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Identification of the Critical Factors of Yarn Breakage in Ring Spinning by Design of Experiment.

Md Moslem Uddin
Senior Scientific Officer
Physics Department, Textile Physics Division, BJRI, Technology Wing, Manik Mia Avenue, Dhaka-1207.

Abstract/ Executive Summary:

Globalization forces the industries to concentrate more on quality of products and process in a continual basis in order to survive in the market. The textile industries cannot escape from it, because of more competition in global market. In the existing method of producing yarn in ring spinning, the percentage of end breaks are high, result in high quality and production loss. The objective of this study is to obtain the optimum spinning parameters so that the end breaks of ring spinning are minimized. Design of Experiment (D.O.E) can accomplish this. Using Design of Experiments, the input parameters at two levels were selected and physical layouts for experimentation were designed. This project work investigation the critical factors of end breaks in ring spinning by DOE. Using the results of the experimentation it was calculated the optimal spinning parameters for the operation. The effects of interaction of critical parameters are also studied. Based on the experimental investigation it was found that there is a considerable reduction in end breaks percentage.

Keywords: Design, Product, Textile Yarn, Breakage and Quality.

Location: Physics Department, Textile Physics Division, BJRI, Technology Wing, Manik Mia Avenue, Dhaka-1207.

Start Date: 01-01-2004

End Date: 30-06-2008

Program Area: Postharvest and Agro-processing

Commodity: Jute

Objectives:

To Identify the Critical Factors of Yarn Breakage in Ring spinning by Design of Experiment

Methodology:

Different types of cotton such as Indian, American, Egyptian, Sudanese, CIS, Pakistan etc were used. American Arizona cotton fibre was used for conducting the experiment. Two types of fibre were used. One type higher strength and the other is lower strength. A mini ring spinning of 8 spindles was used in the experiment. In this experiment spindle speed, fibre strength, twist and draft were optimized through a series of experimental study. In this study, the experimental set-up in the mini ring spinning machine were changed from time to time according to the 4 factor 2 level DOE matrix. To carry out the experimental work two of roving was produced by two types of fibre. One type from lower strength fibre (Roving Hank: 1.2) and another type from higher strength fibre (Roving Hank 1.0). The samples of roving varying with strength of fibres were marked as samples no:1 and sample no:2 respectively successively higher strength. For each single trial for preparation of the yarn about 5kg of cotton fibre was taken from the stock. At first the fibres were opened manually then was fed to the scutcher. The lap then delivered from scutcher was than fed first carding machine. Then this was fed to the drawing machine. The first drawing slivers are then passed to the second drawing machine. Then it was passed to the simplex machine. Finally it was fed to the ring-spinning machine.

Source of Information: Journal of ITET December. July 2008 Vol-2 pp-66-69

Article Link (Online Journal):

Funding Source:

Total Budget (Tk.) :

Achievement/Findings:

The 2⁴ factorial shows that the best are A-, B+, C- & D- In other words spindle speed 10000 rpm. Twist 18.65, fiber strength 25.15gm/tex and draft 15 are best combination for yarn production of the experimental machine. Sometimes, it may be seemed be that if the spindle speed is high, the production will be high. But this assumption is wrong. In our experiment it is found that higher spindle speed causes higher end breakage. So, lower speed should be chosen. Fibre strength contributes to yarn strength about 22%. In our experimental analysis it is found that fibre strength is the most critical factor for the yarn strength. It has the highest effect on end breaks. Stronger fibre reduces the end breaks. So high strength fiber should be chosen. Twist is another important factor of yarn breakage. Higher twist than optimum give more end breaks as well as less production. In this analysis it is found that higher twist than optimum gave higher end breakage so, low twist should be chosen. Finally, Draft shows that it has a lower effect on end breaks. Here, lower draft should be chosen. In this experiment we have determined the critical the factors and selected best combination of the process parameters. Now the management of a textile-spinning mill can make a decision about machine parameters. They can decide what type of fibre should be used, what machine speed, twist and draft should be chosen to minimize higher end breaks.

Knowledge Management: Journal