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Introduction
Friction (DREF) spinning system is an Open-end spinning system. Along with the frictional forces in the spinning zone the yarn formation takes place. The DREF system is used to produce yarns with high delivery rate about 300mpm. It produce a highly uniform yarn from diverse stock including short or difficult to handle at high production rates and low labor and energy expenses.
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Principal of friction spinning

Fibers are delivered onto the drum surface, which transports and stacks the fibers to the fiber bundle rotating between two surfaces moving in opposite directions. The fibers wrap around the bundle surface. wrapped fiber bundle (yarn tail) is tugged by the yarn delivery roll. Therefore twists by fiber arrangement are generated. Due to separate yarn winding and method of twist insertion, it has capability to go for high production rate.

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Principal of friction spinning system Cont

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Type of DREF spinning

DREF-1 DREF-2 DREF-3 DREF-5 DREF-2000 DREF-3000

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DREF-1
DREF-1 friction spinning system was developed in 1973 by Dr.Fehrer.A.G. of Austria.

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DREF-1 Cont
The fibers were opened with an opening roller and allowed to fall on a single perforated cylindrical drum slot The rotation of the drum impart twist to fiber assembly The ratio of perforated drum to yarn surface is very large, hence the drum speed can be kept relatively low. Due to the absence of positive control over the fibers assembly, slippage occurred between the fiber assembly and perforated roller, which reduced twist efficiency Hence this development could not be commercialized

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DREF-2
DREF-2 was exhibited in the year 1975 at ITMA exhibition. It operates on the basis of mechanical/aerodynamic spinning system with an internal suction and same direction of drums rotation.

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DREF-2 Cont
Drafted slivers are opened into individual fibers by a rotating

carding drum covered with saw tooth type wire clothing. The individualized fibers are stripped off from the carding drum by centrifugal force supported by an air stream from the blower. Fibers are transported into the nip of two perforated friction drums where they are held by suction helping in the removal of dust and dirt thereby contributing to production of cleaner yarn. The fibers are sub-sequentially twisted by mechanical friction on the surface of the drums. The low yarn strength and the requirement of more number of fibers in yarn cross-section (minimum 80-100 fibers) were restricted the DREF-2 spinning with coarser counts (0.3-6s Ne).
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DREF-3
The DREF-3 machine is the next version of DREF-2 for

improving the yarn quality came to the market in the year 1981. Yarns up to 18s Ne. can be spun through this system.

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DREF-3 Cont
This is a core-sheath type spinning arrangement. The sheath fibers are attached to the core fibers by the false twist generated by the rotating action of drums. Two drafting units are used in this system, one for the core fibers and other for the sheath fibers. This system produces a variety of core-sheath type structures and multi-component yarns, through selective combination and placement of different materials in core and sheath. Delivery rate is about 300 m/min.

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DREF-5
It was developed by Schalafhorst, Suessen and Fehrer. The range of count to be spun from this system is from 16s to 40s Ne. Production speed is up to 200m/min. This spinning system was not commercialized due to some reasons.

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DREF-5 Cont
The individualized fibers from a single sliver are fed through a fiber duct into the spinning nip at an angle to the yarn axis. They are stretched as far as possible, when fed into the nip.

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DREF-2000
It is the latest development in friction spinning demonstrated in ITMA 99.

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DREF-2000 Cont
DREF-2000 employs a rotating carding drum for opening the slivers into single fibers and a specially designed system being used for sliver retention. The fibers stripped off from front the carding drum by centrifugal force and carried into the nip of the two perforated spinning drums. The fibers are subsequently twisted by mechanical friction on the surface of the drums. Drums are rotates in the same direction.

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DREF-3000
In the ITMA 2003, the first public appearance of the DREF 3000 was made. The yarn can be spun form 0.3Ne to 14.5Ne.

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Yarn formation in Friction spinning system

The mechanism of yarn formation is quite complex. It consists of three distinct operations. Feeding of fibers Fibers integration Twist insertion.

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Properties of Friction Spun Yarns

Friction spun yarns (DREF) yarns have bulky appearance (100140% bulkier than the ring spun yarns) The twist is not uniform and found with loopy yarn surface. Usually weak as compared to other yarns. The yarns possess only 60% of the tenacity of ring-spun yarns and about 90% of rotor spun-yarns. The breaking elongation of ring, rotor and friction spun yarns is equal.

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Properties of Friction Spun Yarns Cont

Depending on the type of fiber, the differences in strength of these yarns differ in magnitude.
100% polyester yarns-strength deficiency is 32% 100% viscose yarns-it ranges from 0-25%

In polyester-cotton blend, DREF yarns perform better than their ring-spun counterparts.
70/30% blend yarn-superior in strength by 25%

DREF yarns are inferior in terms of unevenness, imperfections, strength variability and hairiness. The friction spun yarns are more hairy than the ring spun yarns DREF yarns are most irregular in terms of twist and linear density while ring spun yarns are most even.
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Advantages of Friction spinning system

It can spin yarn at very high twist insertion rates (ie.3,00,000 twist/min). The yarn tension is practically independent of speed and hence very high production rates (up to 300 m/min) can be attainable. Improved dirt particle retention and up to twice the filter service life. Considerable reduced yarn production costs (up to 50%) due to lower yarn mass requirement, lower preparation costs, lower spinning costs and lower personnel expenses.

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Limitations of Friction spinning system

Low yarn strength and extremely poor fiber orientation made the friction spun yarns very weak. The extent of disorientation and buckling of fibers are predominant with longer and finer fibers. Friction spun yarns have higher snarling tendency. High air consumption leads to high power consumption. The twist variation from surface to core is quite high; this is another reason for the low yarn strength. It is difficult to hold spinning conditions as constant. The spinning system is limited by drafting and fiber transportation speeds.

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