AUTEX Research Journal, Vol.

8, No4, December 2008 AUTEX

INFLUENCE OF CORE COMPONENT ON THE PROPERTIES OF FRICTION SPUN YARNS

Rameshkumar C.1, Anandkumar P.1, P.Kavinmurugan P.1, Manojkumar B.1, Anbumani N.2
Department of Textile Technology Bannari Amman Institute of Technology, Sathyamangalam-638401 Department of Textile Technology PSG College of Technology, Coimbatore-641004 crktex@gmail.com
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Abstract:
Friction (DREF II) spinning system is one of the promising spinning methods to produce yarns for technical textile applications. The core positioned exactly center and the spinning tension will be very less compare to ring and rotor spinning systems. In an experimental study to produce 6's Ne core spun yarns in DREF II spinning machine, the polyester /viscose (70/30%) sliver was used as sheath component and drawn polyester filaments (150 denier/36) were used as core component. Yarns were produced with the different core/sheath components (0/100%, 16/84%, 30/70%, 50/50% and 70/30% respectively).Friction ratio was kept at 3.33 and the feed rate was changed to produce above 6's Ne core spun yarns. Core spun yarns found that more even and high modulus than the parent friction spun yarn. The filament-core in the yarn appeared to have twisted configuration. The direction and level of twist was difficult to ascertain in these yarns. High core component yarns were found less hairy. S3 values of the yarn found minimum with increment in the core proportion in the yarn. Sheath strength contribution was analyzed with respect to the core filaments and found that the less core proportion yarns have high contribution to the tenacity.

Keywords:
DREF II, friction ratio, core spun yarns, properties

1. Introduction
Friction (DREF) spinning system is an Open-end and or Core sheath type of spinning system. Along with the frictional forces in the spinning zone the yarn formation takes place. The DREF spinning system is used to produce yarns with high delivery rate (about 300mpm). Still it has to gain its importance with the growth along with technical textiles in India. Amongst the spinning systems, DREF provides a good platform for production of core spun yarns due its spinning principle. It offers less spinning tension to the core and core will be positioned exactly at the centre of the yarn. Due to complete cover of the core filaments yarns can be produced with required tensile properties by altering core proportion. Development of DREF core-spun yarns unveils a path for new products including high performance textiles, sewing threads and in the apparels due to its exceptional strength, outstanding abrasion resistance, consistence performance in sewing operation, adequate elasticity for the stretch requirements, excellent resistance to perspiration, ideal wash and wear performance and permanent press[1].

of the sheath over the core improve the cohesion between the core and sheath and within the sheath. The breaking elongation ring, rotor and friction spun yarns have been found to be equal. Better relative tenacity efficiency is achieved during processing of cotton on rotor and friction spinning as compared to ring spinning system. Depending on the type of fibre, the differences in strength of these yarns differ in magnitude. It has been reported that 100% polyester yarns, this strength deficiency is 32% whereas for 100% viscose yarns, it ranges from 0-25%. On the other hand, in polyester-cotton blend, DREF yarns perform better than their ring-spun counterparts. A 70/30% blend yarn has been demonstrated to be superior in strength by 25%. The breaking strength of ring yarns to be maximum followed by the rotor yarn and then 50/50 core-sheath DREF-3 yarn. DREF yarns have been seen to be inferior in terms of unevenness, imperfections, strength variability and hairiness. DREF yarns occupy an intermediate position between ringspun and rotor spun yarns as far as short hairs and total hairiness s concerned. For hairs longer than 3mm, the friction spun yarns are more hairy than the ring spun yarns. Rotor spun yarns show the least value in both the values. DREF yarns are most irregular in terms of twist and linear density while ring spun yarns are most even [3].

2. Friction Spun Yarns Properties

Friction spun yarns (DREF) yarns have bulky appearance (100-140% bulkier than the ring spun yarns).Twist is not uniform and found with loopy yarn surface. Friction spun yarns with high %age of core have high stiffness. Friction spun yarns are usually weak as compared to other yarns. The yarns possess only 60% of the tenacity of ring-spun yarns and about 90% of rotor spun-yarns [2]. The increased twist and wrapping
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3. Experimental
3.1. Material and Methods Polyester/Viscose sliver with Polyester (0.2%) tracer fibres was used to produce sheath component and Polyester multi 106

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filament yarn (150 denier/36filaments) has been used as core component in a DREF II friction spinning machine. The staple length of polyester and viscose fibres is 44mm and 40mm respectively. Slivers (0.14) contain 70% of polyester and 30% of viscose fibres. This sliver was spun with various core-sheath ratios in DREF-II spinning system. The friction ratio was maintained at 3.33 to produce resultant count of 6 Ne and the properties of core spun yarns were studied. The process parameters of the DREF yarn production is given in the table 1.

150d/36 drawn filaments were used to produce various coresheath ratios. The description of the filaments in the yarn production is furnished in the table 2. 3.2. Physical properties The physical properties such as cross section, longitudinal section, fibre configuration and yarn dimensions were studied. Longitudinal and cross section was seen through Nikon Eclipse polarized microscope with the magnification of 5X. The longitudinal views of the yarns were found with Nitro benzene with refractive index of 1.55 and equivalent to the polyester fibre (C6H5NO2) as medium to trace out the coresheath structure of the yarns. 3.3. Tensile Properties

Table 1. Process parameters for the production of DREF yarns.

Delivery speed, mpm 185 185 185 185 185 Drum speed, rpm 2000 2000 2000 2000 Sliver feed rate, mpm 1.15 1.10 0.88 0.72

Code

Yarn description

Core %

Sheath %

Friction ratio

Y1 Y2 Y3 Y4 Y5

yarn without core component Yarn with 16% of multifilament core Yarn with 30% of multifilament core Yarn with 50% of multifilament core Yarn with 70% of multifilament core

0 16 30 50 70

100 84 70 50 30

3.33 3.33 3.33 3.33

Tensile properties such as tenacity, elongation, 2000 3.33 0.55 strength realization, initial modulus and work of rupture were measured thro Premier Tensomax. The test was conducted in the atmosphere of 21C and 65% RH. The test parameters were given in the table 3.The individual contributions of the core and the sheath to the resultant yarns were analyzed. 3.4. Evenness Properties Unevenness was measured in Uster tester-2-SE.it is working with the principle of change in capacitance. The test parameters are given in the table 4. 3.5. Hair-length distribution test The hairiness test for yarn was carried out in Zweigle G566 hairiness tester. The process parameters were given below in the table 5. 3.6. Singeing of core spun yarns

Table 2. Filaments for DREF core spun yarns.

Code F1 F2 F3 F4 Denier of the filament 150 300 450 600 Number of filaments 36 72 108 144

Table 3. Test parameters for Tensomax.

Test Gauge length Pre-tension speed Parameters 500mm 0.5cN/tex 5000mm/min

Table 4. Test parameters for Uster Tester.

Test Test length of the sample Speed RH Temperature Parameters 1000m 200m/min 65% 27C

The core spun yarns were tested for the performance in the singeing process. The hairiness of the DREF spun yarns was tested to find out the performance in the singeing process even though it is polyester viscose fibres; this test has been carried out to find the appearance of loops and hairiness values. The singeing was done in SSM- singeing machine shown in the table 6.
Table 6. Yarn Singeing.
Singeing M/c Speed Singeing type Gas to Air ratio RH Temperature at the gas burner Parameters 525mpm Gas burner 1:3 60% 800C

Table 5. Test parameters for Hair-length distribution.

Test Test length pretension Test speed RH Temperature Parameters 100m 5cN 50m/min 65% 27C

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4. Results and discussion

A friction spun yarn structure differs from that of ring and rotor spun yarn. The yarn is characterized with inferior fibre orientation and loose packing of fibres. Further, the structure of the friction spun varies depending on the mode of yarn formation. 4.1. Physical properties There are distinct difference were found through the microscope study of yarns with different core sheath ratios. The resultant count of yarns was found with 6Ne. 4.1.1. Diameter of the yarn

components. It is found that the breaking elongation and the tensile strength were improved due to high number of filaments from F1 to F4. 4.3. Yarn strength realization Yarn strength realization was done by making an assumption that core only contributing for the strength. Table 10 shows strength realization of sheath component .In case of Y2 the sheath strength contribution is found maximum. For higher core proportion the sheath strength contribution is minimum.
Table 10. Yarn strength realization.
Yarns Sheath Strength realization % 100-(Y2/F1*100) 100-(Y3/F2*100) 100-(Y4/F3*100) 100-(Y5/F4*100) Sheath strength contribution % 131.3 38.2 25.3 16.3

The core spun yarns diameter was studied through the polarized microscope and the results are furnished in the table 7.The Y1 yarn has bulky structure and the other yarns Y2 to Y5 bulkiness reduces with increment in core component.
Table 7. Yarn diameters in mm.
Yarns Y1 Y2 Y3 Y4 Y5 Mean Dia(mm) 0.522 0.510 0.498 0.432 0.410

Y2 Y3 Y4 Y5

4.4. Yarn evenness 4.4.1. Unevenness (U %) The Yarn evenness (U %) of the core spun yarns was shown in the figure 1. Y5 yarn evenness was higher than the other four yarns. This is due to the higher ratio of multi-filament polyester core yarns. The Y1 yarns having very high unevenness than other multi-filament core yarns due to high sheath component.

4.2. Tensile properties The tensile properties of the filament yarns and the core spun yarns were furnished in the table 8and 9 respectively. CV % of tenacity, elongation and work of rupture reduces with increment in the core component. The tenacity and elongation values improved with high core %age.
Table 8. Tensile properties of core spun yarns.
Yarn Tenacity, g/tex Elongation, % Work of Rupture Y1 9.47 (12.35) 10.4 (7.3) 2513.8 (17.11) Y2 14.98 (7.32) 13.30 (5.66) 4914.97 (10.75) Y3 19.37 (4.36) 14.44 ( 7.88) 5839.64 (13.35) Y4 22.4 (3.91) 20.16 ( 7.36) 12278.4 (12.90) Y5 29.55 (1.94) 24.92 ( 4.81) 20067.1 (7.82)

12 10 8 10.56 9.84 8.65 7.82 7.13

U%

6 4 2 0 Y1 Y2 Y3 Yarn Y4 Y5

Figure 1. Unevenness of Core spun yarns.

Values in the parenthesis are CV% Table 9. Tensile properties of filaments.

Yarn Tenacity g/tex Elongation% Work of rupture F1 36.19 (3.75) 18.1 (6.65) 2926.04 (11.37) F2 34.58 (4.21) 17.32 (6.32) 5494.33 (10.41) F3 35.24 (3.40) 17.96 (6.57) 8714.50 (11.56) F4 37.52 (2.76) 19.09 (2.73) 13190.55 (5.94)

350 300 250 200 150 100 50 0 Y1

T h in p l a c e s ( - 3 0 % )

325

187 74 21 Y2 Yarn Y3 Y4

Values in the parenthesis are CV%

The parent filament yarns tensile properties were tested to find out the strength realization of the core and sheath
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Figure 2. Thin places /Km.

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Thick place(+35%) 5

comparision of yarn before and after singeing

3

Thick place(+35%)

4 3 2 1 0 Y1

6000 4000 2000 0 y1 y2 y3 yarn y4 y5

before after

Y2

Y3 Yarns

Y4

Y5

Figure 5. S3 values for before and after singing. Figure 3. Thick places/Km.

4.4.3. Thick places/Km

200 177
neps (+140%)

150 100 50 0 Y1 Y2 Y3 yarn Y4 Y5 97 52 52 32

Thick places /km are totally low .This is due to the even feed sliver. The yarn appearance also found with less loopy in this proportion. Figure 3 shows the thick places per km for +35% to the normal size 4.4.4. Neps/Km The Neps per Km is also found with recession trend for increment in the core component proportion.Y1 yarns found with maximum Neps /Km shown in the figure 4. 4.5. Hair-length distribution

Yarn/Hair-Length distribution Y1 Y2 Y3 Y4 Y5

The hair-length distribution was found high in case of 1mm length.S3 values found drastically reducing with increment in Figure 4. Neps/Km. the core component proportion. The same trend is obtained for after singed core Table 11. Hair-length distribution before singeing. spun yarns. These are shown in the table 11 and 12.
1mm 32577 38582 41533 40012 36364 2mm 434 599 761 919 539 3mm 2001 2420 2361 2381 1576 4mm 1359 1303 1117 993 802 6mm 206 160 148 116 138 8mm 38 32 22 26 53 10mm 0.00 0.00 0.00 1.00 2.00 S3 3604 3915 3648 3518 2571

The comparison of S3 values of before and after singeing was shown in the figure 5. The gassed yarns found with less S3 values and less loop structure.

5. Conclusion
Cross sectional study of the core spun yarns revealed that the core Yarn/Hair-Length 1mm 2mm 3mm 4mm 6mm 8mm 10mm S3 distribution component placed exactly at the centre of the 8522 174 140 67 8 1 0.50 217 Y1 yarns. Y5 yarn has high 9527 149 139 63 8 2 0.00 212 Y2 tenacity (37.52g/tex) than the other yarns. The 9775 159 173 85 13 2 0.00 273 Y3 CV% diminishes with 7897 160 116 70 14 2 0.00 203 Y4 increment in the core 6765 256 228 103 17 5 0.00 354 Y5 content. The breaking elongation of the core spun yarns found higher with increment with the core 4.4.2. Thin places/km component. The same trend was found in the work of rupture. The stiffness of core spun yarns increasing with increment in Figure 2 is shown the recession trend in the thin places /km. the core components. The tracer fibres in the sheath This is due to the contribution of even core to the yarns. component found wrapped over the core in different helix
Table 12. Hair-length distribution after singeing.

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angles. The sheath component also contributes for tensile strength. In Y2 yarn, the sheath strength realization found higher. The Core filaments were found with untwisted structure. More loop fibres were found in the Y1 yarns than other yarns. The U% is found decreasing trend with increment in the core component. The S3 value found higher with Y1 yarns.

Acknowledgement
We like to express our sincere thanks to Mr.A.Subramaniam, Consultant, Roots Industries, Coimbatore, India and Mr.Nagarajan, Factory Manager, Prime Textiles Sathyamangalam, India for their kind permission to yarn preparation.

References:
1. Salhotra, An over view of spinning technologies, applications and limitations, Indian Journal of Fibre and Textile Research,Dec1992,255-262. Chattopadhyay and Banerjee .S, The frictional behavior of Ring Rotor and Friction spun yarns, 1997 Journal of textile instittue,88,Part INO 3,59-66. IsthiaqueS.M.,and SwaroopaT.K,Internal properties of DREF yarns III, Asian Textile Journal,1998 No10,28-33 Oxenham, Zhu and Leaf, Observation of the tensile properties of Friction spun yarns, Journal of Textile Instittue,1992,No 4,621-623. Reviewed: 15.01.2009

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Received: 27.07.2007

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