Analysis of Yarn Tension in the Yarn-Forming Zone in Friction Spinning

Faculty of Engineering, Gifu University, Gifu, Japan

ABSTRACT
We have analyzed the tension distribution along the yarn tail in the yarn-forming
zone of a friction spinning machine by considering the effective parameters of the
torque applied to the yarn tail. Tension is applied to the yarn tail by suction air pressure
and rotation of friction rollers. The yarn tension in the yarn-forming zone is measured
for various yam Counts and suction air pressures. The effects of the parameters on yarn
tension are considered in a theoretical analysis based on tension distribution along the
conical yarn tail. Theoretical results are compared with the experimental data. The
results of this research show that yarn tension increases with increasing suction air
pressure and yam size in tex, and yarn diameter decreases with increasing suction air
pressure for the same yarn size. Therefore, because of the low tension experienced
with fine yarns, it is difficult to properly produce such yarns through friction spinning.

In spinning, the magnitude and pattern of tensions
applied to the yarn strongly affect the spinning process.
In the case of ring spinning, yarn tensions are influ-
enced in large part by the spindle speed and, hence, the
yarn balloon size [I-41.In rotor spinning, the rotor
supports much of the yarn during formation, and there-
fore yarn tension is lower than that in ring spinning for
a given yarn twist level. In air-jet spinning, the yarn
tension is low during spinning due to the nature of the
twisting. In friction spinning (Figure 1a), the fibers are
transported to a shear field that generates a torque in
the fiber assembly, which usually takes place along a
narrow zone equal in length to that of several fibers.
The torque is generated about an axis in close proximity
to the fiber assembly zone. The yarn tail (Figure lb)
lies along the torque axis; twisted yarn is drawn off
continuously along this axis. The yarn tail forms an
"open end" and is tapered due to constant removal of
the yarn and distributed flow of fibers into the spinning
zone. In friction spinning, the torque is applied directly
to the surface of the yarn by frictional contact with the
relatively slowly rotating friction rollers. The yarn ro-

....,...
..\\\\\\\\\
-)51*
.......................
.........................
.\,\\\\\\\\\\\\
,\\,\\\\\\\\\\\\\\
....................
perforated r o l l e r

FIGURE1. (a, top) Diagram of yarn-forming

zone, and (b, bottom) diagram of theoretical
tapered yarn in yarn-forming zone.

Textile Res. J. 67(9), 643-653 (1997)

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 tates only about its own axis, and the tensile stresses
are lower than those in the rotor and ring spinning sys-
tems. Stalder cites the low spinning tension as a major
factor in deciding the yarn count range [ I l l . Due to
low spinning tension, it is not possible to create suffi-
cient friction between the fibers, which results in low
yarn strength. FIGURE 2. Diagram of torque acting on yam element
In friction spinning, yarn tension depends on certain in yarn-forming zone.
parameters such as suction air pressure and yarn di-
ameter, and we (Konda et al. [6-81) have considered In general, the yarn torsional moment M can be ex-
the effect of suction air pressure on yarn tension. We pressed as a function of spinning tension (F), M
have determined that as the suction air pressure is in- = M(F), in which the yarn tension is a function of
creased, yarn tension also increases. friction forces between the yam and friction rollers FI
and F2, F = F (FI, F 2 ) (Figures 3a and b). Friction
Theory forces (F,, F2) are a function of the force of suction
DEFINITIONOF THE PROBLEMS air pressure in the suction slit (P or S), machine pa-
rameters and spinning conditions, and yarn structural
To determine yarn tension in the yam-forming zone characteristics (chiefly yarn radius, yam size, and fiber
in friction spinning, it is necessary to know the torque density), F, = F1(T, r, S ) and F, = F2(T,r , S ) (Figure
acting on the yarn, which normally involves consider- 3a, b). Therefore, F = F ( T , r , S) and M = M(T, r ,
ation of the particular yam formation and the mechan- S ) , where T = yam count, r = yarn radius, and S
ical forces acting on it. Yarn tension in the yarn-form- = amount of suction air pressure in the suction slit.
ing zone in open-end friction spinning is considered a
four-region problem (Figure la, b) : ( 1 ) from the be-
ginning of the friction rollers ( x o ) to the beginning of
the suction slit ( x , ), ( 2 ) from the beginning of the suc-
tion slit ( x , ) to the beginning of the transport channel
slit (x2), (3) from the beginning of the transport chan-
nel slit (x2) to the region where the yarn diameter be-
comes equal to the friction rolIers gap 2r = y (x3). and
(4) from the region 2r = y ( x 3 ) to the end of the trans-
port channel slit r = 0 (xs).
The fibers are assembled in regions 3 and 4 into the
yam-forming zone. The fibrous material in regions 2,
3, and 4 is subjected to suction air pressure. The fibrous
material leaving region 1 is not in contact with the ro-
tating rollers that create torque.
The yarn tail in the yarn-forming zone executes a
rotation about its own axis, which, together with the
yarn delivery speed, establishes the amount of twist
inserted in the yarn. The yarn tail in the yarn-forming
-
F yarn tension

zone is rotated by torsional forces created by friction

between the yam and friction rollers. Yam tension be- FIGURE 3. (a, top) Diagram of forces acting on yarn in yam-form-
havior is strongly influenced by the radius of the yam, ing zone, and (b, bottom) diagram of yam tension in yarn-forming
the width of the suction slit, the yarn-to-friction-rollers zone.
drag coefficient, and the suction air pressure.
In this research, we are studying the fundamental
mechanisms that give rise to fluctuating tensions during
spinning in the yam-forming zone from beginning to In the mathematical formulation developed below,
end. In this zone, the torque acting on a yam element we assume the yarn is inextensible and perfectly flex-
i~ elastic torque (torsional moment) due to yam tor- ible with a uniform mass linear density, a circular cross
sional deformation M and M + dM,and external spin- section, and uniform mass distribution into elements of
ning torque mdx, as shown in Figure 2 [ 9 ] . equal radial spacing. We ignore the effect of the out-

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coming air flow of the transport channel on yarn ten-
sion. This formulation neglects fluctuations in machine
parameters, spinning condition, and yarn vibration in
the yarn-forming zone (Figures 3a and b) . To consider
dynamic forces acting on the yarn, let us assume that
the yarn path in the yarn-forming zone is nearly
straight, and each point-segment rotates about the yarn
axis at constant speed. Therefore, no dynamic forces
are developed by the yarn circumferential acceleration.
Forces due to frictional drag on the friction rollers
surface are the forces acting on the yarn (Figure 3a,
b) . The magnitude of these frictional forces is assumed
to be proportional to the normal forces between the
yam and the friction rollers, and they act in a direction
opposite that of yarn motion (Figure 3b). Thus, where
p1 and p2 are the drag coefficients of the perforated
roller and the rubber roller with yarn, respectively, F,,,
and FZjiare the forces per unit length of yarn in the
yarn-forrning zone.
The external forces acting on yarn segments have
been analyzed. General equations of forces are
(Fl + Fz) sin p
(W + P s i n a ) + Pcosa(sinp
+ pz cos ~ ) I ( c o ps - pz sin p )
F1 = 9
(sin/3-pIcosS) + (sinP+p2cos8)
Fz = [ F l (cos p + p1 sin p)
- P cos a]l(cos p - pz sin p ) , (4)
where (Y = angle of suction slit, P = angle of Fl and
, = dynarnic coefficient of friction between per-
F ~ pI
forated roller and yarn, k = dynamic coefficient of
friction between rubber roller and yarn, r = yarn radius,
R = perforated roller and rubber roller radii, W = yarn
weight, X = length along yarn tail, F = yarn tension
in spinning, and S = suction air pressure.
These generalized equations of forces (Equations 3,
4) can be used with suitable modifications and bound-
ary conditions to describe the physics of a particular
problem. The external force F can be understood more
fully by looking at the side view of the yarn-forming
zone (Figure 3b).
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FI,,and Fa, are the forces per unit length acting on
the yarn in the yarn-forming zone. Each material ele-
ment of the yarn can be considered a cylinder in regions
1 and 2 and a truncated cone in regions 3 and 4, with
its axis at an oblique angle to the friction rollers. An
exception is region 4, where the yarn axis is assumed
parallel to the friction rollers (Figure 2b). Thus, it is
necessary to consider components of Fljiand F2,,. As-
sume that both friction rollers are of the same diameter,
and that o! is constant along the whole width of the
suction slit. Hence P is in the vertical direction of the
yarn diameter along the whole yarn diameter.
If we assume % = 0, since y, T, r, W, P are depen-
dent on x, we can get the variable parameters for the
four regions:
where xji = xi-, + iAxj, xjo = xi-I, Ax, = (xi -
nj* Yji = Y4 + (YO- ~ 4 ) ( ~ - 4xji)l(x4 - XO)- (YO
- y4)Axj/2(x4 - x0), q,= To and rji = ro in regions
1 and 2, q i= TO(x4- xji)/(x4 - x2) - TOAxj/2(x4
- xz), and rji = rO(x4- xji)/(x4 - x2) - rOAxj/2(x4
- x2) in regions 3 and 4, cos Pji = 1 and sin pjl = 0 in
(3) region 4, and P,, = 0 in region 1, where y is the friction
rollers gap. Then,
"/
F k j =lim 2 Fui k = 1 and2 , (10)
4 4 "1
Fk= 2 Fkj= C lim C Fkji , (11)
2 4 "/
F= C pk C lim Fkji . (12)
There is no suction in region 1 ( P = 0), so it seems
that the torque exerted in this region is only created by
the yarn weight. Therefore, the amount of torque ex-
erted on the yarn is insignificant in this region.
The yarn in region 2 is in contact with both friction
rollers. The length of this region is one of the most
important parameters specifying the amount of torque
created in this region.
 The yarn in region 3 is in contact with its equivalent
of the friction rollers, and most of the torque seems to
be created in this region. Its length (Figure lb) varies
with yam diameter:

Therefore, when yam diameter or yam size (tex) de-

creases, the length of the yarn subjected to frictional
force (torque) in this region L3(Figure 1band Equation
13) is reduced, which reduces torque accumulation and
yarn tension in this zone, resulting in a loss of spinning
yam tension. This supports the notion that yarn diam-
eter plays an important part in yarn tension during fric-
tion spinning.
Theoretically, in region 4, yarn diameter is less than
the friction rollers gap, so there is insufficient contact
between the yarn and both friction rollers simulta-
neously. Thus the amount of friction force created by
the friction rollers is negligible. Although the yam tail FIGURE4. Diagram of yam position in yarn-forming zone.
in region 4 is voluminous, the tip of the yam in this
zone is unstable [lo]. Fibers in this region do not have
sufficient cohesiveness in the yam structure, so we an- where, z, z,, and z3 = vertical positions of yarn (yam
ticipate that the forces experienced by the yarn tail here axis), and y = width of the suction slit.
are negligible. The values of r l and r, can be derived from Equa-
tions 14 and 15. We use values to obtain the best yarn
position in the yarn-forming zone.
Other yam positions in the yarn-forming zone in-
Next, it is important to determine the yarn position clude
in the yarn-forming zone. The best range of yarn po-
sition in this zone is when the whole yarn diameter is
situated across the suction slit (Figure 4). Then the when the yams are placed lower and higher than the
boundary conditions are suction slit (Figures 5a and b ) . When the yarn is placed
lower than the suction slit bottom edge (Figure 5a),
then
zl = (R + y12) tan a - (y12) cos a
2r, = 2r - [z, + rlcos cr - (R + r ) sin a + rlcos a ]
z3 = (R + y12) tan a + (yf2) cos a

When the yarn is placed higher than the suction slit top
edge (Figure 5b), then
For r = r , .
2re = 2r + [z3 - rlcos a - ( R + r ) sin p - rlcos a ]
z, + rllcos a

where 2re = effective diameter of yarn exposed to suc-

tion air pressure. Therefore,
For r = r3,
P = 2SreAx . (19)
In these equations, the yam radius has a special com-
plication. which depends on the fiber properties, yarn
twist, twisting method, fiber packing, machine pararn-
and eters, and spinning condition. Fiber packing in a twist-
ing zone usually varies along the yarn length [lo]. The
external manifestation of fiber packing in the yarn is in

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 ing zone is one of the most important of them. The yarn
radius depends on yarn tension, provided all machine
parameters and spinning conditions are constant.
f/
r
::;:i::O:i;f
pressure
Hence, in order to measure the yarn radius, it is nec-
essary to know the relationship between yarn radius
and yarn tension, and vice-versa.
To elucidate easily the physics of the problem of
effective parameters for yarn tension, we assume that
the length of yarn in region 2 is 0 (XI = X2). and the
forces subjected to the yarn tail in regions 1 and 4 are
negligibly small. Therefore, most of the forces impact-
ing on the yarn tail are in region 3. Let us assume y is
constant through the yarn-forming zone. The value of
a and 0 are too small to assume cos a and cos p are
equal to 1 and sin a and sin 0 are equal to a and D,
respectively. The effect of the yarn weight is also neg-
ligibly small. As a consequence, FI and F2 in Equations
3 and 4 are given by

direction of

z and

Neglecting terms plP and p d , from Equation 5 , we

have

For region J = 3. we have

mourn 5. Diagram of yarn position (atop) lower than suction slit and
in yarn-forming zone, and (b, bottom) higher than suction slit in yarn-
fonning zone.

the specific volume of the yarn, which, of course, de- where Ax, = - (x, - x2)Ar31ro.Equation 23 therefore
pends on the volume occupied by the fibers and the becomes
amount of air space between them. Since the volume
of the unit length of an idealized yarn is ?rr2 and its
mass is ?rr2/vy,where v, (cm31g)is the specific volume
of the yarn, it follows that

where r = yarn radius (mm) and T = yarn count (tex).

Since the yarn radius depends on the specific volume
of the yarn, it changes with changes in machine p m -
eters and spinning conditions. In friction spinning,
+ [2Sp2(x, - h ) l r o l lim 2
i-0
r3(Ar3 (24a)
n3-- or A r d
there are some variable machine parameters and spin-
ning conditions, and the yarn tension in the yarn-form-

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 tension in the yarn-forming zone at the yarn tension
detection point and yarn diameter at the yarn diameter
(a+ P ~ ) (+
Rr) detection point (Figure 6) were measured simulta-
+ J ( R + t ) 2- ( R + y12)2 neously for the various yam sizes and suction air pres-
rdr sures on the friction spinning machine.
04 - p , ) ( R + r )
+ 2 { ( ~+ r ) 2 - ( R + ~ 1 2 ) ~
combing roller

In these equations, if we assume that the yarn radius

( ro)is constant, then the yam tension becomes a func-
tion of the suction air pressure ( S ) ,F = F ( S ) ,and the
relationship between them is linear, F = CoS.Actually,
the yarn radius ( r O )is not constant for various suction
air pressures ( S ) , so the relationship between them is
not linear ( F + CoS), and F = G ( S ) , which means
F ( S ) + G ( S ) , where Co is a constant.
Also, for a constant yarn size T = To, if we assume
that S is constant, then ro is constant, and therefore
( a + C L Z ) (+Rr )
+ J(R + r)2 - ( R + y 1 2 ) ~ computer
rdr
( C L-~P I ) ( R + r ) FIGURE
6 . Schematic of an experimental apparatus.

Figure 6 shows the experimental friction spinning a p

paratus. Here, yam tension in the yarn-forming zone can
be detected between the friction rollers and the yam deliv-
ery rollers using a tension meter. Yarn diameter can be
where C , and C2are constants. Then the yam tension (F) measured with a semiconductor photoelectric device (time
becomes a function of yam radius ( r ) ,but the relationship constant = 1 rnsec) between the delivery rollers and win-
between them is complex. In these equations, yam tension der drum (yam package). When the yam passes the yarn
is a hnction of yarn radius and suction air pressure in the diameter detection point, it casts a shadow, giving a mea-
yam-forming zone F = F ( r , S ) , where the yam radius in sure of its diameter. The amount of suction air pressure is
the yarn-forming zone is a function of final yam radius r, measured in the air suction pipe inside the perforated roller.
and yam size (tex) T, r = g(ro, T ) . Consequently, these Detected and measured signals of these phenomena
equations show that yam tension strongly depends on the are transferred separately to a digital multichannel re-
yarn radius ( r ) ,yarn size (tex) T, and suction air presswe corder and saved in different channels. For every chan-
( S ) in the yam-forming zone, F = F(S, T , ro). nel, the testing time is 32 seconds. A 32-k word mem-
ory is used, so that every word is equal to one
Experimental millisecond of testing time. Yarn speed is 120 mtmin,
so yam length in this test is 64 m. Six data samples are
A cotton sliver (2.7 cm staple fiber length and 4.84 acquired from the results, each 8.2 m long or 4096
g/m sliver size) was used to produce 32, 37, 47, 57, points. After sampling. data are transferred to the com-
65, 75, and 85 tex, 100% cotton yams on an experi- puter and analyzed using our original programs.
mental friction spinning machine with only one per-
forated roller. Typical spinning parameters included
120 rnlmin spinning speed, 9000 rpm combing roller Results and Discussion
speed, 4000 rpm friction rollers speed, and a distance The experimental yarns were spun on the friction
of 0.25 mrn between the perforated roller and the spinning machine with one perforated roller at various
rubber roller. Using these spinning parameters, yam yarn diameters and suction air pressures. Yam tension

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in the yarn-forming zone and its effects on yarn prop-
erties are pertinent to this discussion.
The most important effectiveparameters on yarn ten-
sion in friction spinning are suction air pressure in the
suction slit and yarn size. As we saw in Equations 24a
and b, if we assume the amount of suction air pressure
(S) is constant and monotonous along whole length of
the suction slit, the relationship between yarn spinning
tension and suction air pressure is linear. Yarn dime-
ter, however, is changeable during spinning under var-
ious suction air pressures, and it is impossible to de-
termine the relationship between yarn tension and
suction air pressure as an independent relation during
spinning. To demonstrate this independent relationship,
we used a modified experimental friction spinning ap- FIGURE8. Relationship between y a m tension and suction
paratus (Figure 7 ) . Here, the yarn is only contacted by air pressure (yam count = 85 tex).
a roller in the suction slit region. In other
words, the yarn is first produced on the friction spin-
ning machine (Figure 6), it is set for twist, and it is onstrate this, initially we developed a computer pro-
then fed to this apparatus (Figure 7). The resulting yarn gram in Basic to solve the equation of yarn tension in
tension for various suction air pressures is detected at the yarn-forming zone (Equations 24a and b). Typical
the yarn tension detection point with a tension meter. machine parameters and spinning conditions included
yarn pre-tension is detected at the yarn pre-tension de- 115 mm yarn length in regions 3 and 4 (L3 + LA),
tection point with a tension meter. The value of yarn considered to be divided into 200 segments, 0.25 mm
tension is calculated by gap between friction rollers. 2" angle of the suction slit,
0.15 dynamic coefficient of friction between perforated
Yarn tension (F) roller and yarn, 0.2 dynamic coefficient of friction be-
= detected yarn tension-yarn pre-tension tween rubber roller and yarn. With these machine pa-
rameters and spinning conditions, we calculated yarn
The results of these experiments are shown in Figure tension for various yarn diameters at 1000 mmAq suc-
g. As the figure shows, the relationship between yarn tion air pressure. The results of these calculations and
tension (F) and suction air pressure (S) is linear. experiments (Figure 9) show that yarn tension in-
Equation 25 shows that the relationship between creases with increasing yarn diameter, but this relation-
yarn tension and yarn diameter is complex. To dem- ship is not linear. Theoretical results show no increase

Tarn delivery r o l l e r s

RGURE 7. Schematic of an experimental a p

paratus used to measure the relationship be-
tween y a m tension and suction air pressure.

r with
h -d i g;i t aol m p u t e r

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FIGURE9. Relationship between y a m tension and yarn diameter
(suction air pressure = 1000 rnmAq), *(Equation 28)
in yam tension at low diameter (2r d 0.25 mrn). Ex-
perimental results, however, show that there is some
tension for the low-diameter yarn. It increases slowly
until the yarn diameter becomes equal to the friction
rollers gap ( 2 r = y ) , and then increases sharply. Ac-
tually, it is possible that the low-diameter yarn does not
contact both friction rollers simultaneously and is fluid
in the yarn-forming zone. The resulting tensions in
these yams are created by the suction air pressures and
the alternate contact of the yarn with the friction rollers.
Hence, the effect of the yarn diameter is diminished for
low-diameter (fine) yarns.
The effect of suction air pressure and yarn diameter
(yarn size) on yarn tension in the yarn-forming zone
is shown in Figure 10. Here, we see that yarn tension
increases with increasing suction air pressure and yarn
size. The effect of suction air pressure on yarn tension
can be described by the amount of P in Equation 7 or
Figure 8. When suction air pressure increases, the
amount of P increases, and the yam is held more firmly
against the surface of perforated roller. Thus, the
amount of yam tension increases.
We considered the relationship between yarn ten-
sion and yarn diameter variations using the cross cor-
relation method [ 7 ] . The high correlation between
them ( r = 0.65) demonstrates that the yarn diameter
influences yarn tension in the yarn-forming zone.
The effect of yarn size (thickness) on yarn tension
in spinning can be described by the yarn radius and
the length of the yarn subjected to the suction force
(torque) in region 3 (Figure Ib). Increasing yarn
thickness at the same suction air pressure increases
yarn length in region 3, L, (Equation 13). and yarn onstrate that yarn tension in friction spinning depends
radius. Hence, as expected, yarn tension will in- on the suction air pressure and the yarn size (tex),
-'rease. But, as seen in formula 25 and Figure 9, this which are the two most important parameters. Because
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relationship is not linear. Therefore, the interrela-
tionship of yarn tension, yam diameter, and suction
air pressure is complex (Figure 10). This relation is
not linear because the yam diameter is not constant
for various suction air pressures (Figure 11) . Yam
diameter decreases with increasing suction air pres-
sure [9]. Reducing the diameter reduces the amount
of P for high suction air pressure. As Figure 11
shows, yarn diameter decreases with increasing suc-
tion air pressure with the same yarn size, which is
not linear. This means that the yarn becomes denser,
i.e., it has more fiber-packing density (Equation 22).
When the suction air pressure increases, the yam is
held more firmly against the surface of the friction
rollers, and so the amount of friction increases (Fig-
ure 3a), consequently increasing yam tension. This
+ a.
causes the amount of torque created by F, , Fz, P to
increase and the yam is twisted further. Then the yarn
becomes more condensed (higher fiber-packing den-
sity) as the amount of F, , F z , P and the resulting
yarn tension (from them) increase. This tends to re-
duce yam diameter (Equation 22).
In the low-diameter yarns (32 and 37 tex), yam
diameter is less than the gap between the friction
rollers (i.e., r, < y I 2 ) . Therefore, in the spinning
process, these yarns are not completely in contact
with both friction rollers, and the yarn is not firmly
held to the perforated roller or the suction slit.
Hence, increasing the suction air pressure does not
clearly influence yarn diameter (Figure 11) and
yarn tension (Figure 10). Despite this, yarn tension
variations and yarn diameter irregularity increase
(Figure 12). These results confirm that in friction
spinning, the low-diameter yarns are not completely
in contact with both friction rollers and in fact, they
are fluid in the yarn-forming zone, thus reducing
yarn twist (Figure 13).
Twist efficiency is expressed as a percentage of
yam turning in contact with the friction rollers with-
out slipping [7].As Figure 13 shows, there is a sig-
nificant reduction in twist efficiency of the 37- and
32-tex yarns, because their diameters are smaller
than the gap between the friction rollers. Thus, our
research shows that it is very difficult to properly
produce fine (tex) yams in friction spinning, and we
do not advise it.
Conclusions
In the analysis presented here, we have tried to dem-
 YARN COUNT = 85 .El( YARN COUNT = 75 TEX YARN COUNT = 66 lEX

SUCTIONAIR PRESSURE1-( SUCTION AIR PRESSURE (mnAq) SUCTION AIR PRESSURE (mnAq)

YARN COUNT = 57 TU( YARN COUNT = 47 E X YARN COUNT a 37 TEX

SUCTION AIR PRESSURE (m SUCTION AIR PRESSURE (tnnAq)

YARN COUNT = 32 TEX

15 r = - J 10. Yam tension in yam-forming zone.
FIGURE

sented here can be used as a basic tool in machine

design.

Appendix

M and M yarn torsional moment

+ dM
of the low tension of fine (tex) yarns, however, it is ma!! external spinning torque
difficult to produce fine (tex) yarns by friction spin- F yarn tension in spinning
ning. Equally important, we have also demonstrated j regions=1,2,3,4
that it is possible to predict tension variations at the i divisions = 1, 2, 3, . . n, .
yam-forming zone for a given set of processing con- nj number of divisions in region j
ditions and machine parameters. The analyses pre- F, friction forces between yarn and perforated
sented here are capable of further refinement. For roller
example, the yam tail in the yarn-forming zone needs Fl, F,in region j
to be properly defined for its comet shape, fiber pack- Fiji components of Flj
ing, and fiber slippage. But we believe the analysis pre- F2 friction forces between yarn and rubber roller

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 YARNCOUM=MTE% YARN COUNT = IS TM YARN COUNT=MTD(

0.2

2wo 1000 2000

SUcm>N U R PRESSURE (mnAp) SUCTION AJR PAESSWIE (mnAq)

YARN COUNT 67 E X - YARN COUNT = 47 E X YARN COUNT = 37TO(:

k0.4
= -
I- ------.---------.I
SUCTION AIR PRESSURE (mnAq)

-
- -
YARN COUNT 32 E

- - - . -
loo0

- - - - - - -
X

- ' 0
2000
SUCTKM AIR PRE58URe (mnAq)

Rouw 1 1 . Effect of suction air pressure on yam diameter.

-
S
1000
m AIR PRESSURE (mnAq)

1 '
go.= r
ro
yarn radius
yarn radius at the beginning of the friction rollers
(Figure 2). or radius of produced yarn
0.2 . n
I e r,
rji
yarn radius at the end of region j
yarn radius in region j at the ith division
- - - . - - - - - - - - - # A
low 2000
S suction air pressure in suction slit
sumcm AIR PRESSURE (mn~q) a angle of suction slit
D angle of F1 and FZ
pIi angle of FI and Fz in region j at the ith division
Fa F2in region j p, dynamic coefficientof friction between yam and
Fa, components of Fa perforated roller
P force of suction air pressure in suction slit p2 dynamic coefficient of friction between yarn and
PI, components of P in region j rubber roller
T yarn size (tex) R perforated roller and rubber roller radii
Yarn size (tex) at the beginning of the friction W yarn weight
rollers (Figure 2), or the size (tex) of pro- w,~ weight components in region j at the ith
duced yarn division
Yarn size (tex) at the end of region j x length along the yarn tail
Ti Yarn size (kx)in region j at the ith division beginning of the friction rollers

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 r yarn radius placed in z position
r, and r3 yam radii at lowest and highest positions
'

in yam-forming zone, respectively.

when the whole yarn is exposed to suc-
tion air pressure
y width of suction slit
2r, effective diameter of yarn exposed to suction air
pressure
v, specific volume of yarn

10:
Literature Cited
1. Batra, S. K.. Ghosh, T. K., Zeng. Q., Robert, K. Q., and
YARN DIAMETER (MM) Barrie Fraser, W., An Integrated Approach to Dynamic
Analysis of the Ring Spinning Process. Part IV: Inherent
Instability of the Free Balloon. Textile Res. J. 65 (7).
FIGURE12. Relationship between yam diameter and irregularity 417-423 (1995).
in spinning process (Suction air pressure = 1000 mmAq).
2. Batra, S. K., Ghosh, T. K.. and Zeidman, M. I., An In-
tegrated Approach to Dynamic Analysis of the Ring
Spinning Process, Part I: Without Air Drag and Coriolis
Acceleration. Textile Res. J. 59 (6). 309-3 17 ( 1989).
> - 3. Batra, S. K., Ghosh, T. K., and Zeidman, M. I., An In-
Yw -- tegrated Approach to Dynamic Analysis of the Ring
Spinning Rocess, Part 11: With Air Drag. Textile Res. J.
59 (7), 416-424 (1989).
Y 4. Ghosh. T. K..Batra, S. K., Zeidman, M. I., and Dua, B.,
b 0 An Integrated Approach to Dynamic Analysis of the Ring
Spinning Process, Part In: The Effect of Coefficient of
Friction and the Balloon Control Rings, Textil Prar. Int.
47,791 -800 (1992).
5. Hearle, J. W. S., Grosberg, P.,and Backer, S.,"Structural
of Fibers, Yams, and Fabrics." vol. 1. Wiley-Intersci-
10 40 60 80 ence, NY, 1969.
YARN COUNT (TU() 6. Konda, F., Okamura, M.. Merati, A. A., and Youki. T..
Fiber Speed and Yarn Tension in Friction Spinning. Tex-
FIGURE13. Twist efficiency of various yarn counts tile Res. J. 66 (5). 343-348 ( 1996).
(suction air pressure = loo0 mmAq). 7. Konda. F., Okamura, M., and Merati, A. A., Effect of
Suction Air Pressure on Yarn Properties in the Friction
Spinning Process, Textile Res. J. 66 (7). 446-452
end of region j ( 1996).
length along the yarn tail in region j at the ith 8. Konda. F., Okamura, M., Merati, A. A.. and Kato, H.,
division Simultaneous Measuring of Fiber Flow. Yarn Tension.
components of x and Yam Diameter in Friction Spinning, in "Proc. New
components of x in region j Spinning Systems into the Future." Shanghai, China.
gap between friction rollers Nov. 1995.
gap between friction rollers at the end of region 9. Lord, P. R., and Rust. J. P.. Twist Distribution in Open-
end Friction-spun Yarn, J. Textile Imt. 81 (2), 21 1-213
j (1990).
gap between friction rollers in region j at the ith 10. Miao. Menghe. and Chen, Renzhe. Yam Twist Dynarn-
division ics, Textile Res. J. 63 (3). 150- 158 ( 1993).
length of yarn in region j 11. Stalder, H., Spinning in the Ninenties. Int. Textile Bull.
vertical position of yam in yarn-forming zone Yarn Forming 1189,151- 157 (1989).
vertical position of suction slit bottom edge
vertical position of suction slit top edge Manuscript received June 4, 1996; ucepfed November 18, 1996.

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