Indian Journal of Fibre & Textile Research

Vol. 33, March 2008, pp. 45-51

Simulation analysis of weft yarn motion in single nozzle air-jet loom to study the
effective parameters
H Nosratya, Ali A A Jeddi & Y Mousaloo
Textile Engineering Department, Amirkabir University of Technology, Tehran 15914, Iran
Received 25 July 2007; accepted 14 February 2008

A simulation model has been suggested for a single nozzle air-jet loom to analyse weft yarn motion under different
conditions of weaving procedure. For this purpose, weft yarn motion equation has been derived using this model, physical
laws and combination of air velocity and air-yarn friction coefficient equations. This analytical model for drum storage
system is developed to investigate the weft yarn behaviour during weft insertion, i.e. displacement, velocity, and yarn
tension. Numerical solutions of yarn motion equations have been obtained. Tension analysis of weft insertion has been
carried out both theoretically and experimentally using different cotton-polyester yarn counts under different air pressures.
The results show good agreement between theoretical and experimental values of weft yarn tension.
Keywords: Air-jet loom, Air-yarn friction coefficient, Simulation model, Weft insertion, Weft yarn motion
IPC Code: Int. Cl.8 D03D

1 Introduction Adanur and Bakhtiyarov3 presented an analytical

Air-jet weaving is an advanced weaving method
with high efficiency and productivity. However, the
weft yarn motion in air-jet filling insertion is very
complicated. It is not a positively controlled process,
and the air stream during the filling insertion process
is turbulent and unsteady with regard to its velocity, it
could be compressible. The transferred material, i.e.
weft yarn, also has its complications, especially in the
case of staple yarns. The weft yarn propulsion force is
provided by the friction between the yarn surface and
the air stream.
Many researches in the field of simulating the air-
jet filling insertion have been performed. Salama and
Mohamed1 simulated the air-jet filling insertion by
using a single nozzle for insertion and a tube to guide
the air. They presented the air velocity distribution
along regular and slotted tubes in terms of the tube
configuration and its interaction with the air-jet at the
tube entrance. Adanur and Mohamed2 modified this
simulator with automatic data acquisition and
analysis, and measured the weft insertion time, air and
weft yarn velocity, air pressure, and weft yarn tension.
They2 reported the influence of different weft
insertion system parameters and yarn characteristics
on yarn velocity. They found that the increase in yarn
linear density and twist increases the insertion time.
___________
a
To whom all the correspondence should be addressed.
E-mail: hnosraty@aut.ac.ir
model to simulate air flow through the channel. They
calculated the drag coefficient in the guide channel
and propelling force acting on the yarn, and found the
results in good agreement with the experimental data
obtained for the same conditions. Nosraty et al.4
obtained the weft yarn position, the weft yarn velocity
and the weft yarn tension graphs by using a
simulation model for weft yarn motion.
Adanur and Mohamed5 developed analytical
models to investigate the air-jet filling insertion.
These models enable yarn velocity to be calculated
from measured values of air velocity. Then they5
compared the predictions of the models with
experimental results. Ishida and Okajima6 in an
experimental study analyzed the flow characteristics
inside the main nozzle of the loom by changing
air tank pressures and acceleration tube lengths, to
obtain basic data for an optimum design of the main
nozzle.
In the present study, different theoretical and
experimental equations of the air velocity of the
nozzle (U) and the friction coefficient between air
and yarn (Cf), as reported by previous researchers,
have been applied in the weft yarn motion
equation. Thereafter, the equation, which has the
theoretical results nearest to the experimental results,
has been suggested as an analyzing model to predict
the weft yarn motion at different conditions.
46 INDIAN J. FIBRE TEXT. RES., MARCH 2008

2 Materials and Methods where

c1 = 0.4193 and c2 = −0.4883 for cotton yarn.
2.1 Theoretical Background c1 = 0.4274 and c2 = −0.4887 for textured polyester
Hitherto, several models have been presented in the yarn.
literature to describe the yarn motion during insertion. The dimensionless coefficient Cf is function of the
Many parameters influence yarn motion equation. Reynolds number Re=UD/V, where U is the air
Some of them are due to yarn diameter and surface velocity in channel (m/s); D, the channel diameter
properties7, and the others depend on the loom setting, (m); and V, the air dynamic viscosity (m2/s). The
such as air velocity. Uno8 expressed the air velocity following equations have been presented for Cf
distribution along the guide channel as follows: according to Reynolds number:
Smith and Goud12:
13U 0
U = …(1)
300 x + 1 C f = 0.27 Re −0.61 …(7)
where x is the distance from the nozzle (m); U0, the
Matsui13:
initial air velocity at the core of nozzle (m/s); and U,
the air velocity at distance x from the nozzle (m/s).
Salama et al.9 found experimentally that the air C f = 0.24 Re −0.61 …(8)
velocity of the nozzle is a function of time, as shown
below: Orii and Sano14:

U = U 0t τ …(2) C f = 0.27 Re −0.64 …(9)

where τ is a constant and is related to the running Selwood15:

speed and the air pressure.
Duxbury et al.10 estimated velocity distribution C f = 0.37 Re −0.61 …(10)
along the axis of air jet with steady flow, as follows:

U = U 0 e − L/C …(3) Limming and Ming16:

0.0706
where C is the constant = 30 (dimension of length); Cf = K …(11)
and L, the distance from the nozzle to be expressed as ( Re ro . Re x ) 0.1111
a function of time in the form as shown below:
0.3566
cx(t)
where K = + 0.787
U = U 0e …(4) V . Re ro

Friction coefficient between air and yarn which
would be depended on the nature of used yarn has
been suggested by previous workers, like:
Uno8 found experimentally for spun yarn:
1 Cf =
C f = 0.02 + …(5)
(U − V ) + 2
where Cf is the friction coefficient ; U, the air
velocity(m/s); and V, the yarn velocity (m/s).
Adanur and Mohamed11 found experimentally the
relationship between friction coefficient and air
velocity (range of 1-350 m/s) in the form of:
C f = c1U − c 2 …(6)
Rero = Reynolds number on the weft yarn radius
Rex = Reynolds number on the weft yarn length
Adanur and Bakhtiyarov4:
96ψ
…(12)
Re
where ψ is the function of guide channel and its slots
dimensions.
2.2 Proposed Model for Yarn Motion
The present model17 is based on the Adanur and
Mohammed5 model on an Investa single nozzle air-jet
loom with weft yarn drum storage (Fig.1). The
general assumptions for this model are:
 NOSRATY et al.: SIMULATION ANALYSIS OF WEFT YARN MOTION IN SINGLE NOZZLE AIR-JET LOOM 47

Fig. 1 — Schematic diagram of the drum - storage model for single nozzle air - jet loom19 [1— Weft package, 2— Weft yarn, 3— Weft
yarn feeder, 4 —Weft yarn drum storage, 5— Yarn clamp, 6— Yarn guide,, 7— Air nozzle, 8— Scissors, 9— Confusor, 10— Suction
pipe, and 11— Suction tank]

(i) Weft yarn has uniform properties, such as linear F2 = 0.5mV 2 e µα …(15)
density and diameter, and is inextensible.
(ii) The fluctuation in the movement of the yarn due where m is the linear density of the yarn (kg/m); µ, the
to turbulent and unsteady flow is not taken into friction coefficient between yarn and guide; and α, the
account. Therefore, the yarn moves along a angle of wrap around the guide (rad).
straight line inside the confusor along the center. The function of the total yarn mass involved in the
(iii) The effect of gravitational force on the yarn motion is given as follows:
motion is neglected, since its value is small.
(iv) The starting point for the weft yarn motion is M ( x ) = m ( x + k1 ) …(16)
taken as the confusor entrance and its
displacement in confusor is chosen on X-axis. where k1 = l1 + l2 + l3 + l4 + l5 + l6
Newton’s second law governs the yarn motion Thus
during the course of insertion. Thus, the equation for
the yarn motion can be written as5: 2
d ( MV )  dx  d 2x
d ( MV ) = m  + m( x + k1 ) 2
= ΣF = F1 − F2 …(13) dt  dt  dt
dt
Thereafter
where M is the total yarn mass involved in the motion 2 2
(kg); V, the yarn velocity (m/s); t, the time (s); ΣF, the  dx  d x
m  + m( x + k1 ) 2 = 0.5πρdCf (U 0 − V ) 2
total force acting on the yarn; F1, the air friction force  dt  dt
on the yarn; and F2, the force applied by the yarn l7
guide.
∫
(l 4 + l5 + l 6 ) + 0.5πρd C f (U − V ) 2 dx
0
2
F1 = 0.5πρdC f (U 0 − V ) (l 4 + l 5 + l 6 ) − 0.5πpdC f V l 2 − 0.5mV 2 e µα
2
l7

∫
+ 0.5πρd C f (U − V ) 2 dx − 0.5πρdC f V 2 l 2 ...(14)
0
With simplified assumptions as A= 0.5πρd and k2 =
l4 + l5 + l6, the following second-order non-linear
where Uo is the initial air velocity at the core of differential equation for weft yarn motion is obtained:
nozzle (m/s); U, the air velocity at a distance from the
nozzle (m/s); V, the yarn velocity (m/s); d, the yarn d2x Ak 2 C f (U 0 − V ) 2 AC f (U − V ) 2
= + x (t )
diameter (m); ρ, the air density (kg/m3); Cf, the dt 2 m[ x (t ) + k 1 ] m[ x (t ) + k 1 ]
friction coefficient between air and yarn; l2 = the yarn  dx 
2

length between the guide and nozzle; l4 + l5 + l6, the  

−  
dt
lengths of yarn exposed to nozzle’s air flow; and x, [ AC f l 2 + 0.5me µα + m] …(17)
the distance from the confusor entrance (m). m[ x(t ) + k1 ]
48 INDIAN J. FIBRE TEXT. RES., MARCH 2008

In solving Eq. (17), the parameters Cf and U should theoretical prediction with experimental results is
be substituted in according to distance (x) or time (t), made when Eqs (4) and (5), respectively for air
and the initial conditions taken into account. velocity and friction coefficient, are substituted into
the yarn motion Eq. (17). Consequently, the following
2.3 Numerical Solutions equation was selected as the simulating model for
weft yarn motion:
2.3.1 Initial Conditions
The confusor entrance was taken as the starting 2
point, i.e. at this point the distance of yarn is zero  dx   
Ak 2 U 0 − 
(x = 0). At this instant (t = 0, x = 0), the length of the
2
d x  dt   1 
2
=  + 0.02
yarn that is under the influence of the air-jet is equal dt m[ x(t ) + k1 ] U 0 e cx(t) − dx + 2 
to l4 + l5. Therefore, the total force on the yarn is  dt 
given by the following relationship: 2
 dx   
A U 0 e cx(t) − 
 
+ 
2
ΣF = 0.5πρdC f U 0 (l 4 + l5 ) …(18) dt  1
 + 0.02 x(t )
m[ x(t ) + k1 ] U 0 e cx(t) − dx + 2 
and the yarn mass, when the clamp opens but the yarn  dt 
is still stationary, is given by using the following  dx 
2

equation:  
−  
dt
M = m(l1 + l 2 + l3 + l 4 + l5 ) …(19) m[ x(t ) + k1 ]
   
Since there is a force acting on the yarn, the yarn   1
 
×  Al 2  + 0.02  + 0.5me µα + m
acceleration is not zero, while the yarn velocity is   U e cx(t) − dx + 2  
zero (V = 0) because still clamped.  
  
0
dt 
Hence
2 …(22)
dV 0.5πρdC f U 0 (l 4 + l 5 )
a= = …(20) 3 Results and Discussion
dt m(l1 + l 2 + l 3 + l 4 + l 5 )
3.1 Influence of Variable Parameters in Model
Owing to the fact that the distance l6 is very small, the The parameters that could be changed practically
yarn acceleration along this distance can be assumed on the air-jet loom are yarn count and air-supply
not changed. Thus, the yarn velocity at the starting pressure. Yarn count causes a change in the yarn
point, i.e. the entrance of confusor, can be written as: diameters (d) and linear density (m) in the model, and
air-supply pressure could change air density (ρ) and
V0 = 2al 6 …(21) initial air velocity (U0). Therefore:

2.3.2 Solution Procedures 5.905 × 10 −4

m= …(23)
By substituting each of the air velocity distribution Ne
equations [Eqs (1), (2), & (4)] and friction coefficient
equations [Eqs (5), (6), (7), (8), (9), (10), (11), and 8.745 × 10 −5
(12)] into weft yarn motion equation [Eq. (17)], a d= …(24)
numerical equation was obtained for yarn motion. Ne
These second-order non-linear equations with initial
conditions were solved by using 4th order Runge-kutta P
ρ= …(25)
numerical method. Then, weft yarn displacement, RT
velocity, and tension graphs were obtained from the
yarn motion equations for a cotton-polyester 30/2Ne where P is the air pressure (N/m2); ρ, the air density
weft yarn under 3 bar pressure and compared with (kg/m3); T, the air absolute temperature (Kelvin); and
experimental results. It was concluded that the nearest R, the gas constant equals to 287 j/kg.K.
 NOSRATY et al.: SIMULATION ANALYSIS OF WEFT YARN MOTION IN SINGLE NOZZLE AIR-JET LOOM 49

Equation (25) shows that with the increase in air

pressure at a constant temperature, air density (ρ) is
increased. Therefore, the constant value of A= 0.5πdρ
in simulating model is increased. Owing to the
increase in air pressure, the weft yarn acceleration and
the force acting on the yarn are increased. Thus, the
initial air velocity at the core of nozzle can be
calculated with different air pressure by using the
following equation18:

U 0 = M .C …(26)

2  γ / γ −1 
ln( P / P0 )

where M = 2
e − 1 …(27)
γ −1  

Fig. 2 — Effect of weft yarn count on weft yarn tension from
Cp theoretical model (under 3 bar air pressure)
γ= = 1 .4 …(28)
Cv

where M is the Mach number; C, the sonic velocity

(335 m/s); Cp, the isopiestic specific heat ; Cv, the
isovolumetric specific heat ; γ, the adiabatic index for
air ; P0, the atmosphere pressure (105 Pascal ); and P,
the air supply pressure .
Thereafter, the theoretical solutions to simulating
model Eq. (22) were obtained by 4th order Runge-
kutta method by using a written program19 and Matlab
software. Theoretical results were achieved for
different conditions of variable factors of the yarn
counts 20/2, 30/2, and 40/2Ne, and air-supply
pressures 2.5, 3.0, 3.5, 4.0, and 4.5 bar. The following
information of the Investa single nozzle air-jet
loom model is necessitated to solve the model: reed
Fig. 3 — Effect of air pressure on weft yarn tension from
width = 1.5m; l1 = 0.01m; l2 = 0.085m; l3 = 0.055m; theoretical model (yarn count 30/2 Ne)
l4 = 0.015m; l5 = 0.015m; and l6 = 0.015m; channel
diameter (D) = 0.018m; angle of wrap around the on machine efficiency. If it is less than the yarn
guide (α) = 21.42 rad; machine speed = 300 rpm; breaking strength, the efficiency increases and hence,
and timing— yarn release = 105○, and clamp the production costs decrease. This parameter can be
closes = 235°. Thus, time ( t) = 0.075 s; and air obtained easily from the weft yarn tension graphs. On
temperature (T) = 298 K (25°C). the other hand, measuring of weft yarn displacement
Figures 2 and 3 show the influence of variable and velocity needs more complex instruments. For
factors theoretically on the weft yarn tension under this reasons, the peaks of theoretical and experimental
different conditions. tension graphs have been compared at a weft insertion
Weaving trials were made commercially on an cycle to consider the simulating model equation.
Investa single nozzle air-jet loom (Model 15Zs–8MZ– All weft yarn tension measurements were made by
1979–PN155) at the air pressure for weft insertion an electronically Rothschid tensiometer. The average
from 2.5 bar to 4.5 bar with 0.5 bar intervals using of the maximum tension of weft yarn was calculated
blends of 20/2, 30/2, 40/2Ne cotton (33%) and for 100 successive weaving cycles. In all experiments,
polyester (67%) yarns. It is worth noting that the the weaving room temperature was kept nearly
maximum weft yarn tension plays an important roll constant at 25○C. The experimental results were
50 INDIAN J. FIBRE TEXT. RES., MARCH 2008

Table 1 — Average of maximum yarn tension under different

air pressure

Yarn Air pressure Theoretical yarn Experimental

count bar tension peak yarn tension
Ne cN peak, cN

40/2 2.5 99.64 102.64

3.0 102.65 104.58
3.5 105.68 106.41
4.0 109.79 108.21
4.5 112.44 110.24
30/2 2.5 106.40 111.94
3.0 111.21 114.19
3.5 115.69 116.44
4.0 120.09 118.70
4.5 125.12 120.95
20/2 2.5 145.32 148.57
3.0 150.54 152.45
3.5 155.76 155.73
4.0 161.24 159.39 Fig. 4 — Theoretical and experimental graphs for maximum yarns
4.5 166.34 163.02 tension under different air pressures

compared with the theoretical values (Table 1).
Statistical analysis at 95% level of confidence shows
that there is no significant difference between the
average yarn tension peaks of theoretical and
experimental results. However, in 2.5 and 4.5 bar of
air-supply pressure the difference is nearly
considerable in comparison with the medium pressure
(Fig. 4). This can be attributed to the yarn buckling
which is created due to turbulent and unsteady flow,
neglecting the simulating model. Perhaps, this
phenomenon at lower and higher air pressure is more
effective on yarn tension than at medium pressure.
With regard to a good agreement between the
theoretical values obtained for the weft yarn tension
peaks and the experimental results, the suggested
simulating model equation Eq. (22) for weft yarn
motion is a suitable prediction method for the
behaviour of weft insertion. The importance of
simulating model is that with this method, it is
possible to minimize the air-supply pressure for
different yarn with different characteristics.
Therefore, it is avoided from the extra-consumed
energy and also the number of weft yarns breaking
during weft insertion due to using extra air pressure.
For this reason, weaving machine efficiency increases
and the energy cost decreases.
4 Conclusions
Weft yarn motion using a single nozzle is highly
affected by the air velocity distribution and the feed
yarn structure and conditions. Hence, to consider the
weft yarn behaviour through weft insertion channel
and to establish the most suitable conditions of weft
insertion, a simulating analysis model is found to be
very useful. For this purpose, the equation has been
developed for weft yarn motion by using different
equations of air velocity distribution and air-yarn
friction coefficient. Finally, a theoretical model is
suggested to describe the weft yarn motion, i.e. yarn
displacement, yarn velocity and yarn tension.
In the second part of this work, maximum peak of
weft yarn tension has been determined analytically
and compared with the obtained experimental data
under different conditions of air-supply pressure and
yarn count. The results show good agreement between
theoretical and experimental values. This model
enables the air-supply pressure to be minimized for
different conditions of yarn and weft insertion.
Therefore, this kind of simulation is useful to increase
machine efficiency and decrease energy costs.
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