Practical measurements 4

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4 Practical measurements ....................................................................... 4.1

4.1 Trials with splices........................................................................................................................4.1

4.2 Effect of periodic mass variations on tensile force .................................................................4.2
4.3 Loop testing .................................................................................................................................4.3
4.4 Effect of periodic faults on elongation with spun yarns .........................................................4.4
4.5 Quality management in a cotton spinning mill.........................................................................4.5
4.6 Effect of long-term mass variations ..........................................................................................4.7
4.7 Start-up of a spinning process for filament yarns ...................................................................4.9
4.8 Measurement of drawn polyester ............................................................................................4.14
4.9 Hysteresis tests .........................................................................................................................4.15
4.10 Retardation test .........................................................................................................................4.16
4.11 Relaxation test ...........................................................................................................................4.17
4.12 Quality management in a filament yarn spinning mill ...........................................................4.17
4.13 Quality management for ply yarns...........................................................................................4.19
4.14 Investigations in a monofilament spinning plant...................................................................4.21
4.15 Selection of a report for routine tests in a spinning mill.......................................................4.23
4.16 Explanation of terms in the report ...........................................................................................4.24

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4 Practical measurements

4.1 Trials with splices

A yarn, 100% combed cotton, count 12 tex (Nm 83, Nec 50), is required to be spliced at the winder.
In order to ensure that the splice satisfies the requirements set for the yarn, 200 splices were tested
in terms of tensile strength with an automatic tensile testing instrument. The results were compared
with the same yarn which had neither been knotted nor spliced.

Fig. 4-1 shows the frequency distribution diagram of the yarn before winding. The breaking tenacity
was 17.5 cN/tex, the coefficient of variation CVFH was 11.4%.

Fig. 4-2 shows the frequency distribution diagram of the spliced yarn. The breaking tenacity, in this
case, was 15.05 cN/tex, the coefficient of variation CVFH was 20.8%.

In both cases, 200 tests were carried out. The splices were cut out of the yarn and measured by
means of the single yarn control arrangement.

0 5 10 15 20 25 30 35
F (cN)
60

critical 80
values
100
0 5 10 15 20 25 30 35
F (cN) 120 cN 120

140

160 160

180 x = 180,6 cN 180

200 200
x = 210 cN
220 220

240 240

260 260

280

300

Fig. 4-2
Fig. 4-1
Splices
Yarn being compared

Measured results below 120 cN were considered as critical values because values in this range in-
crease the probability of end breaks during weaving. In this case, 10 results or 5% of all values were
below this critical limit. The values under the critical limit can be counted in the frequency distribution
diagram or, by setting the lower limit value at 120 cN, these can be calculated by the testing installa-
tion. The mean value of breaking force of the splices was at approx. 14% below that of the non-
spliced yarn.

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4.2 Effect of periodic mass variations on tensile force

In this example, it will be shown that the short periodic variations can also influence the tensile force.

The influence of these periodic mass variations on the appearance of a woven fabric can be seen in
the photograph shown in Fig. 4-3. The fault results in a quite distinct stripiness.

Fig. 4-3

After having tested the OE rotor yarn with an evenness tester it could be recognized that the yarn has
a strong periodic mass variation with a wavelength of 12 cm. It is the result of a contaminated rotor
groove. The spectrogram of the yarn is shown in Fig. 4-4.

Fig. 4-4

This periodic fault also affects the tenacity and the elongation of the yarn. As the frequency of this
fault is high the distance of the clamps has no effect on the test result, because the fault occurs 4
times within a specimen length of 50 cm. The comparison of the strength and elongation results with
a fault-free yarn has shown the following differences:

cN/tex CVFH eH CVEH

Fault-free yarn 14,1 5,95% 7,8% 5,1%

Faulty yarn 11,3 7,98% 6,2% 7,2%

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4.3 Loop testing

In a sewing thread manufacturing plant one would like to test the suitability of a two-fold yarn for
sewing purposes. In this respect, one is interested not only in the breaking force and the corre-
sponding elongation, but also in the loop tensile force because the testing of the loop tensile force
provides directives with respect to what is possible in terms of loading the two-fold yarn when this is
applied to sewing. The loop tensile force is determined under single yarn control conditions as re-
ferred to in Fig. 4-5.

With this test, a loop is formed with a yarn length of approx. Upper clamp
80 cm, such that the loop is positioned at approximately the
middle of the measuring zone, and two ends are fixed in the
upper clamp. A similar yarn sample is fixed in the lower
clamp, whereby this yarn is first threaded through the loop of
the upper yarn.

Lower clamp

Fig. 4-5

In this test, a 60 tex x 2 (Nm 17/2, Nec 10/2) yarn has been used. In total, 100 measurements were
carried out. The following table shows a comparison of the values of force and elongation between
normal testing and loop testing.

Characteristics Normal testing Loop testing

Breaking force 27.2 N 41.1 N

CVFH 3.67% 8.44%

Breaking elongation 13.50% 10.60%

CVEH 2.79% 6.82%

With loop testing, the force values are higher and the elongation values lower than with normal test-
ing. On the other hand, the coefficient of variation values CV, both for force and for elongation, are
higher in the case of loop testing. In the case of loop tensile testing one would expect that the
strength will be twice the amount of the single yarn test. However, this is not the case, because the
total yarn length between the clamps is also twice the length of a single yarn, and, therefore, the
probability of a weak place in the sample is higher.

In this factory, knot strength in technical yarns which are used for nets is also tested in a similar man-
1
ner. The loop testing is set out as a standard test method .

1
For instance, under the term "Loop tensile testing" according to DIN 53843

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4.4 Effect of periodic faults on elongation with spun yarns

The following example shows how periodic faults in spinning mills can also affect the strength of spun
yarns.

Fig. 4-6 shows the evenness diagram of a rotor yarn, 100% PAN, 31.3 tex (Nm 32, Nec 19). The dia-
gram shows a periodic mass variation with a wavelength of about 13 m.

Fig. 4-6

The spectrogram, Fig. 4-7 also shows a strong periodic mass variation with a wavelength of 13 m.

Fig. 4-7

The fault was caused by a defective front roller of the finisher drawframe.

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Fig. 4-8 and Fig. 4-9 show the stroke diagrams of force and elongation. Here it is interesting to notice
that in the stroke diagram of the elongation, Fig. 4-9, the above mentioned fault could not be recog-
nized as well as in the stroke diagram of the force, Fig. 4-8.

Fig. 4-8

Fig. 4-9

The coefficient of variation of the elongation of 8,2% of the faulty yarn can hardly be distinguished
from the fault-free yarn. However, in the case of the coefficient variation of the force of the faulty yarn
equals 12,6% and is nearly twice as much as the V of the fault-free yarn.

4.5 Quality management in a cotton spinning mill

In an OE rotor spinning mill a blended yarn (75% cotton, 25% polyester) is produced. The count is 20
tex (Nm 50, Nec 30). The limit values for this yarn were determined after months of trials. In this
spinning mill it was also known that small deteriorations of quality characteristic can have fatal effects
on subsequent processes. Therefore, apart from the strength and elongation the spinning mill also
introduced limit values for the coefficient of variation.

Fig. 4-10 shows the diagram of the mass variations. Fig. 4-11 is the spectrogram of the same yarn.
Both diagrams show a periodic yarn fault. The stroke diagram of the force also represents the strong
periodic variations of the force (upper stroke diagram, Fig. 4-12).

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The stroke diagram of the elongation (lower stroke diagram, Fig. 4-12) does not show the periodic
fault as intensively as the stroke diagram of force.

Fig. 4-10

Fig. 4-11

Fig. 4-12

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Breaking force FH CVFH Breaking CVEH

Mean elongation EH
mean
Allowed limit values 250 cN <10% 7% <12%
Values from the sample 243 cN 18.3% 6.38% 10.0%

The breaking force as well as the breaking elongation are below the limit values. The periodic mass
variation can easily be seen in the diagram (Fig. 4-10). The spectrogram indicates that the fault has a
wavelength of 25 m. The most considerable deviation from the limit value can be recognized by the
coefficient of variation of the breaking force (18,3% instead of less than 10). The coefficient of varia-
tion the elongation is less significant and lies within the allowed range.

The periodic fault is caused by the front roller of the finisher drawframe.

4.6 Effect of long-term mass variations

In a ring spinning mill a yarn of the following characteristics is produced: Count 11,8 tex (Nm 85, Nec
50), 100% cotton. With the evenness tester in the laboratory the fault according to
Fig. 4-13 was found. The diagram is characterized by strong periodic mass variations over a length of
20 m. Afterwards, over a length of 40 m the diagram does not show the fault anymore. The fault
length equals 60 m.

Fig. 4-13

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Fig. 4-14

Both stroke diagrams breaking (upper Fig. 4-14) force and breaking elongation (lower Fig. 4-14) are
considerably affected by this fault. Whenever the fault occurs the force as well as the elongation drop
by more than 50%.

The origin of the fault was a defect of the front roller of the ring spinning machine on one side, and
whenever the fiber assembly is brought to the defective position by the reversal mechanism it leads
to an intensive mass variation.

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4.7 Start-up of a spinning process for filament yarns

Fig. 4-15 shows the results of a partially oriented polyester yarn, count dtex 283f32.

Fig. 4-15

Description of the individual columns:

Time to break Time from the pretension to breaking force

B-Force Breaking force
Ref.F 25% Breaking force at 25% elongation
Ref.F 50% Breaking force at 50% elongation
Ref.F 100% Breaking force at 100% elongation
Elong Elongation at breaking force
Ref.E 2N Elongation at a force of 2 N ( » 0.2 kgf)
Tenac Tenacity
B-Work Work done to break
Work 50% / 75% Part work between the elongation values 50 and 75%
Modul Ch 10cN/tex / 15cN/tex Tangent modulus. Tangent is defined between the tenacity values 10 and 15
cN/tex

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Modul S 75% / 95% Tangent modulus. Tangent defined between the elongation values 75 and 95%

Modul 0% Initial modulus when pretension is reached

NDR Extens. Natural draw ratio, elongation
NDR Load Natural draw ratio, force
NDR Ratio Natural draw ratio, ratio of elongation
NDR Stress Natural draw ratio, ratio of tenacities
Y-Point Load 0.2% Strength at yield point 0,2%
Y-Point Strain 0.2% Elongation at yield point 0,2% if there is no peak available at the beginning of
the FE-diagram (see also description for Fig. 2.41).
Y-Point Stress 0.2% Tenacity at yield point 0,2%

Fig. 4-16 represents the stroke diagram of the force of the same yarn. Fig. 4-17 is the corresponding
stroke diagram of the elongation.

Fig. 4-16 Fig. 4-17

In both diagrams only the envelope is represented in order to better indicate deviations from the
nominal value.

Fig. 4-18 represents the force-extension diagram of the same yarn. Fig. 4-19 is the corresponding
modulus-extension diagram.

Fig. 4-19
Fig. 4-18

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Fig. 4-20 shows the histogram of the breaking force.

Fig. 4-20

Fig. 4-21 shows the histogram of the breaking elongation.

Fig. 4-21

The histograms indication whether the force and the elongation are normally distributed and whether
outsider values are available.

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Other representations of the force-extension diagrams:

Fig. 4-22 shows a typical force-extension diagram which is calculated after 500 individual tests. The
grey zone represents the variation of the individual values.

Fig. 4-22

Fig. 4-23 shows the mean force-extension diagram of also 500 individual tests. The grey zone repre-
sents variation of the individual values.

Fig. 4-23

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Fig. 4-24 a scatter plot of all tests. Each dot represents a test. The corresponding histograms for
force and elongation are shown at the force and elongation scales. Color code: The first 20% of the
dots are printed in dark blue, the second 20% in light blue, afterwards in green, dark red and light
red. With this color code the sequence of the tests can be recognized.

Fig. 4-24

Fig. 4-25 and Fig. 4-26 represent the normal stroke diagrams of force and elongation.

Fig. 4-25

Fig. 4-26

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4.8 Measurement of drawn polyester

A filament yarn, drawn polyester, dtex 150f51, was tested with the USTER® TENSORAPID 4.
Fig. 4-27 shows the numerical results of the test.

Fig. 4-27

Fig. 4-28 and Fig. 4-29 show the force-extension diagram and the modulus-extension diagram of the
test. The typical flow range at the beginning of the test as shown with partially oriented polyester, Fig.
4-18, is not available anymore with drawn polyester (Fig. 4-28). The force-extension diagram is very
steep between the elongation range zero and 10% which also leads to high values in the modulus-
extension diagram (Fig. 4-29).

Fig. 4-28 Fig. 4-29

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4.9 Hysteresis tests

The USTER® TENSORAPID 4 allows the repetition of load cycles. With such tests the fatigue be-
havior of the yarn can be tested.

Fig. 4-30 represents the same yarn as shown under paragraph 4.8, i.e. polyester, dtex 150f51. The
following limits of the load cycles were selected: upper limit 2,5 N, lower limit 0,2 N. The strength
tester was set for 5 cycles.

Fig. 4-30

The same test can be carried out by entering 2 elongation values instead of force values. Fig. 4-31
shows such a hysteresis diagram whereas the upper limit of the cycles was set to 80%, the lower
value was 60%. The number of cycles was 5.

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Fig. 4-31

4.10 Retardation test

The retardation test was introduced to measure how a filament yarn reacts to a constant load over a
defined period of time. Fig. 4-32 shows the retardation diagram of the same filament yarn, dtex
150f51. The constant force applied on the yarn was 3.5 N, the duration was 30 seconds. The load
has caused an initial elongation of 107.3%. The elongation has changed from 107.3 to 133% during
this period.

Fig. 4-32

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4.11 Relaxation test

With the relaxation test a defined load is applied on the filament yarn. As soon as the defined load is
reached the elongation is kept constant for a predetermined period of time. The relaxation diagram
shows the deviation of the force.

The defined load applied in the relaxation diagram, Fig. 4-33, was 3.5 N. Material: Polyester, dtex
150f51.

Fig. 4-33

The force has dropped by 0.96 N after 30 seconds.

4.12 Quality management in a filament yarn spinning mill

In a filament yarn spinning mill a polyester filament yarn, dtex 156f51, is manufactured. After start-up
of the spinning process the individual process parameters are tested by means of the force-extension
diagrams of each spinning position (Fig. 4-34). After start-up it was decided to stop the printout of
force-extension diagrams and to do a permanent check by determining the part work between 40 and
70%, because the part work within this elongation range reacts considerably to process changes.

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Fig. 4-34

The following table shows the tolerated nominal values for this drawn polyester filament yarn and the
test values. Sample 50 packages.

Part work done DW Coefficient of variation

E = 40....70% CVDW
Allowed limit values 4100 ..... 4200 cNcm 0.....1.40%
Values from the sample 4125 cNcm 0.79%

In order to test the force-extension behaviour from zero to the 25% elongation the 4 reference values
at the elongation 1.5% 3% 10% and 25% are determined.

Coefficient of variation of
Elongation Reference force Fr
reference force CVFr

1.5% 0,55 N 1.87%

3% 1,17 N 1.75%
10% 1,57 N 1.53%
25% 2,25 N 2.61%

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4.13 Quality management for ply yarns

Ply yarns are also checked by means of force-elongation characteristic curve traces, and corrections
made to the yarn parameters by modifications to the manufacturing machines. Fig. 4-35 shows the
FE characteristic curves of a sample of 20 bobbins with reference to a two-fold ply yarn, yarn count
22 tex x 2 (Nm 45/2, Nec 27/2), 100% polyester.

Fig. 4-35

As from practical experience, it is known that the FE-characteristic curves have a relationship to each
other, i.e., that they only differ from each other in their inclination but do not cross over each other. A
very good quality check can be found by determining the part work done up to a point just below the
maximum breaking elongation, and this for that yarn having the lowest elongation. This procedure
was described in Section 2, Fig. 2-14 / Fig. 2-15, and serves for the numerical determination of dif-
ferences in the force-elongation characteristic curves.

The yarn with the lowest elongation was found, by previous trials, to have a maximum breaking elon-
gation of 28.5%. As the upper limit value for the work done, therefore, 25% elongation was chosen.

Material: 2-ply yarn, polyester 100%, 25 tex

Part work done DW Coefficient of variation

E = 0....25% CVDW
Allowed limit values 3300 ..... 3480 cNcm 0.....4.10%
Values from the sample 3438 cNcm 3.29%

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In the same factory, the force which will be exerted on a sewing yarn 22 tex x 2 (Nm 61/2, Nec 36/2),
polyester 100%, two-fold, during sewing is known to be in the lower range of the FE-characteristic
curve. As this refers to a particularly critical application, the FE-characteristic curve up to approx. 5%
elongation may only vary within quite close limits. A total of 50 package is always taken into consid-
eration in order to represent a sample. In order to institute quality control conditions in this particular
case, the calculation of the part work done DW and the corresponding coefficient of variation value
CVDW was made. The area corresponding to the part work done DW is shown shaded in Fig. 4-36.

Fig. 4-36

In this case, for quality control purposes, the limit values for part work done and coefficient of varia-
tion were set based on practical sewing trials.

Part work done DW Coefficient of variation

E = 0....5% CVDW
Allowed limit values 500 ..... 550 cNcm 0.....2.2%
Values from the sample 513 cNcm 1.72%

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4.14 Investigations in a monofilament spinning plant

In a monofilament yarn spinning plant monofilaments of dtex 133 are manufactured. Evenness tests
have shown that periodic mass variations are available. The wavelength was 6.4 m (Fig. 4-37). The
coefficient of variation was 0.75%.

Fig. 4-37

The spectrogram has shown that the monofilament has 3 periodic faults (Fig. 4-38). One fault can
also be seen in the diagram Fig. 4-37 and has a wavelength of 6.4 m. The second periodicity can be
recognized at a wavelength of 50 cm and the third at 6 cm. The peak at 3.2m is an upper harmonic of
the periodicity of 6.4 m and not a separate fault.

Fig. 4-38

After having carried out the strength tests it was obvious that the preset limits for the coefficient of
variation of strength and elongation were exceeded. The CV of force was 2.6%, the CV of elongation
was 10%. The analysis of the stroke diagrams has shown that most of the exceeding coefficient of
variation was caused by the periodicities with a wavelength of 6.4 m.

The stroke diagram of elongation, Fig. 4-39 (lower diagram), also shows a periodic variation whereas
the reaction on the stroke diagram of force can hardly be seen.

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Fig. 4-39

A systematic investigation in order to find the origin of the fault has shown that the fault was caused
by a defective reversal mechanism at the spinning package.

Fig. 4-40

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4.15 Selection of a report for routine tests in a spinning mill

An OE rotor spinning plant has to test several yarn samples every day. For this purpose the spinning
mill has decided for the following report for routine tests (Fig. 4-41):

Fig. 4-41

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4.16 Explanation of terms in the report

Header:
®
USTER TENSORAPID 4 1.5 Designation of the measuring system, software version V = 1.5
Fri 04.05.01 13:43 Date and time of the measurement
Operator Name of operator
Style Designation of the sample
Sample ID Identification of the test
Nom. Count Nominal count
Nom. Twist Nominal twist
Tests 10/200 Tests of 10 packages, 200 tests per package
v = 5000 mm/min Test speed 5000 mm/min
FV = 15 cN Pretension = 15 cN
LH = 500 mm Specimen length 500 mm at horizontal position of the clamps
P = 30% Clamp pressure 30%

Statistical values:
The table which was selected for routine tests include the columns time to break, breaking force,
elongation, tenacity and work done to break.

The statistical values include the mean of each column, the standard deviation s, th4 coefficient of
variation CV, the 95% confidence range Q 95% and the minimum and maximum value of a test series.

Graphical values:
The 2 blue diagrams are stroke diagrams for breaking force and elongation.

The multi-color diagram represents the force-extension diagram. The color code can be interpreted
as follows: The first 20% of the tests are printed out in dark blue, the second 20% are printed out in
light blue, the next 20% in green, the next 20% in dark red and the rest in light red.

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