National Textile University

LAB PARACTICLE
NAME SHAHAN AKHTAR
REG NO. 2020-NTU-MSTT-6077
TT-5061 Adv F. Filament & yarn Techniques

Lab No. 01
Title:
Introduction to rotor spinning and parts identification of rotor spinning.

Objective:
In this practical, I have learn rotor spinning and its parts name.

Introduction:
Open-end spinning or rotor spinning is a process in which fibrous material is highly drafted,
ideally to the individual fiber state, creating a break in the continuous of the fiber mass.
The individual fibers are subsequently gather onto the open end of a yarn that is rotated to twist
the fibers into the yarn structure to form a continuous yarn length. The length of yarn spun is
then wound to form a package.
Rotor spinning is characterize from the outset by incomparably higher production potential than
ring spinning. This potential has steadily increased by the continuous rise in rotor and winding
speeds. Rotor spinning combines two process stages of ring spun yarn technology into a single
machine these are (spinning & winding).
This system is much less labor intensive and faster than ring spinning with rotor speeds up to
150,000rpm. Rotor spinning is more cost-effective than ring spinning in the manufacture of yarns
with coarse to medium counts. In recent years, there have been many attempts to develop rotor
spinning further into the area of fine counts, i.e. yarn counts finer than 40s cotton count.
One disadvantage of open-end spinning is that it is limited to coarser counts, and secondly
structure of the yarn itself where fibers are less parallel as compared to ring spun yarns.
Consequently, cloth made from open-end yarn has a ‘fuzzier’ feel and poorer wear resistance.
Rotor spinning machine contained following major components
A device for drafting the fibrous mass into individual fibers. A means of transporting the fibers
and depositing the fibers onto the yarn end. Device for collecting the separated fibers onto the
yarn end in a manner that enables the correct yarn count to be obtained. Device for rotating the
yarn end to insert twist into the collected fibers. Means of winding the yarn into a package.
Diagram with parts
Feed roller, Feed plat, Opening roller, Fiber transport channel, Ring cup, Yarn package assembly

Sliver path Feeding of sliver to feed roller and then opening roll

Opening roller with card wires Fiber channel to ring cup

Conclusion
It was concluded that the rotor spinning machine is easy to operate.
TT-5061 Adv F. Filament & yarn Techniques

Lab No. 02
Title:
To Study the driving mechanism of rotor spinning machine.

Objective:
In this practical, I will learn mechanism of rotor spinning machine, and how the main drive
transferred from motor to major parts of rotor machine.
Introduction
The heart of the open-end process is a rotor, wherein fibers can be collected and then drawn off
as a yarn. Most rotors are 31 to 56 millimeters in diameter and may contain a shallow "U" or "V"
shaped fiber alignment groove around their periphery. In opened spinning, the rotor rotation
provides the twisting force.
Procedure

The sliver obtained from carding or draw frame is used as feed material for the open-end
spinning. The working of rotor spinning can be understood in the below steps:

Sliver feed:
A card or draw frame sliver is fed through a
sliver guide via a feed roller and feed table to a
rapidly rotating opening roller. The rotating
feed roller helps to grip the sliver and carries it
forward over the feed table into the opening roller. The feed table is equipped with spring-loaded
pressure which ensures strong gripping of the fed sliver toward the feed roller. This assembly gets
equipped with automatic stop motion. When sliver a yarn end down, sliver feeding gets stopped
immediately by disengaging of feed clutch. The feed roller also stops to rotate.

Sliver opening:
The opening action gets performed with the help of a combing roller in the rotor spinning machine. This
roller gets covered with saw tooth wire clothing. When the sliver gets passed through a rotating combing
roller, the individual opening of fibers takes place.

Fibres drafting zone:

In the drafting zone, the fibers get further opened. these fibers are sucked with the help of a transport
tube. An air current flows in this tube, which carries the opened fibers to the rotating rotor. These fibers
get accumulated on the inside wall of the rotor. The suction current in the fiber channel helps to pick off
the fibers from the surface of the opening roller and send them into the rotor. In the course of this
movement, both the air and the fibers are accelerated due to the converging shape of the feed tube. This
represents a second draft following the nip trough/opening roller and results in further separation of the
fibers. The fibers are straightened in this air current. A third draft creates upon the arrival of the fibers on
the wall of the rotor. Since the peripheral speed of the rotor is many times greater than the speed of the
fibers, the parallelization of fibers takes place in this zone. The arrangement of fibers improves. When the
fibers slide down the wall of the rotor into the rotor groove due to the high centrifugal force generated
within the rotor. The fibers are straightened finally here.

Cleaning assembly:
Most of the transport air enters only at the trash removal slot and only a small amount through the draw-
off tube. One result of the centrifugal force of the opening roller is that impurities carried with the
incoming sliver are expelled through an outlet of the opening roller
housing. The expelled waste falls onto a conveyor belt, which carries
it either to one or to both ends of the spinning machine, where it is
removed by suction nozzles on each side of the machine.

Fiber condensation system:

When the rotor revolves at a very high speed, a centrifugal force
gets generated. This centrifugal force causes the fibers to collect in
the groove of the rotor. A ring of fibers forms in the rotor groove.
This fiber ring is then swept from the rotor continuously by a newly
formed yarn, which contains untwisted fibers.

Twisting:
Twist insertion in this spinning process is performed by means of a
rotor. Each revolution of rotor inserts one turn in the yarn.
The yarn gets produced is pulled out of the rotor with the help of the navel continuously, the free end of
the yarn is allowed to extend from the rotational axis to the rotor periphery. The centrifugal force (more
than 100 000 times the weight of the fiber) acting at this point presses the yarn end firmly against the wall
of the collecting groove, exactly as in the case of the fibers in the ring. The yarn end, therefore, adheres to
the rotor wall. As the rotor turns, it, therefore, carries the yarn along, and the latter rotates around the
nozzle like one arm of a crank. Each revolution of the rotor generates one turn of genuine twist in the
yarn. When the yarn has reached its maximum twist level as determined by the prevailing force
conditions, the yarn end begins to turn about its own axis, i.e., it rolls in the rotor groove. Now the open
yarn end is resting in the binding-in zone on a strand of parallel fibers; rolling of the yarn end, therefore,
causes the brush-like yarn end to grasp fibers from the ring and twist them in to give a new yarn portion,
which proceeds to grasp the next fibers and twist them in, and so on. A yarn is thus spun continuously. It is
simply necessary to pull this yarn out of the rotor via yarn compensation bar by means of take-off rollers
and wind it up on a winding drum into the cross-wound package

Yarn take-off/ winding:

The yarn formed in the rotor is continuously taken off by the delivery shaft and the pressure roller
through the nozzle and the draw-off tube and wound onto a cross-wound package. Between takeoff and
package, several sensors control yarn movement as well as the quality of the yarn is checked.

Conclusion
It was concluded that it is necessary to know about the driving mechanism to develop the
required count (liner density) yarn.

TT-5061 Adv F. Filament & yarn Techniques

Lab No. 03
Title:
Development of 16s yarn and its comparison with ring spinning.

Objective: In this lab, I learn how much draft and twist is required to make 16/1 yarn.
Experimental Procedure:
In rotor spinning machine, the input feeding is sliver. First of all, we calculate sliver count.

By using wrapping drum, take 4 specimens of 6 yards length each and weight on digital scale in gram.

Find average wight in grain per yard of the sliver.

Sliver: 56.64 grain/yard

Sliver count= 7000/840/56.64 = 0 .147

Now we find draft:

As our required count is 16/1, so we calculate draft as,

Draft = deliver count/ fed count= 16/0.147= 108.84

We used rotor manual draft table and find the required gears against that draft, i.e.

Z4= 26 and Z3 =19 Also tooth belt changed belt2 270 150

Now we find twist:

TPI= TM under root count= 4* under root 16= 16

Convert TPI to TPM as 16*39.37= 630

We used rotor manual twist table and find the required

gears against that twist, i.e.

Z2= 32, Z1= 29

belt=2

After changing the draft and twist wheel, the foreman

has run the machine. Make a small baby cone of 16s.
then stopped the machine.

Observations and Calculations:

Actual count= 16.5

Actual T/M = 628

Comparison with ring yarn:

Yarn count 16/1 16/1
Spinning system Ring Rotor
TPM/ TM 4.40 628
U% 14.49 12.20
Thin places (-50%) 2 0
Thick places (+50%) 130 18
Neps 155 24
IPI 287 42
Hairiness 5.10 4.01
RKM 16.80 10.90

TT-5061 Adv F. Filament & yarn Techniques

Lab No. 04
Title:
Introduction to electrospinning and formation of Nano fibers by using single needle nozzle.

Objective:

In this practical, I will learn about electrospinning and its fiber manufacturing procedure.

Electrospinning:

It is a process of drawing continuous polymeric fiber from a polymer either solution or polymer melt,
based on an electro hydrodynamics phenomenon, using electrostatic force in a liquid-jet form to fabricate
polymer composite.

Procedure:

• Generally, a typical electrospinning setup consists of three primary components:

 • A high-voltage power supply to charge polymer solution, a syringe with pumps from which the
polymer solution is fed through a capillary connected to a syringe filled with the polymer solution,
and a grounded collector where nanofibers are deposited

• A syringe pump with a constant rate is used to extract the solution (particulate suspension,
polymeric or molten solution) from the needle tip of a syringe containing the solution.

• The droplet at the tip of the needle undergoes two opposite forces: the electrostatic repulsion and
the surface tension. When the electrostatic repulsion starts to overcome the surface tension of a
fluid, the pendant droplet at the tip of the needle will deform into a conical droplet known as the
Taylor cone.

• A fine charged polymeric jet of the solution will eject from the needle tip when the electrostatic
force overcomes the surface tension

A base region in which the nozzle end contains the

charged surface of the solution

A jet region in which the solution path is

straight

A splay region in which the jets stretch and split

forming nanofibers

A collector region in which nanofibers are

positioned

The droplet at the tip of the needle

undergoes two opposite forces: the
electrostatic repulsion and the surface
tension. When the electrostatic repulsion
starts to overcome the surface tension of a
fluid, the pendant droplet at the tip of the
needle will deform into a conical droplet
known as the Taylor cone. A fine charged
polymeric jet of the solution will eject from
the needle tip when the electrostatic force
overcomes the surface tension

Observations:

the morphology and uniformity of nanofibers are determined by considering a number of parameters
which are investigated under three main parts:

Polymer solution parameters : molecular weight, solution viscosity, surface tension, dielectric constant etc

Processing conditions (setup parameters)

Ambient conditions