinning frame used for this
research was producing yarn of commercial quality.

III. 2. Yarn Strength

III.2.a. The Effect of the Combing Roller on Yarn Strength
Figure 4 shows the effect of combing roller speed on
yarn strength. In all cases, increases in combing roller
speed resulted in a slight decrease in yarn strength. These
reductions in yarn strength can be attributed to the increased
fiber breakage associated with higher combing roller speeds.
Although the differences in yarn strength with respect to
combing roller speed were not found to be statistically
significant in this research, previous studies have indicated
slight decreases in strength as combing roller speed was
increased. These slight decreases are shown by the best fit
regression lines in Figure 4. The sensitivity of each yarn
to increases in combing roller speed is represented by the
steepness of their respective best fit regression lines. A
steeper line indicates a greater degree of sensitivity than
a relatively flat one. Figure 4 shows that the 32 and 42
tex cotton yarns are equally sensitive to changes in combing
roller speed. Figure 4 also shows the 32 and 42 tex cotton/
 22

16

32 Tex Cotton/Polyester
14

12 42 Tex Cotton/Polyester
X
CD (D)
-M

OD

X.
-M
OC

<D
J-i
4-> 32 Tex Cotton
(7)
(X)
J-i
TO
>^ 42 Tex Cotton
(o)

6 7 8
Combing Roller Speed (ooo)

Figure 4. Hffect of Combing Roller Speed on Yarn Strength

 23

polyester yarn as having different sensitivity rates from

each other as well as the two cotton yarns.
Previous studies by Toyoda and Dyson have concluded
that increased combing roller speed slightly reduces the
strength of cotton yarn through increased fiber breakage.
Dyson also studied the effects of combing roller speed on
rayon and found significant reductions in yarn tenacity when
the combing roller speed was increased. The study on rayon
led Dyson to recommend a combing roller speed of 5340 rev/min
to spin a 23 tex rayon yarn with a fiber length of 36.5 mm.
This differs significantly from the Toyoda recommendation of
using a combing roller speed of 8000 rev/min for cotton yarns.
An interesting point introduced by Dyson is that the
optimum combing roller speed for different fibers and linear
densities may not be the same. This may be attributed to
differences in interfiber friction resulting from increased
surface contact or increased coefficients of friction between
fibers. The interfiber friction acts as a force holding
the fibers back into the sliver while the combing roller is
exerting a force to pull it out. A longer fiber length will
increase the area of contact which increases the total inter-
fiber friction. Different fibers may have different coeffi-
cients of friction between them which in turn changes the
interfiber friction per unit area. It is well known that
for opening to take place, the force exerted by the combing
roller to pull fibers from the sliver must be greater than
 24

the interfiber friction holding them back. The relative

difference between combing force and interfiber friction
determines the degree of opening that takes place; however,
there is a limit to the total forces that can be put on a
particular fiber. When the interfiber friction holding the
fibers back is increased, the total stress on the fiber is
increased and a higher combing force is required for the same
opening to take place. The higher combing force, achieved by
increasing the combing roller speed, increases the total
stress on the fiber. A decrease in the wire angle or an
increase in the wire point density on the combing roller
would also increase the total stress on the fiber. ' As the
forces exerted from both ends of the fiber approaches the
fiber breaking stress, more fibers will be broken and yarn
made from these fibers will be relatively weak.
Ill.Z.b. The Effect of Twist Multiple on Yarn Strength
The differences in cotton yarn strength with respect
to twist multiple were statistically significant at the 95%
confidence level while the differences in the cotton/
polyester yarn were not found statistically significant.
However, the best fit regression lines in Figure 5 will be
used in the ensuing discussions. In all but one case, yarn
strength increases as twist multiple increases. For each
yarn, the sensitivity of yarn strength to changes in twist
multiple appears different for each yarn. As twist increases,
the surface contact and the cohesive forces between the
 25

16

32 Tex Cotton/Polyester
14

X
(U
4-^ 1 2
OD
42 Tex Cotton Polyester
- (a)
x:
c
cu
f- 1 0
CO
otton (x)
c
oj
>-
otton (o)

3.8 4.0 4.2 4.4 4.6

Twist Multiple

I'igurc 5. l',ffcct of T w i s t M u l t i p l e on Yarn Strength

 26

fibers increase. This increase in cohesive forces contributes

to increased yarn strength; however, there is a corresponding
increase in the helix angles of the fibers which decreases
the fiber contribution to yarn strength. Strength will
increase when twist is increased if the increase in cohesion
force is greater than the decrease in the component of the
fiber strength. Previous studies by Toyoda and Dyson have
found that the twist-tenacity relationships for open end
spun yarn are similar to those of ring spun yarn except that
the open end yarn is 10-30 percent weaker. This weakness
can be attributed to the unique structure of open end spun
yarns. Lord shows that O.E.S. yarns have characteristic
"wrapper fibers which form a very steep helix angle with
respect to the yarn axis as shown in Figure 6 and conse-
quently these fibers contribute little to the strength of
o
O.E.S. yarns.
Increasing the twist is accomplished by increasing
the rotor speed while the yarn throughout speed remains
constant. Increasing the rotor speed also increases the
static pressure within the rotor. Vaughn and Hiranprueck
found that there is an interaction between static pressure
and rotor speed which can cause variations in yarn strength.
At rotor speeds approaching 60,000 rev/min small decreases
in the physical properties of cotton yarn were noted.
Dyson found no significant decrease in the strength of cotton
yarn between 32,000 and 45,000 rev/min; however, there was
 27

Ring Spun Structure

Wrapper Fibers

Open End Spun Structure

Figure 6. Structure of Ring and Open End Spun Yarns

 28

a significant decrease in the strength of rayon yarn as the

2
rotor speed was increased from 26,000 to 36,000 rev/min.
The differences in the variation of cotton and rayon yarn
strength with changes in rotor speed indicate that fiber
type plays an important part in bringing about this sensi-
tivity; therefore fiber type is an important parameter which
effects how yarn strength to changes with rotor speed and
should be considered when choosing a rotor speed.
The reaction to the rotor speed of the 42 tex cotton/
polyester yarn may explain why this yarn lost strength when
the twist multiple was increased. This yarn was spun with a
rotor speed range at 26,000 to 36,000 rev/min where Dyson
noted decreases in strength with increasing rotor speed.
Another possible explanation for increasing rotor speed could
be related to the fiber transport channel. During open end
spinning, fibers are transported from the opening section to
the spinning section through an air duct. The velocity of
the air in this duct is determined by the speed of the rotor.
Different fibers or blends of fibers may exhibit different
and possibly nonuniform aerodynamic flow properties at
different air flow velocities. If this happens, the fiber
alignment in the spinning chamber may be» reduced resulting
in decreased yarn strength.
III.2.C. The Effect of Yarn Linear Density Tenacity
Figures 4 and 5 show that low yarn linear densities
have a greater tenacity at almost all the combing roller
 29

speeds and twist multiples tested. These differences are

statistically significant at the 95% confidence level. This
may be attributed to the lower fiber feed rates used to make
the smaller linear densities. The lower feed rate results
in an increase in fiber opening because there are less fibers
being fed in proportion to the number of teeth on the
combing roller which in turn results in better fiber separa-
tion. Better fiber separation will cause increased alignment
of the fibers in the spinning chamber which will result in
better individual fiber contribution to yarn strength.

III.3. Yarn Elongation

III.3.a. The Effect of the Combing Roller Speed on Yarn

Elongation

Figure 7 shows the effect of combing roller speed on

elongation. The differences in elongation were not found

statistically significant in this research but a previous

study conducted by Vaughn and Cox found them statistically

9
significant at a 95% confidence level. Because of the

Vaughn and Cox findings, the best fit regression lines

obtained from data collected in this research will be used
in the ensuing discussion as if they represented statistically
significant differences. In all cases an increase in combing
roller speed results in a decrease in yarn elongation. The
elongation of both the 32 and 42 tex cotton yarns had rela-
tively less variation with changes in combing roller speed
 30

16

o
42 Tex Cotton/Polyester (o)
^ 14
irti
Ofi 32 Tex Cotton/Polyester f^)
C
o
1—1

m
•*->

c
<^ 1 2
L>

0)

a,

10

-32 Tex Cotton W

^42 Tex Cotton (o)

6 7 8
Combing Roller Speed (ooo)

Figure 7. Effect of Combing Roller Speed on Yarn

Elongation
 31

than the cotton/polyester yarn. The sensitivities of both

cotton yarns were about equal whereas the polyester yarn had
different sensitivities at the two different linear densities.
Fiber elongation, the amount of yarn twist, and length
of fiber, help effect yarn elongation. Increasing combing
roller speed subjects the fibers to greater forces resulting
in more short fibers through increased breakage. Faster
combing roller speeds, in effect, reduce the average fiber
length. As the fiber length is reduced the fibers can move a
small distance along the yarn axis before they completely
slip past each other. The sensitivity of yarn elongation to
combing roller speed depends on interfiber friction.
The cotton/polyester yarn used in this research could
not be spun at combing roller speeds below 7000 rev/min.
Here, the spinning difficulty is a consequence of high inter-
fiber friction which exists because the polyester fiber is
longer than the cotton fiber. As high interfiber friction
is the case, there will be a greater force holding the
fibers back and accordingly more force will be required by
the combing roller to pull the fibers out and achieve
adequate opening which results in higher fiber breakage.
III.5.b. The Effect of Twist Multiple on Yarn Elongation

Figure 8 shows the effect of twist multiple on yarn

elongation. Elongation for both the 42 tex cotton yarn and
the 42 tex cotton/polyester yarn decreases as the twist
multiple was increased while both 32 tex yarns had an increase
 32

16

32 Tex Cotton/Polyester (A)

14
o "^ 42 Tex Cotton/Polyester
•H
-M (a)
DC

O
T—I

OJ
12
-M

CD
O
5H
0)
P-,

10

32 Tex Cotton (x)

42 Tex Cotton (o)

o

3.8 4.0 4.2 4.4 4.6

Twist Multiple

Figure 8. Effect of Twist Multiple on Yarn Elongation

 33

in elongation with increasing twist multiple. As the twist

multiple \vas increased, two parameters which affect open
end yarn are increased. The first parameter is the helix
angle of the fibers and the second parameter is the rotor
speed. The increased helix angle results in a lower compo-
nent of strain transferred to the fibers enabling the yarn
to extend a greater distance before breaking than yarns with
fibers aligned at lower helix angles. This explains the
increase in elongation of the 32 tex yams when the twist
was increased. The only explanation that can be offered for
the decrease in elongation for the 42 tex yarns is that the
increased rotor speed, which has been shown in previous
studies to decrease elongation, had a greater effect on the
change in elongation than the increase in the twist multiple
and helix angles of the fibers on these heavier 42 tex yarns

III.4. Yarn Energy to Break

III.4.a. The Effect of Combing Roller Speed on Yarn Energy
to Break
Figure 9 shows the effect of combing roller speed on
energy to break. Energy to break is a function of both
strength and elongation; therefore, the energy to break will
be effected the same way as the yarns strength and elonga-
tion. Both the strength and elongation of the 32 tex
cotton, 32 tex polyester/cotton and 42 tex cotton were
reduced as combing roller speed was increased. It logically
 34

32 Tex Cotton/Polyester

42 Tex Cotton/Polyester

X
(D
•M

Oj

bO

32 Tex Cotton (x)

42 Tex Cotton (o)

(DJO
;M

<D

6 7 8 9
Combing Roller Speed [ooo)

Figure 9. Effect of Combing Roller Speed on Yarn Energy

to Break
 35

follows and is shown in Figure 9 that the energy to break

for these three yarns should be reduced as the combing roller
was increased.
III.4.b. The Effect of Twist Multiple on Yarn Energy to
Break
Figure 10 shows the effect of twist multiple on energy
to break. The 32 tex cotton, 32 tex cotton/polyester and
42 tex cotton had an increased energy to break as the twist
multiple was increased. These results follow the increasing
trends of strength and elongation for these three yarns as
the twist multiple is increased. The 42 tex cotton/polyester
had losses in both strength and elongation as the twist
multiple was increased; therefore, it follows logically and
is shown in Figure 10 that this yarn should require less
energy to break at higher twist multiples.

III. 5. Yarn Uniformity

III.5.a. The Effect of Combing Roller Speed on Yarn
Uniformity
Figure 11 shows the effect of combing roller speed
on yarn uniformity. In all the specimens tested, an increase
in combing roller speed resulted in a decrease in %CV. This
improved uniformity can be attributed to the increase in
opening resulting from higher combing roller speeds. As the
combing roller is speeded up, the teeth on it strike the fiber
more times with more force resulting in better fiber separation
 36

32 Tex Cotton/Polyester

42 Tex Cotton/Polyester
X
CD
-P

B
u
I

oj
W)

r ^
OJ
(D
f-i
CQ
O 32 Tex Cotton (x)
4->

42 Tex Cotton (o)

?-i
CD

U-1

3. 8 4.0 4.2 4.4 4.6

Twist Multiple

Figure 10. Effect of Twist Multiple on Yarn Energy

to Break
 37

42 Tex Cotton/Polyester
>
u

4->
•H

e
o
MH
•H on/Polyester
:D

x Cotton (x)
42 Tex Cotton (o)

6 7
Combing Roller Speed (ooo)

Figure 11. Effect of Combing Roller Speed

on Yarn Uniformity
 38

and less tangled fibers. As the number of fiber clumps and

tangles are reduced, uniformity improves.
Ill.S.b. The Effect of Twist Multiple on Yarn Uniformity
Figure 12 shows the effect of twist multiple on yarn
uniformity. The 32 tex cotton, 42 tex cotton and 42 tex
cotton/polyester showed lower uniformity as the twist
multiple was increased while the 32 tex cotton/polyester had
an increase. The twist multiple was increased by increasing
the rotor speed while keeping throughout constant. Increased
rotor speeds have been found to cause variations in yarn
physical properties. Increases in rotor speed also cause
an increase in the air velocity of the transport channel.
Some fibers or blends may be subject to buckling or tangling
in the transport channel when the velocity is increased. As
tangling occurs there will be a reduction in evenness.
III.5.C. Yarn Evenness and Strength
In general, for open end spun yarns, there exists an
inverse relationship between strength and evenness. Stated
another way,as evenness increases,strength decreases. The
strength evenness relationship observed for open end spun
yarns is opposite of what is observed for ring spun yarns. The
combing roller of the open end spinning frame is probably
the cause of this inverse effect. The combing roller breaks
the continuity of the fiber flow by pulling at fibers from a
sliver. At higher combing roller speeds, fiber separation
increases but there is also a corresponding increase in fiber
 39

19

42 Tex Cotton (o)

> 15
^a
32 Te'x Cotton/Polyester (^ )

e
;-i

o 2 Tex Cotton/Polyester
i-M
•H
'ZD

11

3. 8 4.0 4.2 4.4 4.6

Twist Multiple

Figure 12. Effect of Twist M u l t i p l e on Yarn Lfniformity

 40

breakage. The increased separation results in improved

evenness while the increased fiber breakage results in
reduced strength.

III.6. Optimization of Open End Yarn Properties

with Respect to Energy Consumption
The basic premise behind optimizing yarn properties
is that a particular level of a yarn property can be produced
at different combinations of combing roller and rotor speeds.
The results of testing yarn in this research shows that
increased combing roller speeds and rotor speeds usually have
opposite effects on yarn properties. Strength, elongation,
and energy to break usually decrease with increased combing
roller speeds but increase with increased rotor speeds.
Uniformity improves with increasing combing roller speed
while it decreases at increasing rotor speed.
In order to formulate an optimization problem, the
effects of the combing roller and rotor on yarn strength,
elongation, energy to break, uniformity and power consump-
tion have to be determined at different combing roller and
rotor speeds. Examining the data indicates that the best
approximation for the model is planar; therefore, a multiple
linear regression is used to model the effects of the
machine parameters on yarn properties. Although there is
considerable scatter in the actual data, the linear models
are adequate because the primary purpose of this section is
 41

to present a methodology for analyzing the yarn properties

with respect to energy consumption and not to formulate exact
mathematical models.
Each yarn with a different linear density or fiber
type which is spun is modeled separately. The general model
is presented in Table 6 and the specific model for 42 tex
cotton is presented in Table 7. The models in Tables 5 and
6 consist of five simultaneous equations. The object of this
optimization is to minimize power consumption with respect
to a given yarn property. The optimization problem for 42
tex cotton is formulated in Table 8.
The requirements for the method used to solve this
minimization are universal applicability to other textile
processes, relative ease of use once the system is programmed
on a computer, and flexibility, so that different questions
can be answered without major program changes. Both linear
and nonlinear programming are specialized and lack flexi-
bility. The method selected to solve these equations and
determine the minimum energy consumption for a given yarn
property is a conversational language which can solve
simultaneous equations. The language is formally named
"Question Answering System on Sets of Algebraic Equations,
(QAS)." This system has the ability to store mathematical
models and related data bases. Any conceivable question can
be asked concerning the model instead of having to set up
7
different programs to solve particular problems (Appendix C).
 42

Table 6. The General Model for Energy Consumption

and Yarn Properties
(TM = twist multiple, CRS = combing roller
speed; A,B,C are coefficients computed using
a multiple linear regression)

A^(TM) + B^(CRS) + C^ = Strength

A2(TM) + B2(CRS) + C2 = Elongation

A^(TM) + B^(CRS) + C3 = Energy to break

A^(TM) + B^(CRS) + C^ = Uniformity (%CV)

A^(TM) + B^(CRS) + C^ = Energy consumption

 43

Table 7. The Model for Energy Consumption and Yarn

Properties of 42 Tex Cotton

987(TM) - .146(CRS) + .5039 = Strength

1095(TM) - .1177(CRS) + 9.052 = Elongation

0971(TM) - .0297(CRS) + .6025 = Energy to break

9840(TM) - .1033(CRS) + 10.28 = Uniformity (%CV)

2361(TM) + .0467(CRS) + .7461 = Energy consumption

 44

Table 8. The Optimization Problem for 42 Tex Cotton

Minimize:
.2361(TM) + .0467(CRS) + .7461 = Energy consumption

Subject to the restrictions:

.9270(TM) - .1460(CRS) + 5.039 > x^ (strength)

-.1095(TM) - .1177(CRS) + 9.032 > x^ (elongation)

.0971(TM) - .0297(CRS) + .6025 > X3 (energy to break)

.9840(TM) - .1033(CRS) + 10.28 > x^ (uniformity)

 45

Minimization of energy consumption with respect to a

particular yarn property is based on the premise that the
particular property can be achieved at different combinations
of combing roller and rotor speeds. In order to clarify
this, a series of iso-graphs (Appendix D) are presented from
data calculated using the "Question Answering System." Each
iso-curve shows the different combinations of combing roller
speeds and rotor speeds with which a given level of a
particular yarn property can be achieved. Figures 13 through
16 show the iso-graphs for 42 tex cotton. The twist multiple
is substituted for the rotor speed. Since throughput speed
is held constant throughout this research, the twist multiple
is linearly proportional to the rotor speed.
In Figure 17, an iso-line for each property is combined
onto one graph resulting in a hypothetical solution space.
The optimal solution is the combination of combing roller
speed and twist multiple in this solution space which yields
the lowest energy consumption. Since decreases in combing
roller speed increase strength, elongation and energy to
break, the optimal solution for these parameters will always
be at the lowest possible combing roller speed in the solution
space. Optimal solutions with respect to strength, elonga-
tion, and energy to break can be found using QAS. After the
optimal solution with respect to these parameters is found,
uniformity can be computed. If it is acceptable, an optimal
solution with respect to all four properties is found. If
 46

Energy Consumption ( k w - h r s / k g of yarn)

Yarn S t r e n g t h (g/tex)

8.7 g/tex .5 g/tex

3 g/tex

1 g/tex

2 kw - h r s / k,

1 kw-hrs/kg

6 7
Combing R o l l e r Speed (ooo)

Figure 13. Strength-Energy Iso-Curves f o r 42 Tex C o t t o n

 47

Energy Consumption k w - h r s / k g of yarn

% Elongation —

4. 8

2.2 kw-hrs/kg

2.1 kw-hrs/kg

5 6 7

Combing R o l l e r Speed (ooo)

I'igure 14. E l o n g a t i o n - Energy I s o Curves f o r 42 Tex C o t t o n

 48

Energy Consumption (kw-hours/kg of yarn)

Energy to Break (gram-cm/tex)

6 g-cm/tex
/ t,ex
80 g-cm/tex

7 g-cm/tex

2 kw-hrs/kg

1 kw-hrs/kg

6 7
Combing Roller Speed (ooo)

I'igure 15. Energy to Break-Energy Iso-Curves for

42 Tex Cotton
 49

Energy Consumption (kw-hrs/kg)

Uniformity C%CV} ——

4. 8

17.5%

1 7 . 3%

\2 . 2 kw-hrs/kg
17.0%

16.8%

.1 kw-hrs/kg

6 7
Combing R o l l e r Speed (ooo)

F i g u r e 16. Un i f o r m i t y - F m e r g y Iso-Curves f o r 42 Tex C o t t o n

 50

YARN STRENGTH :S:.':; YARN ENERGY TO BREAK;^

YARN ELONGATION YARN EVENNESS'/.;-

4 .8 " O i . ? . , * * * . - - . - - .
rtrryr
.o . r j . • ? ; ; . - f • . ; c.. , . , o ' . *. ' o . '_» / , «».•

. * ; • . ° ' ' ' ' . ' ' ^ • - *•„'••••*.'.•;".• o - / " . : ' . •*. \ r ;

:.°'-.-;'".'--v.°- •'
•• * ' . ' o - . . / _.«
. .* o' ^ , • * . - ' , • • * " , , o * "-Q
; • . ' • • • / ; • : • ' . • " . : « • > • ' • . " °.". . - • • • > • •
• • . . ' • ' • - * . ' . o - . . . - . • , •
* • ' • ; I » • • • o . • - " . • , » o • • . <" •
<D _• o - • . " » • t , » . . • # , • * » • *
• . .f '^ ' ^ • " ' « • • . - • » • .
r—I . * . • . » * - • o . . - . , » ,
CI. • • » ' . . . . - a . I •_, • ; « . ' » »
, • ^ . ••_ff. • " • ' . * • 0 • " . " • : • • F'
."• i ' * . » ^ - , * < » • » : * 0:'*^•'."'
• • o • .* • " • ' . . * • • .
r • . . • "'o • . • • • • . • . o
<sr .... .-/.<».-. ; - - v . •/
i 4 •.•'*,•'•« ° '.•• «
• o • * . ' o . » • o . *. c».

cr,
•.•.:^.'.'.. .-.•.'„•-•. SOLUTION
•.'-rvV-.-o'V./ SPACE
'*?/-o". '•'.':• •
H

• • . . • . • • •

6 7
Combing R o l l e r Speed ( o o o )

I'igure 17. Solution Space f o r 42 Tex C o t t o n

 51

it is not acceptable, there is no tractable solution for all

properties and concessions in either strength, elongation

or energy to break will have to be made if better uniformity

is required. Energy consumption cannot be optimized with

respect to uniformity and strength, elongation or energy to

break because improvements in uniformity require lower twist

multiples or higher combing roller speeds which result in

reductions in strength, elongation and energy to break;

however, if uniformity is paramount, energy consumption can

be optimized with respect to uniformity alone.

Figure 18 presents a flow chart showing how QAS is

used to minimize energy consumption with respect to strength,

elongation, and energy to break. It also maps out an

iterative procedure which can be used to make trade-offs

between strength and evenness. Each block contains the

commands required to do the underlined step in that block.

Figure 19 is an illustration of the minimization of energy

consumption using the flow chart presented in Figure 18. It

also illustrates how the iterative procedure is used to trade

off strength for evenness.

The flow chart (Figure 18) can be divided into three

main sections. Blocks 1 to 5 compute the combination of

combing roller and rotor speed which minimize energy consump-

tion with respect to strength, elongation and energy to break

They also compute the resulting evenness. If the evenness

in block 7 is satisfactory, no further computing is necessary.

 52

OPTiMizii YS-YI:X-I:TB

A[ VS-requi r e d . CRS 5
AO r.NC, TM

If TM i s w i t h i n I f 'I'M not wi thin

can;ilii 1 i t y o f i:i;ichina Nil. capability of machine
>i; — ^
coMi'inr. vc
RKSOITS
r„\c
3k
TM COMPlJrn NHIV TM
RI YS
AI TM o p t i m a l RI CRS
AO vc; AI TM within capability
closest to original
TM

^
RliSllLTS
VC
r.N'C

I f XC not
Acccj)tal)lc
\k-
coMi'irrr, CRS THAT
KOiJi.nGivn DiiSiRni) vc
V Al vc Desired
RI CRS
RO VC
AO CRS

sroi'

Key: YS Strength AI Assign t o Input

YEX Elongation AO Assign t o Output
ETB Energy t o Break RI Remove from Input
VC Uniformity RO Remove from Output

F i g u r e 18 Flowchart for Minimizing Energy Consumption

Considering S t r e n g t h , Elongation, Energy
t o Break and Uniformity
 53

AI MT C0T14
? AI YS 8.5,CRS 5
? AO ENC,TM;EX
RESULTS: RESULTS:
ENC 1.9821E+00 ENC 2.2877E+00
TM 4.2462E+00 CRS 8.7438E+00
? RI YS ? AI CRS 8743*DEL*
? AI TM 4.2462 AI CRS 8.7438
? RO TM ? RI YS
? AO VC;EX ? AO VC
RESULTS ? RO CRS
O T' "VT"
ENC 1.9821E+00 ? EX
VC 1.3942E+01 RESULTS:
? AI VC 13 ENC 2.2877E+00
? RI CRS VC 1.4100E+01
? RO VC ? AO YS,YEX,ETB,VC;EX
,
? AO CRS;EX
RESULTS:
RESULTS ENC 2.2877E+00
ENC 2.4079E+00 VC 1.4100E+01
CRS 1.4117E+01 YS 8.5000E+00
? RI VC YEX 7.4773E+00
? AI CRS 14 ETB 8.0889E-01
? AO YS
? RO CRS;EX
RESULTS:
ENC 2.4024E+00
YS 7.1860E+00
? AI YS 8.5
? RI TM
? AO TM
? RO YS
? RO CRS;EX
RESULTS:
ENC 2.7167E+00
TM S.5775E+00
? RI CRS
? AI TM 4.8
? RO TM
? AO CRS

Figure 19. Minimization o£ Energy Consumption with

Respect to Strength Elongation and Energy
to Break
 54

The energy consumption at this point is minimized. If the

evenness in block 4 is not acceptable, blocks 6 through 9

can be used to decrease %CV to an acceptable level by

computing a higher combing roller speed; however, the reduc-

tions in %CV will be accompanied by decreases in strength,

elongation and energy to break. If by reducing %CV, the yarn

strength falls below an acceptable level, blocks 10 through

14 will compute a higher twist multiple which would increase

strength while slightly decreasing evenness. The energy

consumption computed at each step is optimal for the condi-

tions imposed.

If uniformity is paramount, QAS can minimize energy

consumption with respect to uniformity alone. This is

accomplished by assigning to input (AI) the desired evenness

(VC) and the lowest twist multiple (TM), while assigning to

output (AO) energy consumption (ENC) and combing roller speed

(CRS). If the combing roller speed computed is within the

spinning range of the open end frame and the fiber type,

energy consumption is minimized with respect to uniformity.

If the speed is out of range, the desired evenness cannot be

achieved for the particular material (Figure 20).

 55

/AT,QAS/UN=LIBRARY
/QAS
? DF ENCOl
? AI VC 13,TM 3.8 MT C0T14; AO ENC,CRS;EX
RESULTS:
ENC 2.1249E+00
CRS 9.8664E+00

Figure 20. Minimization of Energy Consumption

with Respect to Uniformity
 56

CHAPTER IV

CONCLUSIONS

The laboratory open end spinning frame built at

Georgia Tech produces yarn of production quality. Increasing
the combing roller speed generally decreases yarn strength,
elongation, energy to break and increases evenness and energy
consumption. Increasing the twist multiple increases strength,
elongation, energy to break, energy consumption and decreases
evenness. Increasing rotor speed, increases twist but also
has a negative effect on all yarn properties. The degree
that the properties of a particular yarn will be affected
by changes in the combing roller or rotor speed is dependent
on the type of fiber or fiber blend being spun. Longer
fiber lengths or higher coefficients of friction between
fibers will require a higher combing force which results in
a higher percentage of broken fibers. Fibers with higher
torsional rigidities and larger yarn linear densities
produce higher reactions to the turning moment of the rotor
resulting in lower twist efficiency. This results in lower
than expected strength, elongation, energy to break and
improved evenness.
A given level of strength, elongation, energy to
break or uniformity can be achieved at different combinations
 57

of combing roller and rotor speeds. Since lower speeds

result in lower energy consumption, the properties of open
end spun yarn can be optimized with respect to energy
consumption by finding the lowest combing roller and rotor
speed combination that produce yarn of acceptable strength,
elongation, energy to break and uniformity.
 CHAPTER V

RECOMMENDATIONS

For open end spinning, extensive efforts are needed

to investigate and model the effect of different fiber types
and staple lengths on yarn properties at different combina-
tions of combing roller and rotor speeds. Such work leads
to findings that show different optimum combing roller and
rotor speeds for each fiber and staple length.
In addition, more research in textile manufacturing
needs to be directed to optimizing energy consumption with
output and quality. This research shows that optimizing
energy consumption and quality is possible for the open end
spinning process. However, more extensive investigations are
needed in open end spinning as well as most other wet and
dry textile processes.
 59

APPENDIX A

YARN TEST RESULTS

 60

Table 9. Yarn Tensile Strength for 32 Tex

Cotton (gms/tex)

Twist Multiple 3. 4.3 4.7

Combing Roller 5000 8.6 10.0 12.0

6000 7.9 9.2 11.0

7000 8. 3 9.4 11.0

8000 8.1 9.2 11.0

9000 8.4 9.0 11.0

Table 10. Percent Elongation for 32 Tex Cotton

Twist Multiple 3.8 4.3 4.7

Combing Roller rpm 5000 8. 3 8.6 9.1

6000 7.6 8.1 8.9

7000 7.9 8.1 8.4
8000 8.0 7.9 8.0

9000 7.9 8.1 8.3

 61

Table 11. Energy to Break for 32 Tex Cotton

(gm-cm/tex)

Twist Multiple 3. 4.3 4.7

Combing Roller rpm 5000 .90 1.1 1.2

6000 . 79 .95 1.1

7000 .83 .97 1.1

8000 .83 .92 1.0

9000 .85 .92 1.0

Table 12. %OJ for 32 Tex Cotton

Twist Multiple 3.8 4.3 4.7

Combing Roller rpm 5000 12.8 13.9 14.6

6000 12.9 13.5 14.1

7000 12.4 12.5 13.3

8000 11.3 12.5 13.0
9000 11.5 12.4 12 .6
 62

Table 13. Yarn Tensile Strength for 42 Tex Cotton Yarn

(gms/tex)

Twist Multiple 3.8 4.3 4.7

Combing Roller rpm 5000 8.2 8.8 8.4

6000 7.8 8.5 9.1

7000 7.7 8.2 8.8

8000 7.8 7.8 8.6
9000 7. 3 8.2 8. 3

Table 14. Percent Elongation for 42 Tex Cotton

Twist Multiple 3.8 4.3 4.7

Combing Roller rpm 5000 7.9 7.8 8.9

6000 7.5 7.5 8.1

7000 7.9 7.4 7.1

8000 8.2 7.4 7.7

9000 8.0 7.4 7. 3

 I 63

Table 15. E n e r g y to Break for 42 T e x Cotton

(gm-cm/tex)

Twist Multiple 3.8 4.3 4.7

Combing Roller rpm 5000 .82 .85 .96

6000 .74 .80 .99

7000 . 77 . 76 .80
8000 .82 .71 .85

9000 .74 .76 .76

Table 1 6 . %CV for 42 T e x Cotton

Twist M u l t i p l e 3.8 4.3 4.7

Combing Roller rpm 5000 12.6 12.8 13.6

6000 11.6 12.5 12.4
i 7000 13.6 12.4 12.3
11.5

I
8000 12.3 12.4
9000 12.3 12.6 12.4
 64

Table 17. Yarn Tensile Strength for 32 Tex

65^0 Polyester/35% Cotton
(gms/tex)

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 13.8 13.8 15.8

8000 13.2 13.8 15.2

9000 12.8 13.1 14.8

Table 18. Percent Elongation for 32 Tex

65% Polyester/35% Cotton

Twist Multiple 4.1 4.4 4. 7

Combing Roller rpm 7000 15.4 15.5 15.7

8000 14.8 14. 7 14.9

9000 13.1 14.3 14.2

 65

Table 19. Energy to Break for 32 Tex

65^ Polyester/35% Cotton
(gm-cm/tex)

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 2.70 2.71 2 . 11

8000 2.48 2.57 2.74

9000 2.13 2.58 2.74

Table 20. ICV for 32 Tex 65% Polyester/35% Cotton

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 15.9 14.1 14.4

8000 12.3 12.8 13.1

9000 12.4 12.5 12.9

 66

Table 21. Yarn Tensile Strength for 42 Tex

65% Polyester/35% Cotton
(gms/tex)

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 12.7 11.9 11.9

8000 12.6 13.5 11.2

9000 12.4 12.4 11.6

Table 22. Percent Elongation for 42 Tex

651 Polyester/35% Cotton

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 14.8 13.6 14.9

8000 14.5 17.7 13.3

9000 15.3 14.2 11.6

 67

Table 23. Energy to Break for 42 Tex

6S% Polyester/35% Cotton

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 2.00 2.06 2.25

8000 2.33 3.05 1.89

1 9000 2.42 2.22 1.98

Table 24. ICV for 42 Tex 65% Polyester/35% Cotton

Twist Multiple 4.1 4.4 4.7

Combing Roller rpm 7000 12.8 11.9 14.4

8000 12.3 12.3 12.5

9000 11.1 12.4 12.8

 68

APPENDIX B

ENERGY CONSUMPTION MEASUREMENTS

 69

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 70

APPENDIX C

QAS PROGRAM
 71

ENCOL -- ENERGY CONSUMPTION IN OPEN END SPINNING

23 1 6 1
1 YS YARN STRENGTH
2 YEX YARN EXTENSION
3 ETB YARN ENERGY TO BREAK
4 VC LINEAR DENSITY VARIATION COEFFICIENT
5 ENC ENERGY CONSUMPTION
6 TM TWIST MULTIPLIER
7 CRS COMBING ROLLER SPEED
8 Al MULTIPLE REGRESSION COEFFICIENT
9 Bl
10 CI
11 A2
12 B2
13 C2
14 A3
15 B3
16 C3
17 A4
18 B4
19 C4
20 A5 TYPE OF YARN
21 B5
22 YS=A1*TM+B1*CRS+C1
C5
23 YEX=A2*TM+B2*CRS+C2
MT
1 ETB=A3*TM+B3*CRS+C3
2 VC=A4*TM+B4*CRS+C4
3 ENC=A5*TM+B5*CRS+C5
4 CA1*B2-A2*B1)*CRS=A2*(C1-YS)+A1*(YEX-C2)
NNP
5 DATA BASE FOR ENCOl
6 1 4 15
Al Bl CI A2 B2 C2
C0T14 9.870E-01 - 1 460E-01 039E+00 -1.095E-01-1 177E-01 032E+00
C0T18 2.996E+00 1 . 8 4 7 E - 0 1 - 947E+00 6.682E-01-1 280E-01 256E+00
C/P14 -1.668E+00 1.670E-02 971E+01 -2.667E+00-3 6 6 7 E - 0 1 910E+01
C/P18 3.333E+00 -4 5 0 0 E - 0 1 967E+00 8.333E-01-8 333E-01 773E+01
A3 B3 C3 A4 B4 C4
C0T14 9 . 7 1 0 E - 0 2 -2 970E-02 6 . 0 2 5 E - 0 1 9.840E-01-1 033E-01 1.028E+01
C0T18 2 . 6 1 0 E - 0 1 2 . 8 2 0 E - 0 2 4 . 5 2 0 E - 0 2 1.225E+00-3 533E-01 7.548E+00
C/P14 - 3 . 5 0 0 E - 0 1 5 . 1 7 0 E - 0 2 3.371E+00 1.556E+00- 3 . 6 6 7 E - 0 1 6.067E+00
C/P18 5 . 2 2 2 E - 0 1 1 . 2 1 7 E - 0 1 1.278E+00 - 5 . 5 6 0 E - 0 2 - 8 . 3 3 3 E - 0 1 1.757E+01
A5 B5 C5
C0T14 .2361E+00 .0467E+00 .7461E+00
C0T18 .5820E+00 .0633E+00 . 8 0 3 0 E - 0 1
C/P14 .3889E+00 .0500E+00 .0333E+00
C/P18 .5000E+00 .0833E+00 .2778E+00
 72

APPENDIX D

ISO-GRAPHS FOR ENERGY CONSUMPTION

AND YARN PROPERTIES
 73

Energy Consumption ( k w - h r s / k g of yarn)

Yarn S t r e n g t h (grams/tex)

4. 8
\ 11.6 g/tex
\
\

\
4.6 -^ 11.9 g/tex
\
\ \
\
•\2.2 kw-hrs/kg
•^x-
a, 4.4 — ^ 12. 2 g / t e x
•M
i-H
Z3
\

IS)
\
•H 12.5 g/tex
i 4.2 \
\ \
"2.1 k w - h r s / k g
\

4.0

2.0 kw-hrs/kg

3. 8
6 7 8
Combing R o l l e r Speed (ooo)

Figure 21. Strength-Energy Iso-Curves for

42 Tex C o t t o n / P o l y e s t e r
 74

Knergy Consumption (kw-hrs/kg of yarn)

Percent Elongation

CD
I—( 2 kw-hrs/kg
P.
•M
4-^
,—i

<^
•M 14.5%
f)

1 kw-hrs/kg

15.01

2.0 kw-hrs/kg

15.51

6 7
Combing R o l l e r Speed (ooo)

I'igurc 22. Percent Elongation-Energy Iso-Curves

f o r 42 Tex C o t t o n / P o l y e s t e r
 75

Energy Consumption (kw-hrs/kg of yarnl

Energy to Break (gram-centimeters/tex)

4.8 2.16 g-cm/tex

.22 g-cm/tex

.2 8 g-cm/tex

.2 kw-hrs/kg

.34 g-cm/tex

. 1 kw-hrs/kg

.0 kw-hrs/kg

6 7 8
Combing R o l l e r Speed (ooo)

Figure 23. Energy t o Break-Energy Iso-Curves

for 42 Tex C o t t o n / P o l y e s t e r
 76

Energy Consumption (kw-hrs/kg of yarn)

Uniformity (%CV)

13.3% 12.9%

12.5%

I—I
12.1%

2 kw-hrs/kg

-P
t/)
•H
'7'

1 kw-hrs/kg

4.0

/-« 0 kw-hrs/kg

6 7

Combing R o l l e r Speed (ooo)

Figure 24. Uniformity-Energy Iso-Curves for

42 Tex C o t t o n / P o l y e s t e r
 77

Energy Consumption ( k w - h r s / k g of yarn)

Yarn S t r e n g t h (grams/tex)—

10.5 g/tex

9.9 g/tex

2 kw-hrs/kg

.3 g/tex

8.7 g/tex

0 kw-hrs/kg

- >
6 7
Combing R o l l e r Speed (ooo)

r i g u r e 25. Strength-Energy Iso-Curves for 32 Tex C o t t o n

 Energy Consumption (kw-hrs/kg of yarn)

Percent Elongation—•

8.51
4. 8 8. 3%

2 kw-hrs/kg

0 kw-hrs/kg

6 7 8 9

Combing Roller Speed (ooo)

I'igure 26. Elongation-Energy Iso-Curve for

32 Tex Cotton
 79

Energy Consumption (kw-hrs/kg of yarn)

Energy to Break (gram-centimeters/tex)

.99 g-cm/tex

96 g-cm/tex
i
2 kw-hrs/kg
93 g - c m / t e x

90 g-cm/tex

"3.0 kw-hrs/kg

2.8 kw-hrs/kg
0 7 8
Combing R o l l e r Speed (ooo)

Figure 27. Energy t o B r e a k - E n e r g y I s o Curves for

32 Tex C o t t o n
 80

Energy Consumption (kw-hrs/kg of yarn)

Uniformity ( % C V ) — —

13.4% 13.1% 12.9% 12.6%

4.8

4.6

(D
r—t
CL
•M
•M

4.4
4->
ir,
-hrs/kg

4.2

4.0 -hrs/kg

3.8
6 7
Combing R o l l e r Speed (ooo)

Figure 28. Uniformity-Energy Iso-Curves f o r 32 Tex C o t t o n

 Imergy Consumption fkw-hrs/kg of yarn)
Yarn S t r e n g t h (grams/tex)

4.8 15.2 g/tex

14.6 g/tex

14 g/tex

3.2 kw-hrs/k,
3.4 g/tex

0 kw-hrs/kg

6 7
Combing Roller Speed (ooo)

Figure 29. Strength-Energy Iso-Curves for

32 Tex Cotton/Polyester
 82

Imergy Consumption (kw-hrs/kg)

Percent Elongation —

16.8% 16 . 0 ?6 15.2% 14.41

QJ

OH

-^^
+-)
m 3.2 kw-hrs/kg
•H
[2

3.0 kw-hrs/kg

6 7
Combing R o l l e r Speed (ooo)

F i g u r e 30. E l o n g a t i o n - E n e r g y I s o Curves for

32 Tex C o t t o n / P o l y e s t e r
 83

J:nergy Consumption ( k w - h r s / k g of yarn)

Energy to Break (gram-centimeters/tex)

2.76 g-cm/tex
2.68 g-cm/tex

2.62 g-cm/tex

(U
2.56 g-cm/tex
r—I

• H
•!->

r-^

:^

'Jt
• H
3.2 kw-hrs/kg

3.0 kw-hrs/kg

Figure 31. Energy to Break-Energy Iso-Curves for

32 Tex Cotton/Polyester
 84

BIBLIOGRAPHY

1. Wanner, W., "Energy Questions in Spinning," International

Textile Bulletin, March, 1975.
2. Dyson, E., "A Study of Open End Spinning by Circumfer-
ential Assembly, with Special Reference to the Spinning
of Modified Rayon," Part II: Fiber Assembly, Journal
of the Textile Institute, Volume 74, p. 632-638.
3. Dyson, E., "A Study of Open End Spinning by Circumfer-
ential Assembly, with Special Reference to the Spinning
of Modified Rayon," Part I: Fiber Presentation, Journal
of the Textile Institute, Volume 69, p. 588-594.
4. Tooke, T., "Technical Background of Toyoda Open End
Spinning Machine," Toyoda Automatic Loom Works, Japan.

5. Vaughn, E. A. and T. Hiranprueck, "The Effect of Certain

Machine Parameters and Fiber Preparation on the Properties
of Open-End Cotton Yarns," ASME Paper No. 75 Tex-4.

6. Stalder, H., "Influence of the Rotor Speed on the Yarn

Manufacturing Process," Rei-ter Machine Works Ltd.,
Switzerland.

7. Konopasek, M. , "An Advanced Question Answering System on

Sets of Algebraic Equations," School of Textile Engineering,
Georgia Institute of Technology, Atlanta, Georgia 30332.
8. Lord, P. R. and P. C. Grady, "The Twist Structure of
Open End Yarns," Volume 46, Textile Research Journal,
1976,
9. Vaughn, E. A. and T. S. Cox, "The Effects of Opening
Roller Wire Design and Operating Properties of Open End
Cotton Yarn," ASME Paper No. 75 Tex-4.