Comparing Performance of 3D-Printed and Injection-Molded Fiber-Reinforced Composite Parts in Ring-Spinning Traveler Application

Fiber-reinforced 3D printing (3DP) technology is a recent addition to the material extrusion-based 3DP process unlocking huge potential to apply this technology for high-performance material fabrication with complex geometries. However, in order to take the full advantage of this technology, a comparative analysis with existing technologies targeting a particular application is necessary to understand its commercial applicability. Here, an applied composite part, ring-spinning travelers, has been developed using the unique design features of fiber-reinforced 3DP technology that is beyond the capability of the currently used technology; the injection molding, quality, and performance of the printed and molded travelers were investigated and compared. The results demonstrated that fiber-reinforced 3DP is a promising technology that offers a lot of flexibility regarding reinforcement patterns and materials including both short and continuous fibers to tailor the performance, although the printed travelers showed poorer surface characteristics and wear resistance than the molded travelers. Based on the present analysis, a number of recommendations have been proposed on the design of the traveler to apply the technology effectively and use the printer to improvise and manipulate the performance of the travelers.

Production of Fine Count Yarns from Some Extra-long Egyptian Cottons on Different Spinning Systems

The current research was carried out to produce fine count yarns from extra-long Egyptian cotton varieties using compact and ring spinning systems.in addition, to compare between compact yarns and ring yarns in terms of their physical and mechanical properties. Three commercial extra-long staple Egyptian cottons Giza92, Giza93 and Giza 96 were used to produce four linear densities of 80, 100, 120 and 140 at 3.6 twist multiplier. Results obtained showed that Giza 92 was surpassed significantly other extra -long staple varieties. It recorded the highest mean values of yarn strength and yarn evenness While, the same variety recorded the lowest mean values of yarn hairiness and imperfections. Compact yarns were much better than yarns spun on the ring spinning in yarn strength, yarn elongation, evenness, yarn imperfections and yarn hairiness. Yarn count 80,s gave higher single yarn strength (20.89cN/tex), yarn elongation (5.03%) and yarn evenness (17.49%) and lower yarn hairiness (2.04) and imperfections than yarn count 140s. Single yarn strength, yarn elongation and yarn evenness were decreased with increasing yarn count. While the number of neps, hairiness, the number of thin and thick places were increased with increasing yarn count. Concerning, the effect of interaction between cotton varieties × yarn counts × spinning systems on yarn quality properties. Yarn count 80s recorded the highest mean values of yarn strength (23.14, 21.1 and 20.2 cN/tex) and yarn evenness (17.72, 16.53 and 16.79%) for varieties Giza92, Giza93 and Giza96, respectively for compact spinning system. Yarn strength at count 80, 100, 120 and 140 correlated negatively and highly significant with micronaire value and maturity ratio.

Investigation Of Fiber Length Change In Different Stages Of Ring Spinning Process

Fiber length is one of the major fiber properties that influence yarn strength, evenness, product handle, product luster, and yarn hairiness. To assure yarn quality, fiber passes through a number of machinery during the spinning process, where it is subjected to various sorts of action that modifies the fiber length. As different process parameters are chosen based on fiber length, fiber length analysis throughout the spinning process will benefit in the adjustment of machine parameters to produce better quality yarn. This study will reveal the chronological change in average fiber length at different stages of the carded ring spinning process, as well as a correlation analysis of length change among different phases, using correlation and regression methods. For five distinct mixing samples, raw cotton, card mat, carded sliver, breaker drawn sliver, finisher drawn sliver, roving, and yarn (pneumafil) were examined at each stage from raw cotton to ring frame. Then, using USTER AFIS PRO, all of the samples were numerically evaluated and statistically analyzed using Microsoft Excel 2016. A positive correlation between fiber length changes at several phases was observed in the experiment, with average fiber length increasing in carding, breaker drawing, finisher drawing, and simplex but decreasing in card mat and ring.

A study on detection of roving tension and fine control of yarn breakage

The fine control of yarn breakage is essential for the production of better yarn quality by reducing the tension fluctuationof roving. The detection of roving tension provides important information regarding the yarn formation during spinning.In the present work, we developed a device for roving-tension detection and regulation, which greatly reduces the yarnbreakage rate and improves the production efficiency of ring spinning. By analysing the factors affecting the rovingtensions, we used a signal acquisition system in conjunction with the tension detection device to regulate the spindlerotate speed to realize the fine control of yarn breakage. Our results indicate that the proposed method can ensure auniform spinning tension of the yarn in ring spinning, which significantly reduces the yarn breakage rate, and boost theyarn production. Our work paves the way toward the rational production of high-quality yarn

Construction and analysis of a three-channel numerical control ring-spinning system for segment colored yarn

At present, there have been a significant number of studies of segment colored yarn, and the majority of these studies have made considerable progress, which has made the types and styles of segment colored yarn more abundant. However, the problem that exists in the segment colored yarn is its relatively few kinds of color, which greatly limits its flexibility and diversity in commercial applications. To address the above problems, a multi-channel computer numerical control (CNC) ring-spinning machine was developed, and a digital spinning mechanism with online regulation of the forming linear density and blending ratio was constructed through the developed three-channel drafting mechanism and its driving and controlling system; the spinning mechanism of segment colored yarn using the time-varying three-channel drafting ratio to the spinning time-varying three-colored fiber blending ratio was established by implementing a coupling algorithm for co-drafting of multi-channel roving; the forming process and algorithm of segment colored yarn, which is used to solve the blending ratio of three colored fibers and the drafting ratio of three-channel roving based on segment color, was constructed through the digital color mixing model and the design of segment color of yarn. According to the above mechanism, three rovings with two color combinations of cyan, magenta, yellow and cyan, magenta, black were used to design and spin segment colored yarns with three, five and seven colors, respectively. By testing and analyzing the linear density, twist, unevenness, surface hairiness and tensile properties of the segment colored yarn, it is proved that the timing control of the three-channel drafting ratio based on CNC ring spinning can achieve the timing control of the blending ratio of the three colored fibers, which is beneficial to the spinning of segment colored yarn with color segment distribution.

Manufacturing Color-Blended Slub Yarn: Computer Numerically Controlled Ring-Spinning Frame and Kubelka-Munk Double Constant Theory

In the present work, we used the computer numerically controlled (CNC) ring-spinning frame to produce the color-blended slub yarns made from three different colored rovings with a 10% blending gradient. The blending ratio of rovings was determined by Kubelka-Munk (K-M) double constant theory. The as-manufactured yarns were made into knit fabrics with a circular knitting machine. The relative value method was used to solve the absorption and scattering coefficients of each colored fiber, and the least-square method was used to solve for the blending ratio of color-blended slub yarn. The results show that the average color difference between predicted and measured L*a*b* values was 1.74, and the error of the blending ratio was 7.38%, which are within the acceptable ranges for color matching of yarns.