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DOI: 10.1177/00405175080907802009 79: 548Textile Research Journal Zheng-Xue Tang, Lijing Wang, W. Barrie Fraser and Xungai Wang

In-situ Tensile Properties of a Ballooning Staple Yarn

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Textile Research Journal Article

Textile Research Journal Vol 79(6): 548554 DOI: 10.1177/0040517508090780 www.trj.sagepub.com 2009 SAGE Publications

Figures 1, 2 appear in color online: http://trj.sagepub.com Los Angeles, London, New Delhi and Singapore

In-situ Tensile Properties of a Ballooning Staple YarnZheng-Xue Tang and Lijing WangCentre for Material and Fiber Innovation, Deakin University, Geelong, VIC 3217, Australia

W. Barrie Fraser School of Mathematics and Statistics, The University of Sydney, Sydney, NSW 2006, Australia

Xungai Wang 1Centre for Material and Fiber Innovation, Deakin University, Geelong, VIC 3217, Australia

Yarn breakage (or ends-down) in ring spinning and other

industrial processes involving yarn ballooning reduces yarnproductivity and adds significantly to the cost of yarn pro-duction. The probability of yarn breakage is related to thestrength of a ballooning yarn and the maximum tension inthe yarn during processing. In order to reduce yarn break-age rate, many researchers have studied yarn tensile proper-ties after the yarn is spun, because it has been challenging tomeasure the breaking force and elongation of a ballooning

yarn during ring spinning. Yet it is the in situ tensile proper-ties of a yarn that govern its ability to withstand the spinningtension.

Ramey et al. [1], Frydrych [24] and Pan et al. [5] inves-tigated the relationships between the tenacities of cotton

fibers and yarns. Cheng and Adams [6] and Zeng et al. [7]predicted yarn tenacity based on fiber properties using neu-ral networks. Lizk [8] and Mandl [9] investigated the effectof test length on the yarn breaking force. Aggarwal [10]established a model to estimate the breaking elongation of highly twisted singles ring spun cotton yarns from fibercharacteristics. Majumdar and Majumdar [11] discussedthe methods of predicting breaking elongation of ring spuncotton yarns. Zurek et al. [12] proposed a method to predictthe tenacity and elongation of cotton yarns.

Several attempts have been made in the past to quantify

yarn tension during spinning. Zhu et al. [13, 14] measuredspinning tension using a rubber string and polyester yarnson a Balloon Test System (BTS). Sharma and Rahn [15]measured yarn tension using polyester filaments on the BTS

with a balloon control ring. Skenderi et al. [16] established aprocedure to determine yarn tension under limited condi-tions. Recently, Tang et al. [17] investigated tension in bal-looning cotton and wool yarns using a purpose-built yarnballooning rig. The tension in a ballooning yarn was alsostudied with a dynamic analysis [1821]. 1

However, the above studies did not consider the effect of yarn rotating speed and ballooning on yarn breaking forceand elongation. While there have been studies on yarn

breaking force in the yarn formation zone (i.e. the twist tri-angle) [2224], both the breaking force and elongation of aballooning yarn in ring spinning have not been reported.

The aim of this paper was to clarify if yarn rotatingspeed has any effect on the breaking force, tenacity and

Abstract This study investigated the tensileproperties of a rotating or ballooning staple yarn.The results indicated that the effect of rotatingspeed on the tensile properties of a ballooning sta-ple yarn was significant. As the yarn rotatingspeed increased, the tenacity of the rotating orballooning yarn decreased, while the yarn break-ing elongation increased. The effect of rotatingspeed on the tenacity of a ballooning staple yarn

varied for different yarns. These results demon-

strated that the breaking force of a ballooning yarn was much lower than the yarn breaking forceobtained from normal tensile tests. These resultsprovide new insight into the problems of yarnbreakage in yarn spinning and twisting processes.

Key words air drag, breaking force, elonga-tion, ring spinning, staple yarn, yarn ballooning

1 Corresponding author: Centre for Material and Fibre Innova-tion, Deakin University, Geelong, VIC 3217, Australia. Tel: +61 35227 2894, Fax: +61 3 5227 2539, e-mail: [email protected]

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In-situ Tensile Properties of a Ballooning Staple Yarn Z.-X. Tang et al. 549 TR

elongation of ballooning staple yarns. We measured thebreaking force and elongation of different yarns, while bal-looning, using a yarn ballooning rig at various rotatingspeeds. The results were compared with those obtained fromnormal yarn tensile tests.

We should point out that the yarn ballooning rig we usedcould only provide an approximate simulation of real yarnballooning process in ring spinning, since there was no trav-eller mass so that the boundary conditions were much sim-pler. In addition, the rotating speed of the ballooning rig wasless than the actual yarn ballooning ring spinning, so that the

yarn tensions we could generate on the rig were somewhatlower than in commercial ring spinning. Our main objective

was to examine the effect of balloon dynamics on yarn tenac-ity. The basic observation derived from this work should beapplicable to high speed ballooning processes.

ExperimentalWe used a LLOYD tensile tester and a purpose-built yarnballooning rig (see Figure 1 [25]) to measure the breakingforce of a ballooning yarn at three rotational speeds (2,000rpm, 4,000 rpm and 5,500 rpm) and two extension rates (200mm/min and 500 mm/min). Details of the experimental set-up can be found elsewhere [17]. Three types of yarns withdifferent counts 38.0 tex cotton single yarn, 50.4 tex cottontwo-fold yarn and 70.1 tex pure wool two-fold yarn wereused for the experiments. All yarns were stored understandard conditions (20 2 C and 65 2 % RH) for over24 hours and all tests were performed under the standardenvironment. We repeated each of the tests up to 12 timesand then reported the average values for the test in thispaper. The initial yarn length was set at 500 mm for all tests.

We also conducted normal yarn tensile tests using anUSTER TENSORAPID 3, at a gauge length of 500 mm andtwo yarn extension speeds of 200 mm/min and 500 mm/min.For each yarn type, the number of tests was set at 50. Weused the average yarn breaking force and elongation torepresent that of the corresponding ballooning yarn at arotating speed of zero.

Results and DiscussionStates of a ballooning staple yarn at breakFigure 2 displays an example of the breaking process of a38.0 tex cotton ballooning yarn. Figure 2(a) shows a typicalballoon about halfway from the normal yarn balloon to yarnbreakage. Figure 2(b) shows the instant before the yarnbreakage. It is worth noting that the yarn segment betweenguide-eye and rotating eyelet was not a straight line, whichalso happens in actual ring spinning. This was due to the air

drag on the ballooning yarn. Therefore, the effect of rotat-ing speed, which generates air drag on the ballooning yarn,on the breaking force of a ballooning staple yarn should notbe neglected. Figure 2(c) shows the instant after the yarnbreakage. The upper part of the balloon could be seen tohave multi-loops as tension in the ballooning yarn was sud-denly released. Figure 2(d) shows one situation after yarnbreakage.

It was observed that yarn breakage rarely happened in a

ballooning yarn if the maximum balloon diameter wasgreater than the ring diameter, unless yarn snarling occurred[25].

Breaking force of a ballooning staple yarnTable 1 gives a comparison of yarn tenacity for the bal-looning 38.0 tex cotton single yarn, 50.4 tex cotton two-fold yarn and 70.1 tex wool two-fold yarn at varying rotat-ing speeds. These results confirmed that yarn tenacitydecreased with an increase in yarn rotating speed. Further-

Figure 1 Experimental set-up for investigating the ten-sile properties of a ballooning yarn [25].



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550 Textile Research Journal 79(6)RJRJ

more, the effect of rotating speed on the tenacity of a sin-gle staple yarn was larger than that on the tenacity of atwo-fold staple yarn. When yarn extension speed washigher, the effect of rotating speed on yarn tenacity was

weaker. A ballooning yarn with specific type and count corre-

sponds to a unique value of normalized air drag coefficienton the yarn [26]. Figure 3 displays the relationships betweenthe breaking force of a ballooning staple yarn and rotatingspeed, in which the normalized air drag coefficients of the38.0 tex cotton single yarn, 50.4 tex cotton two-fold yarn

and 70.1 tex wool two-fold yarn were 5.0, 4.0 and 3.3,respectively [27]. From the regression models in Figure 3,

when the yarn extension speed was at 200 mm/min and therotating speed increased from 0 (i.e. in the condition of anormal tensile test) to 10,000 rpm, the breaking forces of the 38.0 tex cotton yarn, 50.4 tex cotton yarn and 70.1 tex

wool yarn decreased 33.5 %, 14.2 % and 13.4 %, respec-tively. When the yarn extension speed was at 500 mm/minand the rotating speed increased from 0 to 10,000 rpm, thebreaking forces of the 38.0 tex cotton yarn, 50.4 tex cotton

yarn and 70.1 tex wool yarn decreased 27.6 %, 6.7 % and1.7 %, respectively. Therefore, for the same yarn extensionspeed, the higher the normalized air drag coefficient on aballooning yarn, the weaker the yarn became with increasingrotating speed. This was particularly obvious for the finest

yarn examined. The breaking force of a ballooning staple yarn increased when yarn extension speed increased, which was similar to what happened in a normal tensile test (i.e.the rotating speed = 0 in Figure 3). The error bars in Fig-ure 3 represent the 95 % confidence intervals for the mean

values.

Qualitative analysis of the breakage of aballooning staple yarnThe tension in ballooning 38.0 tex cotton single yarn, 50.4tex cotton two-fold yarn and 70.1 tex pure wool two-fold

yarn was investigated in our previous work [17]. We havereproduced the yarn tension results in Figure 4 so that theycan be discussed in the context of yarn breakage. For thesame rotating speed, tension in a ballooning yarn increases

when the ratio of yarn-length in the balloon to balloon-height ( ) decreases within the yarn-length range. When

is less than 1.03, the tension at guide-eye increasesrapidly and it may cause yarn breakage. However, when

is greater than a specific value (which depends on the yarn type and count), yarn breakage may also occur due to yarn snarling in the balloon (see Tang et al. [25] for moredetails).

Table 1 Comparison of the tenacities of three ballooning staple yarns.

Yarn tenacity [cN/Tex]Rotating speed [rpm]

0* 2,000 4,000 5,500

Y a r n e x

t e n s i o n s p e e

d

[ m m

/ m i n ]

200

38.0 tex cotton single yarn 6.60 6.17 5.54 5.48

50.4 tex cotton two-fold yarn 13.05 12.99 12.87 11.76

70.1 tex wool two-fold yarn 6.98 6.94 6.74 6.40

500

38.0 tex cotton single yarn 7.14 6.86 6.25 6.13

50.4 tex cotton two-fold yarn 14.11 13.89 13.84 13.52

70.1 tex wool two-fold yarn 7.21 7.19 7.18 7.13

*Data obtained from a normal tensile test.

Figure 2 Breaking process of a 38.0 tex cotton singleyarn at a rotating speed of 5,500 rpm with a yarn exten-sion speed of 500 mm/min during simulated ring spin-ning. (a) A typical balloon about halfway from the normalyarn balloon to yarn breaking; (b) the instant before yarnbreakage; (c) the instant after yarn breakage; and (d) onesituation after yarn breakage.

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Figure 4 displays the relationships between yarn tension atguide-eye and rotating speed when = 1.03. It shows that

yarn tension increased when the rotating speed increased.This agreed with previous results [28]. Furthermore, the

coarser (and hairier) ballooning yarn had higher tension inthe yarn. This result was expected because there was alarger air drag on the yarn [29], which led to higher yarntension.

Figure 3 A comparison of breakingforce against rotating speed withvarious yarn extension speeds ( experimental data regression, ---theoretical prediction).

Figure 4 A comparison of yarn

tension at guide-eye against rotat-ing speed when = 1.03 ( experimental data regression, ---theoretical prediction).

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From the theoretical predictions (from the regression

analysis of the experimental results) in Figures 3 and 4, at arotating speed of 10,000 rpm, the breaking force was166.87 cN and the maximum tension (at = 1.03; itshould be noted that, generally speaking, 1.03 in anormal ring spinning process) was 63.00 cN for the 38.0 tex cotton single yarn. The breaking force was 564.35 cN andthe maximum tension was 85.00 cN for the 50.4 tex cottontwo-fold yarn, and the breaking force was 423.51 cN andthe maximum tension was 130.00 cN for the 70.1 tex wooltwo-fold yarn. Therefore, in normal ring spinning, yarn

breakage should not occur in the balloon unless there are

some gross defects in the yarn. This agreed with previousfinding that yarn breakage rarely occurs in a ballooning yarn in ring spinning [28].

However, when the rotating speed was greater than10,000 rpm and continuously increased, the differencebetween the breaking force of a ballooning staple yarn andthe tension in the yarn reduced quickly, so the breakagechance of the ballooning yarn increased. Table 2 shows thatthe maximum tension at guide-eye of a ballooning 38.0 tex cotton single yarn at rotating speed of 14,000 rpm was very

Table 2 Comparison of yarn breaking force with yarn tension obtained from theoretical predictions in Figures 3 and 4.

38.0 tex cotton yarn 50.4 tex cottontwo-fold yarn70.1 tex wooltwo-fold yarn

Breaking force*

[cN]

Max tension #

[cN]

Breaking force*

[cN]

Max tension #

[cN]

Breaking force*

[cN]

Max tension #

[cN]

R o

t a t i n g s p e e

d

[ r p m

]

10,000 166.87 063.00 564.35 085.00 423.51 130.00

12,000 150.27 090.72 543.55 122.40 409.31 187.20

14,000 133.67 123.48 522.75 166.60 395.11 254.80

16,000 117.07 161.28 501.95 217.60 380.91 332.80

*Breaking force at yarn extension speed of 200 mm/min. #Max tension was the yarn tension at guide-eye when the ratio of yarn-length to balloon-height was 1.03.

Figure 5 A comparison of yarn elongation against rotating speed. (a) Yarn extension speed = 200 mm/min and (b) yarnextension speed = 500 mm/min.

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close to the breaking force of the yarn. Furthermore, whenthe yarn rotating speed was at 16,000 rpm, the yarn tension

was greater than the yarn breaking force, so yarn breakage would happen under this condition. The data also showedthat the finer the ballooning staple yarn, the higher thechance of yarn breakage.

Elongation of a ballooning staple yarn

Figure 5 displays elongation at break against rotating speedfor the three ballooning staple yarns. The yarn elongationincreased when yarn rotating speed increased. Figure 6 dis-plays the elongation property of the three ballooning yarnsat a rotating speed of 2,000 rpm with a yarn extension speedof 500 mm/min. Figure 6(b) shows that the yarns were ten-sioned at the beginning of the tests due to air drag on theballooning yarns. The tension at guide-eye was 2.34 cN for38.0 tex cotton single yarn, 3.94 cN for 50.4 tex cotton two-fold yarn and 18.40 cN for 70.1 tex wool two-fold yarn.These were different from the situations in a normal tensiletest. It was likely that the air drag acting on the entire yarnlength helped sustain the yarn elongation process.

Conclusion

This study investigated the breaking force, tenacity andelongation of three ballooning staple yarns. The results aresummarized as follows:

1. The breaking force of a ballooning yarn decreased when the yarn rotating speed increased. In particu-lar, it was observed that a ballooning fine yarn mayreduce its breaking force by up to one-third at arotating speed of 10,000 rpm.

2. The effect of rotating speed on the tenacity of a sin-gle yarn was larger than that on the tenacity of a two-fold yarn. A general trend was that as the yarn exten-sion speed increased, the yarn tenacity increased andthe effect of rotating speed on yarn tenacity was weaker.

3. The breaking elongation of a ballooning yarn increased with increasing yarn rotating speed.

These results add to our understanding of yarn failure inthe dynamic processes of yarn twisting. In the analysis of

yarn breakage in high speed yarn twisting or ballooningprocesses, it is the in situ strength of the yarn that willdetermine the probability of yarn failure, and this in situ

strength is different from that obtained from a normal yarntensile test.

AcknowledgmentThis work was funded by a grant from the AustralianResearch Council (ARC) under its Discovery Project scheme.The first author was supported by the grant as an ARC Post-doctoral Fellow.

Figure 6 Curves of the tensile force against percent elongation of three staple yarns at a rotating speed of 2,000 rpm andyarn extension speed of 500 mm/min. (a) Full range and (b) initial part.



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