National institute of textile Engineering and Research (NITER), Nayarhat, Savar, Dhaka. Core Yarn Md, Rafiqul Islam, Lecturer of YE, Dept. of TE, NITER Core Spinning: Core-spinning is a process by which fibres are twisted around an existing yarn, cither filament or staple spun yar, to produce a sheath- core structure in which the already formed yarn is the core. Core Spun Yarn: Core-spun yarns are two-component structure with Core and sheath Generally continuous filament yarn is used as core and the staple fibres used as sheath covering. The core-spun yar used to enhance functional properties of the fabries such as strength, durability and stretch comfort. Advantages of Core-spun yarns: Development of core-spun yarn with ring spinning system unveils path for new products including high performance textiles, sewing threads and in the garmenting areas due to its, ‘exceptional strength, outstanding abrasion resistance, consistence performance sewing machine, ¢lasticity for the stretch requirements, excellent resistance in perspiration, ideal wash and wear Performance and permanent press. Exfect of Process variables on Ring Core-spun yarn propert * Core sheath ratio + Pre tension applied to the core material, * Spinning draft + Number of roving feed and rwist * Core- sheath ratio: It has been found that decreasing sheath content will increase the strength ofthe core-spun yarn. Apart from this there isan improvement in the extension and the evenness properties. In the case of core-spun sewing threads, a2: | ratio of core sheath gives poor core coverage, and may raise problem of stripping off the sheath during the sewing, whereas, with a 1:1 core sheath ratio the striping off problem 7 reported to minimize,National Institute of textile Engineering and Research (NITER), Nayarhat, Savar, Dhaka. *Pre- tension to Core materiak: The pre tension is needed to regulate the geometrical positon of the filament. This input tension varies with the twist factor, size and the quality of the filaments used. Balasubramaniam furnished a method for optimizing the tension of the core filament in the core spinning process. Colored filament was passed over a tension device of attachment and fed before the nip of the front roller of the ring frame, The pre tension was gradually raised until the colored filament is completely covered by the cotton fibres, and this value was taken as the optimum input tension. It ‘was approximately 10% of the breaking load of the core yarn. An introduction of a compensatory tensioner can be reducing the tension variation. An extension of | % to the core filaments while feeding to the ring frame ensures no buckling or curling of sheath fibres. Core yams are usually pre- tensioned to an extension of around 5-10% for Mat continuous filaments yarns, about 30% for textured yarns and up to 400% for an eleetrometric core. If insufficiently tensioned, the filament will either periodically appear at the yarn surface, grin through or become wrapped around the fibre ribbon as the ribbon being twisted. * Spinning draft: Spinning drafts can be varied to obtain the required yarn count based on the core the sheath ratio, Number of Roving feed: The possible ways of feeding the core material at the front roller nip with respect to roving are: + Filament at the center of the roving + Filament at the sides of the roving, + Filament on the top of the roving. ‘Two-rove feeding (Filament at the center of the roving) provides better core positioning and control during spinning influences the structure and properties of core-spun yarns. Twist: Adequate cohesion obtained in individual yarns at high twist rates and itis minimize the sheath slippage .In addition to this, the filament pre-twist in opposite direction to the ring twist reduce the sheath slippage. The extension of the core-spun yarn tends to reduce at higher twist levels. Conventional Core spinning attachment in Ring frame: A core spinning attachment in ring spinning is shown in Fig. The attachment consists of metal plate (Bracket) bent to a shape. One end of the device is fitted on the roving traverse guide bar such that the relative position of the roving and the core filament may be kept constant al the time. There is a provision to vary the position of the device if required. The other end of the plate is fitted With a porcelain guide that feed the core filament ata precise position behind the front drafting rollers. This devise is fited with a pre-pensioner and is kept in a horizontal plane. Varying the number of tension dises may vary the input tension of the core filament, The package containing core filament material is suspended from a bar such that they could rotate easily, thus avoiding any tendency to stretch the filament before it is fed to the tensioning device.National atte of textile Engineering and Research (NITER) Nayarht,Savar, aka, Core-spun yarn production by Rotor spinning system: Nield and Ali have developed a technique in rotor-spinning machine to produce core-spun yarns as shown in Fig. Twist efficiency and pre-tension of filament are the influencing factors in core spinning. In order to increase the contact area between yarn arm and doffing tube (for increasing the twist. efficiency), a copper flange was soldered to the inner end of the doffing tube. The doffing tube was mounted on a ball bearing, rotated by a separate drive opposite to the rotation of the rotor with a speed ratio of 1:9. The rotating doffing tube inserts a false twist and pushes twist back to the peel-off point. The rotation of rotor wraps the yarn arm around the continuous filament core. A minimum pre-tension is necessary to avoid filament flung out in to the rotor- collecting surface. The core is not twisted during this process. tis economical to produce coarse core-spun yarns through rotor machine than the ring core-spun yarns, SN ou f Fig 8: Core-spun yarn produc ion by Rotor spinningNational institute of textile Engineering and Research (NITER), Nayarhat, Savar, Dhaka. Core-spun yarn production by Friction spinning system: In friction spinning system the fibres are individually collected and twisted to form yarn. A wide range of staple length can be processed by this system. In Dref II system, the deposition and the twist of fibres on to the yarn-tail is to be replaced by a filament core to obtain full coverage of core. Dref-Il (Wrap spinning system) isa frictional spinning process; a drafted ribbon of parallel fibres that constitute the bulk of the spun yarn is wrapped by either surface fibres protruding from the ribbon or by continuous filaments so as to impart coherence and strength to the resulting yarn. {is believed that the core is false twisted by the rotation of the friction drums before being Wrapped by the sheath fibres. Strength of the Dref III core-spun yarns have direct relationship with the strength of core filaments and number of sheath fibres that are active in generating radial pressure due to theit structural helical configurations, The effectiveness of wrapping of sheath fibres depends on physical and mechanical characteristics of fibres, configuration, length variations, firmness of the wrap and wrap angle. Fig: Dref spinning Core-spun yarn production by MJS spinning system: It was reported that the Air-jet spinning could be used for producing core yarns after optimizing process parameters. A relatively higher first nozzle pressure is advantageous for improving sheath-slippage resistance. The use of higher spinning speed and wider condenser markedly improves the tenacity, breaking extension, initial modulus and sheath-slippage resistance and affects the yarn hairiness, mass irregularity and flexural rigidity. However, yarn properties deteriorate at high spinning speed especially for finer yarns. The schematic diagram of MJS spinning system for the production of core- spun yam is shown in Fig. ing system‘National institute of textile Engineering and Research (NITER),Nayarhat, Savar, Dhaka, Core-spun sewing threads: The sewing thread is subjected to heavy stresses and strain tthe JarvOus Points during the processes. The speed of the needle is accelerated to over 180 km/hr in the forwarded direction brought to rest suddenly and again accelerated to backwards before Feluming to the rest, The whole cycle is repeated approximately !20times per seconds. Incase Of lock stitch the seam sevn at 12sttches per inches each length of thread is passed through the needle up to 40 times before being set into the fabric. Depends on fabric thickness, the Sewing machine needle reaches temperature of about 360 ,a C at 4000 s p.m., the temperature OF the needle during the operation depends on the number of piles of fabri to be sewn and the frictional forces between the needle to fabric and needle to thread {13] 100%Cotton threads hhas difficult to accompany the sewing machine with high speed rat, similarly 100%Synthetic threads has limitations due to high needle temperature, Hence the Core-spun sewing threads can meet the high speed A yd Manu acting 2 ipa | * Doubling: Two or three ends are twisted together to make sewing thread, This twisting process improves the cotton covering of the core-spun yarn Disadvantages of the single core yarn are that the outer cover of staple fibers may rather be easily removed from the core filament by abrasion; tis is not recommended for sewing thread, since thread ism severally abraded against the needle during the sewing, It requires higher resistance to abrasion. The doubling together of two or more single core-spun yarn effectively overcomes this problem by binding with the structure fibers more firmly with the structure, + Heat setting: Fibers and filaments used for the spinning core yarns having different characteristics and the resultant yarn may shrink differently, o to achieve balance and Set of these yarns, heat setting has to be done. Setting of twist is done by steaming the ‘yarn in an auto calve with steam pressure of 0.6 kg/em? for 30-60 minute. Temperature of the steam has to be maintained with 100-105¢X C. The steaming time is decided on the basis of twist level in the doubled yarn. The heat-setting leads to stabilization and ‘equalization of the elongation properties ofthe thread and it prevent the snarling, Polyester and Nylon threads required high pressure steaming and the industrial sewing threads needed low pressure steaming. '* Hot stretching: Hot stretching is a process of heating the thread to pre determined and ‘ontrolled temperature in the range of 180-240¢X Centigrade wih tension and length rol. Heat setting operation causes a decre: ie modulus and increase inthe ensibility of the thread, Consequently when high modulus thréad requires Subsequent stretches. This hot stretching imp thermal stability and reduces the_ extensibility. The sewing thread lengt roved ‘The specific tenacity {Improved to 3-5%, This helps to get improvement in dyeing and kink fre thread."National institute of textile Engineering and Research (NITER), Nayarhat, Savar, Dhaka. * Wet processing: A ter heat setting threads has to be converted in to hank form for, required wet processing treatments. High color fastness and precise shade matching are, the key factor requirements for Core-spun sewing threads. Normally to get uniformity, Eros wound packages with high pressure equipments used, Lubrication: Gliding and cooling effect on the needle could be done with effective lubricants. Good lubricant must not clogs on the needle eye or causes stain. The lubricant must allow the thread to unwind evenly from the package. The friction between the abrading surface should be minimized with lubrications inexpensive lubricants will be preferred, + Final Winding: The core spun sewing threads after the treatments, to be wound on a suitable package like spool, cop or king spool with required length, Problems association with core spinning: Core missing. Tension variation. Alignment of core. * Core % and Sheath % Variation,