Science and Engineering of Composite Materials 2023; 30: 20220212
Research Article
Xi Wang*, Juanfen Chen, Shuai Li, Pei Xiao, Kai Cheng, Yanhe Wang and Tianyong Zheng*
Method for deriving twisting process parameters
of large package E-glass yarn by measuring
physical properties of bobbin yarn
https://doi.org/10.1515/secm-2022-0212
received February 08, 2023; accepted May 21, 2023
Abstract: Twisting is an important part in the production
process of large package E-glass yarn. To derive the
twisting process parameters of large package E-glass
yarn, a method from the physical properties of bobbin
yarn is proposed based on the study of the twisting prin-
ciple of E-glass yarn. After unwinding the bobbin yarn
and measuring its twist, loop pitch, and corresponding
diameter, the calculation is completed according to the
steps of first determining the descending speed of the
traveler, then fitting the spindle speed data, and finally
calculating the elevating speed of the traveler. The result
is that the twisting spindle speed of D450 E-glass yarn
with 31.8 T/m decreases from 5,015 to 4,550 rpm, the ele-
vating speed of the traveler is 0.91 m/min, and the des-
cending speed of the traveler is 1.50 m/min. The accuracy
of the calculation is verified by monitoring the rotating
speed of the roving cake and measuring the loop pitch of
bobbin yarn in the twisting experiment. The result shows
that the prediction error of this method is less than 1.1%,
which can effectively derive the twisting process para-
meters of large package E-glass yarn, and provide a refer-
ence for the twisting process design scheme of glass fiber
strand manufacturers.
Keywords: continuous filament yarn, roving cake, spindle
speed, traveler speed, loop pitch

* Corresponding author: Xi Wang, Jiangxi Center for Modern Apparel
Engineering and Technology, Jiangxi Institute of Fashion
Technology, Nanchang, China, e-mail: wangxi.china@126.com
* Corresponding author: Tianyong Zheng, School of Textile Science
and Engineering, Tiangong University, Tianjin, China,
e-mail: zty_zzti@126.com
Juanfen Chen, Shuai Li, Pei Xiao, Kai Cheng, Yanhe Wang: Jiangxi
Center for Modern Apparel Engineering and Technology, Jiangxi
Institute of Fashion Technology, Nanchang, China
Open Access. © 2023 the author(s), published by De Gruyter.
License.
1 Introduction
E-glass yarn is a kind of continuous filament yarn with
fewer filaments and a small monofilament diameter [1].
The untwisted roving obtained by the drawing process
usually needs a twisting process before it can be used
for weaving E-glass fabric [2]. In the twisting process,
the glass fiber twisting machine is used to unwind and
twist the roving wound on the cake, and meanwhile,
wind it on the bobbin to become a twisted bobbin yarn.
In the production of continuous filament yarn, the twisting
process plays an important role, especially for fine E-glass
yarn. After twisting, the arrangement of filaments in the
yarn changes, and the radial pressure of the yarn gener-
ates friction, which improves the clustering property of the
yarn [3], so the twisted yarn is not easy to spread. How-
ever, the elongation at the break of glass fiber is low, and it
is not resistant to bending and friction. Excessive yarn
twist is easy to cause fiber breakage, and E-glass fabric
needs to be spread in the following process [4], so the twist
of E-glass yarn is usually low. In addition, the twisting
process changes the package form of E-glass yarn, and
the large-diameter roving cake is converted into bobbin
yarn with a small diameter and long traverse, so that the
yarn can be unwound at high speed along the axis of
bobbin yarn in the subsequent process, and it is conve-
nient for transportation and storage [5].
The twisting process is of great significance to
E-glass yarn, and it must meet certain requirements.
First, the twist of the inner and outer layers of the
bobbin yarn should be consistent [6]. Second, the yarn
should be tightly wound, well layered, not entangled
with each other, and not cast off when unwinding.
Meanwhile, the yarn winding and unwinding tension
should be stable, with a low yarn breakage rate and
less hairiness [7]. In addition, the package of bobbin
yarn should be large to reduce the number of bobbin
changes in the subsequent process and improve produc-
tion efficiency.
This work is licensed under the Creative Commons Attribution 4.0 International
2  Xi Wang et al.

E-glass yarn twisting and ring spinning are similar, hook spins one time on the traveler, with a section of yarn
but there are also many differences between them. Ring from the unwinding point of the roving cake to the poly-
spinning is that the roving is drawn by the front roller, amide hook getting a twist, but the yarn is not twisted after
and the short fiber is converged into yarn at the outlet of passing through the polyamide hook [14]. When the poly-
the front roller by twisting [8]. However, E-glass yarn is amide hook spins on the traveler, the friction between the
twisted by unwinding the roving cake to output the yarn polyamide hook and the traveler produces resistance, so the
[9]. The diameter of the roving cake does not remain the polyamide hook speed lags behind the spindle speed, and
same as that of the front roller of the ring spinning but the speed difference between them makes the yarn wind on
gradually decreases. Ring spinning adopts short-traverse the bobbin. A schematic diagram of E-glass yarn twisting is
winding [10], while E-glass yarn twisting adopts long- shown in Figure 1.
traverse winding to realize large package and high-speed As shown in Figure 1, after the yarn is unwound from
axial unwinding, which is convenient for subsequent pro- the roving cake, it first passes through the yarn guide,
cessing. There is a step-up in the short-traverse winding of and a balloon spinning around the spindle is formed
ring spinning, and the spun bobbin yarn is usually spindle- between the yarn guide and the polyamide hook, and
shaped [11]. However, the traverse of E-glass yarn twisting is the balloon is confined in the balloon control ring [15].
usually set to elevate and then descend layer by layer, and After passing through the polyamide hook on the tra-
the twisted bobbin yarn is bottle-shaped. Due to the influ- veler, the yarn is wound on the bobbin, which is set on
ence of the long-traverse setting, there is a difference the high-speed spinning spindle, and the traveler ele-
between the cylindrical loop pitch and the conical loop vates and descends repeatedly to make the yarn wind
pitch of the bobbin yarn [12]. Therefore, it is necessary to all over the bobbin.
increase the traveler speed at the cone stage to compensate If the spindle speed is defined as Nd (rpm) and the
for the difference caused by the change in the winding polyamide hook speed is defined as Ng (rpm), and the
diameter of the bobbin yarn. In addition, in the short- speed difference between them results in winding, then
traverse winding process of ring spinning, the half-cone the winding speed Nj (rpm) can be expressed as follows:
angle of bobbin yarn rises from 0 degrees to the max-
imum and then remains unchanged [13]. While in the
process of E-glass yarn twisting, the half-cone angle of
bobbin yarn starts from 0 degrees and increases linearly
with the twisting length, and the winding diameter also
increases linearly.
Since there are some differences between E-glass
yarn twisting and ring spinning, the traditional ring spin-
ning production process cannot be copied, and the pro-
cess parameters adopted by various glass fiber strand
manufacturers in the twisting process are also different.
Based on the study on the twisting principle of large
package E-glass yarn, this article reveals the relationship
between the physical properties of bobbin yarn and the
twisting process parameters, proposes a method to calcu-
late the spindle speed and the elevating and descending
speed of the traveler by measuring the twist, loop pitch,
and its corresponding diameter of bobbin yarn, and veri-
fies the accuracy of the calculation by conducting experi-
ments on a glass fiber twisting machine.

2 Twisting principle of E-glass yarn

The basic principle of E-glass yarn twisting is that twisting
and winding are carried out simultaneously. The polyamide Figure 1: Schematic diagram of E-glass yarn twisting.
 Deriving twisting process parameters of large package E-glass yarn  3

Nj = Nd − Ng . (1) loop pitch difference caused by the diameter change of the

bobbin yarn can be compensated when winds are at the
According to the relationship between linear velocity
conical part. To ensure the accuracy of loop distance mea-
and angular velocity, if the linear velocity of yarn is
surement, the cylindrical loop pitch of bobbin yarn is taken
defined as Vs (m/min) and the winding diameter of bobbin
yarn is defined as dx (m), then the winding speed can be as the measurement basis in this article, as shown in
expressed as the ratio of the linear velocity of yarn to the Figure 2.
winding diameter of bobbin yarn. With equation (1), the Within a certain traverse of the traveler, if the height
winding speed equation of E-glass yarn twisting can be of the traverse is H (m), the number of windings is S , the
derived as follows: yarn length is L (m), the moving time is t (min), and the
traveler speed is Vg (m/min), then the loop pitch P (m)
Vs can be deduced from the following equation:
Ng = Nd − . (2)
πdx
H H πdxH πdxH Vg
The winding speed equation of E-glass yarn twisting P= = L = = H
= . (5)
S Vst πdx Nj Nj
πd V
is the same as that of ring spinning, but in the process of x g

E-glass yarn twisting, the unwinding diameter of the Equation (5) shows that the loop pitch can be
roving cake does not remain the same as that of the front expressed as the ratio of the traveler speed to the
roller of ring spinning but gradually decreases. If the winding speed of the yarn. With equations (2) and
unwinding diameter of the roving cake is defined as (5), the traveler speed equation is obtained, as shown
Dx (m) and the rotation speed of the roving cake is defined in the following equation:
as Ns (rpm), then according to the relationship between
PVs PNd
the linear velocity and angular velocity, the output yarn Vg = = . (6)
πdx πdxT
linear velocity can be expressed as follows:
Vs = πDx Ns. (3) The elevating speed and the descending speed of the
traveler are different. Generally, the elevating speed of
The length of the yarn unwound from the roving cake the traveler is slow, the loop pitch is small, and the
has a linear relationship with the diameter of the roving winding is tight. The yarn wound in the elevating process
cake. If the rotating speed of the roving cake is constant,
the linear velocity of the yarn will decrease with the
decrease in the diameter of the roving cake. The twist T
(T/m) of the bobbin yarn is the ratio of spindle speed to
yarn linear velocity. When the linear velocity of the yarn
decreases, the twist of the bobbin yarn will be changed.
Therefore, the glass fiber twisting machine controls the
linear velocity of yarn by adjusting the rotation speed of
the roving cake to ensure the accuracy of the twist. With
equation (3), the rotating speed of the roving cake can be
expressed as follows:
Nd
Ns = . (4)
πDx T

During the twisting process, the rotation speed of the

roving cake increases with the decrease of the diameter of
the roving cake, so that the twist remains unchanged.
On bobbin yarn, the distance between adjacent loops
is called loop pitch. Due to the requirement of large
package and high-speed axial unwinding, bobbin yarn
is wound on a slender bobbin in a bottle shape, which
can be divided into cylindrical and conical parts. When the
traveler elevates to the conical part and winds, the diameter
of bobbin yarn gradually decreases, which also reduces the Figure 2: Schematic diagram of loop pitch and winding diameter of
loop pitch. Therefore, by increasing the traveler speed, the bobbin yarn.
4  Xi Wang et al.

forms the winding layer of bobbin yarn. However, the
traveler descends faster, the loop pitch is larger and the
winding is sparse, and the yarn wound in the descending
process forms the binding layer of bobbin yarn. If the des-
cending speed of the traveler is defined as Vgd (m/min) and
the elevating speed of the traveler is defined as Vgu (m/min),
the coefficient between them is k , and the relationship
between them can be expressed as follows:
Vgd = kVgu.
To prevent the yarns of the winding layer and the
binding layer from overlapping, the value of the coeffi-
cient k should avoid integer and take decimal or odd
number. Accordingly, the loop pitch generated when
the traveler elevates is denoted as Pu (mm), and the
loop pitch generated when the traveler descends is
denoted as Pd (mm).
According to equation (6), if the twist, winding dia-
meter, and loop pitch of bobbin yarn are known, the ratio
of spindle speed to the traveler speed can be calculated.
Twist, diameter, and loop pitch are the physical properties
of bobbin yarn, which can be measured by unwinding
bobbin yarn, while the traveler speed is a constant value
on glass fiber twisting machine, so the spindle speed can
be calculated by determining the traveler speed, thus
obtaining the twisting process parameters of E-glass yarn.
3 Measurement of physical
properties of bobbin yarn
(7)
To measure the twist, loop pitch, and corresponding dia-
meter of bobbin yarn, it is necessary to unwind bobbin
yarn in sections until the yarn is completely unwound
from the bobbin. In the experiment described in this
article, the commercial D450 E-glass yarn is unwound
by using the YG086F electronic yarn wrap reel. The
unwinding process is divided into 47 sections, with 48
sets of twist, loop pitch, and diameter data of bobbin yarn
obtained.
Y331C yarn twist counter is used to test the twist of
bobbin yarn. Due to the low twist of E-glass yarn, attention
should be paid to prevent the yarn from unwinding in
advance during sampling and test preparation. Samples
are taken from the full bobbin, and then a group of

Table 1: Measurement results of physical properties of D450 E-glass yarn

No. Yarn Bobbin yarn Elevating loop Descending loop No. Yarn Bobbin yarn Elevating loop Descending loop
twist T diameter pitch Pu (mm) pitch Pd (mm) twist T diameter pitch Pu (mm) pitch Pd (mm)
(T/m) dx (mm) (T/m) dx (mm)

1 26.0 67.5 1.22 2.06 25 28.0 94.3 1.75 3.23

2 31.0 68.8 1.25 2.01 26 32.0 95.2 1.75 3.00
3 26.0 70.4 1.35 2.10 27 36.0 96.2 1.80 3.00
4 32.5 71.7 1.28 2.15 28 28.0 97.1 1.78 3.00
5 31.2 72.9 1.33 2.35 29 29.0 98.1 1.80 3.05
6 31.2 73.9 1.37 2.22 30 31.0 99.0 1.90 3.18
7 40.0 74.8 1.58 2.25 31 27.0 100.0 1.95 3.20
8 34.0 76.1 1.48 2.25 32 36.0 101.0 1.90 3.18
9 34.0 77.1 1.21 2.43 33 25.5 101.6 1.95 3.25
10 37.0 77.2 1.38 2.40 34 32.5 102.2 1.93 3.23
11 36.5 78.3 1.40 2.36 35 32.0 103.2 2.00 3.35
12 39.5 79.6 1.47 2.50 36 25.5 103.8 2.05 3.40
13 27.0 80.6 1.51 2.59 37 38.0 104.5 2.13 3.40
14 37.0 81.7 1.50 2.50 38 34.0 105.3 1.98 3.43
15 35.5 82.6 1.58 2.52 39 37.0 106.1 2.00 3.48
16 27.5 83.9 1.58 2.51 40 27.0 106.7 2.13 3.55
17 34.5 85.0 1.63 2.58 41 28.0 107.8 2.14 3.65
18 27.5 86.0 1.57 2.68 42 31.0 108.8 2.28 3.53
19 29.0 86.9 1.61 2.65 43 25.5 109.6 2.10 3.53
20 37.0 87.9 1.70 2.82 44 29.0 110.5 2.13 3.60
21 40.0 88.7 1.60 2.83 45 31.5 111.0 2.35 3.80
22 29.0 89.8 1.81 2.83 46 27.0 111.8 2.33 3.65
23 40.0 90.8 1.67 2.85 47 29.0 112.7 2.53 3.73
24 27.0 93.0 1.95 3.05 48 37.0 113.7 2.68 3.65
 Deriving twisting process parameters of large package E-glass yarn
samples is taken every 3,500 m of yarn unwound, and the
yarn twist T is tested by the untwist–retwist method. The
twist of each group is tested five times, and the average
value of five times is taken as the twist test result of this
group. A total of 48 sets of twist data are measured for the
whole bobbin yarn. As shown in Table 1, it is known that
the twist of the bobbin yarn is 31.8 T/m.
During each unwinding stage of bobbin yarn, after
sampling and yarn twist test are completed, the loop
pitch and diameter of bobbin yarn are measured with a
steel ruler. To reduce the measurement error of the loop
pitch, the sum of the loop pitch of 20 loops of yarn is
measured at a time and then divided by 20, which is
the measurement result of the loop pitch of this layer of
yarn. The position of the yarn unwound from the first
loop with a black marker is marked as the starting line;
manually unwind the yarn for 20 loops, then the position
of the yarn on the 20th loop is marked as the finishing
line with a marker, and then the pitch between the
starting line and the finishing line is measured with a
steel ruler. As shown in Figure 3, 1/20 of the measured
value is the loop pitch value of this group. When the yarn
moves up one by one during unwinding, the measured
loop pitch is the elevating loop pitch Pu of bobbin yarn,
and then the unwinding is continued until the yarn
moves down one by one, and the above operations are
repeated, and the measured loop pitch is the descending
loop pitch Pd of bobbin yarn, and vice versa. After testing
the loop pitch at each unwinding stage, the current dia-
meter dx of bobbin yarn is measured at once. Therefore,
Figure 3: Measurement of the loop pitch of bobbin yarn.
 5
the measurement results of the physical properties of
bobbin yarn shown in Table 1 are obtained.
4 Calculation of twisting process
parameters
After obtaining the data of bobbin yarn twist, loop pitch,
and its corresponding diameter, the twisting spindle
speed can be calculated according to equation (6) only
by determining the traveler speed. On the glass fiber
twisting machine, the elevating speed of the traveler
and the descending speed of the traveler can be input,
respectively, but the two input speed values are constant
and will not change during the whole twisting process
[16]. In addition, due to the limitation of equipment per-
formance and the working conditions of the traveler plate
counterweight, the elevating and descending speed of
the traveler should not be too high. Generally, twisting
machine manufacturers will limit the elevating and des-
cending speed of the traveler to a certain numerical
range, such as Verdol twisting machine limiting the traveler
speed to 2 m/min, and the Volkmann twisting machine
allowing the traveler speed to be input to be less than
4 m/min. The limit of the traveler speed can limit the
deriving ratio of spindle speed to the traveler speed within
a reasonable range, thus making the calculation of twisting
process parameters more accurate.
As the equipment used to verify the process para-
meters in Section 5 is Verdol twisting machine, and con-
sidering the stability of the equipment operation, it is
assumed that the traveler speed is 75% of the maximum
allowable value of the equipment when calculating the
twisting process. As shown in Table 1, the descending
loop pitch Pd is greater than the elevating loop pitch Pu ,
indicating that the descending speed of the traveler is
greater than the elevating speed of the traveler, that is,
Vgd = 1.5 m/ min. Combined with traveler speed equation
shown in equation (6), the spindle speed of each testing
stage can be calculated by equation (8), as shown by the
blue data points in Figure 4.
1.5πdxT
Nd = . (8)
Pd
The calculated spindle speed data are fitted by the least
square method to obtain the red straight line in Figure 4. The
fitting equation is y = 5,015 − 9.92x , and the goodness of fit
is R2 = 0.577 . Because the number of tests is 48, that is,
x = 47, it is found that the spindle speed linearly decreases
from 5,015 to 4,550 rpm during twisting.
6  Xi Wang et al.

Figure 4: Data fitting of spindle speed.

After the spindle speed is determined, the elevating Table 2: Twisting process parameters of D450 E-glass yarn
speed of the traveler can be calculated by equation (6). As
shown in Figure 5, the blue curve is the calculation result Process parameters Values
of the elevating traveler speed Vgu , and the red curve Yarn twist T 31.8 T/m
represents the descending traveler speed Vgd . Initial bobbin diameter d0 67.5 mm
Take the average of the elevating traveler speed in Full bobbin diameter dmax 113.7 mm
Figure 5, that is, Vgu = 0.91 m/ min. Therefore, the twisting Bobbin yarn height H 293.0 mm
process parameters of D450 E-glass yarn can be calcu- Spindle speed Nd 5,015–4,550 rpm
lated, as shown in Table 2. Elevating traveler speed Vgu 0.91 m/min
Descending traveler speed Vgd 1.50 m/min

machine. The accuracy of the calculation can be verified

5 Verification of twisting process
parameters
According to the process parameters calculated in Table 2,
a twisting experiment is carried out on a Verdol twisting
by monitoring the real-time rotation speed of the roving
cake during the twisting process, measuring the actual
loop pitch of the bobbin yarn after the twisting is com-
pleted, and comparing the actual value with the predicted
value.

Figure 5: Calculation result of elevating traveler speed.

 Deriving twisting process parameters of large package E-glass yarn
Figure 6: Comparison between predicted and actual roving cake speed.
Whether the Verdol twisting machine or Volkmann
twisting machine, the control unit of the equipment can
display the real-time rotating speed of the roving cake
during the twisting process, and the theoretical rotating
speed of the roving cake can be calculated by equation
(4). In the twisting experiment, the initial diameter of the
roving cake is 329 mm, which gradually decreases to
306 mm during the twisting process. Meanwhile, the twist
and spindle speed data in Table 2 are substituted into
equation (4), and the predicted value of the roving cake
speed is calculated. By monitoring and recording the
real-time rotation speed of the roving cake, it is compared
with the predicted rotation speed of the roving cake, as
shown in Figure 6.
By comparing the predicted value and the actual
value of the roving cake speed in Figure 6, it is found
that the theoretical rotation speed of the roving cake is
very close to the actual monitoring result, and the pre-
diction error is less than 0.4%, which indicates that the
Figure 7: Comparison between predicted and actual loop pitch.
 7
analysis and derivation of the twisting principle of
E-glass yarn in Section 2 is accurate and reliable.
When the twisting experiment is finished, the ele-
vating and descending loop pitch of the experimental
bobbin yarn are measured by the same method as in
Section 3. The data of twist, diameter, spindle speed,
and traveler speed in Table 2 are substituted into equa-
tion (6) to calculate the theoretical loop pitch. The pre-
dicted value and the actual value of the elevating and
descending loop pitch of bobbin yarn are compared, as
shown in Figure 7.
By comparing the predicted value and the actual
value of the elevating and descending loop pitch of
bobbin yarn in Figure 7, it is found that the theoretical
loop pitch of bobbin yarn is consistent with the actual
measurement result, and the error between the predicted
value and the actual value is less than 1.1%, which indi-
cates that the deriving method of twisting process para-
meters has a precise result.
8  Xi Wang et al.
6 Discussion
In Section 4, the linear fitting method is adopted to cal-
culate spindle speed data, and the calculated spindle
speed is also in good agreement with the experimental
results. However, for different types of E-glass yarn, there
may be a multi-section spindle speed scheme. Verdol and
Volkmann twisting machine can set the spindle speed of
up to ten sections, and the spindle speed in each section
can be controlled according to the yarn twisting length,
but the spindle speed in each section can only change
linearly or remain constant. By setting the twisting spindle
speed in sections, various influencing factors such as pro-
ductivity and yarn tension can be taken into account
together [17], and more accurate control of the twisting
process can be realized.
Besides, when setting the twisting process parameters
of E-glass yarn, in addition to the main parameters such as
yarn twist, spindle speed, and the elevating and des-
cending speed of the traveler, it is also necessary to input
the diameter of the roving cake at the beginning and end.
Because the diameter of the roving cake gradually
decreases during twisting, the glass fiber twisting machine
will gradually increase the rotation speed of the roving
cake according to the input diameter of the roving cake
to keep the yarn twist stable. Generally, the diameter of the
roving cake is input according to the actual measured
value. For example, the diameter of the roving cake input
in Section 5 is 329–306 mm. However, due to various pro-
cess methods such as covering and stacking layer by layer
during the formation of the roving cake, the diameter
of the roving cake may not change linearly when it is
unwound, so the actual diameter of the roving cake may
not be conducive to the stability of the yarn twist. According
to the roving cake forming process, it may be better to adjust
the input roving cake diameter value appropriately. When
the roving cake is covered layer by layer, the minimum
diameter of the roving cake can be appropriately increased.
When the roving cake is stacked layer by layer, the maximum
diameter of the roving cake can be appropriately reduced.
The study on the diameter change law of the roving cake
during unwinding will help to obtain more accurate values.
7 Conclusion
Based on the research on the twisting principle of large
package E-glass yarn, this article reveals the relationship
between the physical properties of bobbin yarn and the
twisting process parameters and proposes a method to
derive the spindle speed and the traveler speed by mea-
suring the twist, loop pitch, and its corresponding dia-
meter of bobbin yarn. By unwinding and measuring the
D450 E-glass yarn with 31.8 T/m, it is found that the
twisting spindle speed linearly decreases from 5,015 to
4,550 rpm, the elevating speed of the traveler is 0.91 m/min,
and the descending speed of the traveler is 1.50 m/min.
And then, the twisting experiment is carried out on a
Verdol twisting machine. By monitoring the real-time
rotating speed of the roving cake during the twisting pro-
cess and measuring the actual loop pitch of bobbin yarn
after twisting, it indicates that the prediction error is less
than 1.1%. By this method, the twisting process parameters
of large package E-glass yarn can be derived effectively,
providing a reference for the twisting process design scheme
of glass fiber strand manufacturers.
Acknowledgement: This work was supported by the Science
and Technology Research Project of Education Department of
Jiangxi Province (grant number GJJ2202801).
Conflict of interest: Authors state no conflict of interest.
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