Professional Documents
Culture Documents
YARN QUALITY
A PROJECT REPORT
Submitted by
S. VAIDHEESWARAN (200641514)
MASTER OF TECHNOLOGY
IN
TEXTILE TECHNOLOGY
MAY 2008
ii
BONAFIDE CERTIFICATE
knowledge the work reported herein does not form part of any other
ABSTRACT
The aim of this project work (Phase I and II) is to study the effect of
different levels of vibrations at the drafting system of ring frame on the quality
vibration to the front drafting roller. Two levels of vibration were created and
hairiness, tensile strength and elongation at break and classified faults for 20 Ne,
40 Ne and 80 Ne cotton yarn have been studied. The results show that the yarn
imperfections particularly thin places and in the classified faults, short thick
places and long thin places are higher for the yarn produced with vibration.
iv
ACKNOWLEDGEMENT
TABLE OF CONTENTS
ABSTRACT iii
ACNOWLEDGEMENT iv
LIST OF TABLES viii
LIST OF FIGURES ix
1 INTRODUCTION 1
2 LITERATURE REVIEW
2.1 VIBRATION 3
2.1.1 Causes of Vibration 3
2.1.2 Effects of Vibration 3
2.1.3 Types of Vibration 4
2.1.3.1 External force 4
2.1.3.2 Direction of vibration 4
2.2 MEASURES OF VIBRATION 5
2.2.1 Displacement 5
2.2.2 Velocity 5
2.2.3 Acceleration 5
2.3 VIBRATION MEASURING
6
INSTRUMENTS
2.3.1 Displacement Type Instrument 6
2.3.1.1 Contact type instrument 6
2.3.1.2 Non Contact type instrument 6
2.3.2 Velocity Type Instrument 7
vi
2.3.2.1 Transducer 7
2.3.2.2 Laser vibrometer 7
2.3.3 Acceleration Type Instrument 8
2.3.3.1 Servo force balance
8
accelerometer
2.3.3.2 Variable capacitance
9
accelerometer
2.3.3.3 Piezo resistive
10
accelerometer
2.3.3.4 Piezoelectric accelerometer 10
2.3.3.5 Integrated electronic
11
Piezoelectric accelerometer
2.4 ACCELEROMETER MOUNTING 12
2.4.1 Stud Mounting 12
2.4.2 Direct Adhesive Mounting 13
2.4.3 Isolated Adhesive Mounting 13
2.4.4 Triaxial Mounting 13
2.4.5 Magnetic Mounting 13
2.5 STRAIN RELIEVING CABLES 14
2.6 STUDIES ON VIBRATION OF MACHINE
14
APPLIED TO TEXTILE INDUSTRY
3 MATERIALS AND METHODS
LIST OF TABLES
TABLE TITLE PAGE
NO. NO.
3.1 Process parameters used for yarn sample preparation 17
3.2 Specification of piezoelectric sensor 21
3.3 Specification of dynamic signal acquisition system 21
3.4 Effect of spindle speed on vibration at the front roller 23
3.5 Effect of spindle speed on imperfections and hairiness of
24
20 Ne yarn
3.6 Effect of spindle speed on tensile properties of 20 Ne
25
cotton yarn
3.7 Comparison of imperfections and hairiness of yarn
26
produced by LR 6/S and LR G5/1 ring frame
3.8 Comparison of tensile properties of yarn produced by
27
LR 6/S and LR G5/1 ring frame
3.9 Effect of eccentricity of front bottom roller of ring frame
28
drafting system on yarn imperfections and hairiness
3.10 Effect of eccentricity of front bottom roller of ring frame
29
drafting system on tensile property of yarn
3.11 Effect of vibration introducing cam speed at 200 rpm on
30
imperfections and hairiness property of 20 Ne yarn
3.12 Effect of vibration introducing cam speed at 200 rpm on
31
tensile property of 20 Ne yarn
4.1 Effect of vibration introducing cam speed at 400 rpm on
32
imperfections and hairiness property yarn
4.2 Effect of vibration introducing cam speed at 400 rpm on
33
tensile property of yarn
4.3 Effect of vibration introducing cam speed at 400 rpm on
34
classified faults
ix
LIST OF FIGURES
CHAPTER 1
INTRODUCTION
In the textile yarn manufacture, the end breakage rate and quality of
yarn is affected by the vibration of ring spinning frame, as it is the final stage of
yarn production and the delicate nature of the material. At this conversion stage,
vibration may seriously affect the yarn characteristics in terms of evenness,
strength variability and hairiness. Vibration at different elements of the machine
may have different influence on yarn quality.
2
CHAPTER 2
LITERATURE REVIEW
2.1 VIBRATION
Any motion that repeats after an interval of time is called vibration or
oscillation. Vibration is resulting from the application or varying forces to a
structure. The nature of vibration depends upon the nature of force driving it and
on the structure being driven.
2.2.2 Velocity
Velocity is defined as the time rate of change of displacement, which is
the derivative of the time function of displacement. Velocity measurements are
useful for intermediate frequencies i.e. 5 to 50 cps. Displacement at these
frequencies is small.
2.2.3 Acceleration
Acceleration is the time rate of change of velocity. Acceleration
measurements are useful at high frequencies i.e. above 50 cps. The highest
output signals are obtained from these measurements.
When the system is vibrated the magnet is isolated from the system.
The relative motion between the magnet and the coil of wire induces a current
that is proportional to the velocity of vibratory motion. This instrument is heavy,
complex and expensive.
Force given as the current through the coil on the mass in the presence
of magnetic field, the pendulous mass develops a torque proportional to the
product of proof mass and acceleration. It sends an error signal to servo system.
Responding to the error signal, torque motor develops an opposing torque equal
to torque developed by pendulous mass.
9
resistant to poor cable insulation, triboelectric noise, and stray signal pickup.
There is possibility to add electronics such as filters, overload protection and self
identification.
method is ideal for mounting where drilling holes is not practical or where the
mounting surface is not flat.
be used. The accelerometer is first mounted to the magnet. These mounts can
then be moved quickly to measure vibrations at several different locations. Due
to the higher mass, magnets are only recommended for measurements of
vibrations with frequencies up to 1000 Hz. Further, the added mass may affect
the measurement of very light structures due to mass loading.
Drive becomes flexible due to worn bearing in stay bracket, worn shaft
and bearing; bend in stay bracket, roller twist. Amplitude of vibration may be
small at gear and large at off end of the rollers. Stick-slip vibration is often
intermittent observed in speed frame. Their frequency is usually 20 and 30 Hz or
cycles per second.
15
During a stick the draft is high and during a slip the draft is low. Very
short periodic variation in the fibre end arrangement with a wavelength less than
the fibre length.
plane; cot precision on run tapes hardness and texture, tensioning of bottom and
top aprons and their surface condition.
Youjang wang (2007) gave a hypothesis that the drafting waves can be
reduced if a high frequency undulating wave (vibration) is introduced to the
drafting zone. Average drafting force decreases with the increase in the intensity
of imposed vibration.
Apurba Das (2004) discussed about the end breakage in rotor spinning
and classify the end breakage mechanism. Under this head, miscellaneous type
of end breakage can occur due to any faulty parts like rotor, because of vibration
in any machine components or any other external interference.
CHAPTER 3
roller stand. For every rotation of the cam, drafting roller stand would be hit four
times. At that time the vibration is created in the front bottom roller. The speed
of the cam was decided after trial run at 200 rpm, 400 rpm and 600 rpm. Speed
of 400 rpm was selected due to the reason that speed of 200 rpm has not
produced any effect on the yarn quality and the speed 600 rpm damages the
roller stand.
The system used for measuring the vibration at the ring frame consists of
1. Piezoelectric sensor (KISTLER)
2. 4-Input USB Dynamic Signal Acquisition (NATIONAL
INSTRUMENTS)
3. Data acquisition/analysis software (DEWSOFT 6.4)
The above system was used to measure the vibration at the ring frame.
The vibration was measured at the drafting zone of the ring frame by fixing the
sensor on the roller stand.
22
The results had not shown any trend of quality variation for the range
of spindle speed selected. The end breakage rate was higher for the spindle speed
higher than 16000 rpm. So this method was considered as not suitable for
estimating the effect of vibration on quality of yarn.
3.4.2 Comparing the vibration and yarn quality in LR 6/S and LR G 5/1
ring frame machineries
The yarns were produced in LR 6/S and LR G 5/1 ring frame keeping
spindle speed of 16000 rpm as constant. The vibration was measured and it was
4.012g in LR 6/S and 3.950g in LR G 5/1. Though the vibration level in the LR
G 5/1 is low, it is not reflected in the yarn quality results. The yarn produced in
the LR G 5/1 ring frame at a lower vibration resulted in the yarn with inferior
26
quality than that of the yarn produced by LR 6/S ring frame. This depicts that the
reason for this quality variation is not due to the difference in vibration and it
may be due to the other machinery conditions.
Yarn Quality
Um % 12.46 14.05
CVm % 15.96 17.88
CV (1m) % 6.95 6.68
CV (10m) % 4.42 3.95
Index 2.18 2.45
-30% 2000 3719
-40% 158 858
-50% 3 98
-60% 0 6
+35% 1025 1130
+50% 239 242
+70% 49 41
+100% 12 9
+140% 1240 1291
+200% 316 301
+280% 85 76
+400% 22 20
Hairiness Index 6.50 7.85
Sh 1.29 1.59
Sh(1m) 0.42 0.37
Hairs/100m
3mm 712.8 1288.6
4mm 144.0 321.0
5mm 16.6 51.0
6mm 2.8 7.4
7mm 1.0 3.0
27
LR 6/S LR G 5/1
4.012 g 3.45 g
B.Force (gf)
Mean 563.53 387.58
CV% 8.41 13.65
Min. 400.00 255.00
Max. 650.00 492.00
B. Elongation (%)
Mean 5.81 4.73
CV% 8.25 10.87
Min. 4.59 2.90
Max. 7.44 5.99
B.Tenacity (RKm)
Mean 18.17 13.13
CV% 8.41 13.65
Min. 13.55 8.64
Max. 22.02 16.66
B. Work (Kgfm)
Mean 765.37 453.91
CV% 12.91 21.44
Min. 469.80 166.80
Max. 1031.90 712.80
This method of creating vibration was also considered not suitable for studying
the effect of vibration on quality of yarn.
3.4.3 Creating vibration using the eccentric front bottom roller of the
drafting zone
Vibration in machineries can be caused by mass unbalance,
misalignment, eccentricity etc. In this experiment eccentricity was used for
creating vibration. Front bottom roller of drafting zone was selected because it is
rotating at higher speed than middle and back roller and also the final delivery
point. The quality of yarn would be much affected by vibration in the front
bottom roller than others.
28
The yarn sample produced from the eccentric front bottom roller was
compared with the yarn produced with a non eccentric (normal) roller. The
vibration level of eccentric bottom roller was higher than that of the non
eccentric roller. It was 3.93g 4.05g for eccentric roller and 2.22 2.22g for non
eccentric roller. The yarn samples were tested for tensile, evenness, and hairiness
properties. Yarn produced with eccentric bottom roller showed lower quality
than yarn produced with non eccentric roller. The fault wavelength was shown
as the circumference of the front roller and the quality variation is mainly due to
the eccentricity.
Table 3.9 Effect of eccentricity of front bottom roller of ring frame drafting
system on yarn imperfections and hairiness
Without eccentricity With eccentricity
(vibration: 2.22g to 2.23g) (vibration: 3.93g to 4.05g)
Um % 15.85 16.77
CVm % 20.23 21.30
CV (1m) % 7.98 6.88
CV (10m) % 5.19 3.96
Index 2.77 2.91
-30% 5010 6047
-40% 1441 2151
-50% 222 454
-60% 19 48
+35% 2163 2895
+50% 679 1009
+70% 155 217
+100% 26 27
+140% 2073 1942
+200% 540 479
+280% 142 115
+400% 36 25
Hairiness Index 6.70 6.49
Sh 1.52 1.57
Sh(1m) 0.35 0.32
Hairs/100m
3mm 756.2 825.0
4mm 170.0 189.7
5mm 23.8 27.3
6mm 2.6 4.5
29
Table 3.10 Effect of eccentricity of front bottom roller of ring frame drafting
system on tensile property of yarn
This method of creating vibration was also not suitable because the quality
deterioration of yarn may be due to eccentricity and its effect on drafting
irregularities rather due to vibration.
Table 3.12 Effect of vibration introducing cam speed at 200 rpm on tensile
property of 20 Ne yarn
There was no effect found in the imperfections, hairiness and tensile property of
20 Ne yarn due to cam speed at 200 rpm. Hence it was decided to select the cam
speed of 400 rpm for studying the effect of vibration on quality of yarn.
32
CHAPTER 4
Table 4.2 Effect of vibration introducing cam speed at 400 rpm on tensile
property of yarn
Table 4.3 Effect of vibration introducing cam speed at 400 rpm on classified
faults
40s Ne 80s Ne
Without With Without With
vibration vibration vibration vibration
(0.4g) (1.57g) (0.4g) (1.57g)
Faults
A1 5334 15885 862 4280
A2 728 2042 247 813
A3 107 242 58 108
A4 23 57 18 36
B1 348 822 53 218
B2 142 324 58 111
B3 31 55 26 50
B4 15 29 5 15
C1 127 67 19 59
C2 58 38 26 42
C3 8 8 26 24
C4 8 7 15 11
D1 39 2 4 30
D2 27 11 13 11
D3 4 2 8 11
D4 2 4 3 20
E 101 19 10 40
F 54 69 28 107
G 25 1 8 11
H1 77 61 47 36
H2 227 1087 159 997
I1 1 0 0 0
I2 12 0 13 0
A4+B4+C3+C4+D3+D4 60 107 75 117
E+F+G 180 89 46 158
H1+H2+I1+I2 317 1148 219 1033
Total faults 7498 20832 1706 7030
35
8000
7000
6000
Imperfections/km
5000
4000
3000
2000
1000
0
Thin -30% Thin -40% Thick +35% Neps +140%
1400
1200
1000
Imperfections/km
800
600
400
200
0
Thin -50% Thick +50% Neps +200%
400
350
Imperfections/km
300
250
200
150
100
50
0
Thin -60% Thick +70% Thick Neps Neps
+100% +280% +400%
25000
20000
Faults/100 km
15000
10000
5000
0
Total fault
40s Ne Without vibration (0.4g) 40s Ne With vibration (1.57g)
Figure 4.4 Comparison of faults present in the yarn produced with and
without vibration
The Table 4.3 shows the comparison of faults present in the 40 Ne and
80 Ne yarn produced with and without vibration at the drafting zone. It can be
seen from the Table 4.3 and Figure 4.4 that the total number of faults is
increased due to vibration. Objectionable faults (A4, B4, C3, C4, D3, and D4)
and long thin faults (H1, H2) are higher in case of yarn produced with vibration.
The total faults particularly objectionable faults, long thin faults increase due to
vibration.
The deviation in yarn quality is due to the vibration alone since all the
parameters were kept unchanged. The reason for deterioration in quality with
respect to classified fault is due to change in draft when the nip position of the
front drafting rollers is changed due to vibration. The quality of yarn is not
affected upto a certain level of vibration. Beyond a certain level the quality
deteriorates. The imperfections and tensile property of the yarn would also be
affected by the vibration above the levels at which this study is conducted. The
long thin faults and short thick faults are affected much by the roller vibration.
39
CHAPTER 5
CONCLUSION
5.1 CONCLUSIONS
There is no effect on the yarn quality due to vibration level upto
acceleration of 1.3 g at the drafting roller. But due to increased vibration level at
1.57 g in the drafting zone,
1. Thin places in the yarn increases particularly at higher sensitivity levels.
2. Classified yarn faults, particularly short thick faults and long thin faults
increases
3. No trend is observed in tensile and hairiness property of yarn.
2. The effect of vibration at spindle and machine frame on yarn quality can also
be studied.
40
REFERENCES
13. Youjiang Wang and Ning Pan (2007), Frequency Effect of Drawing
Behaviour of Staple Fibre Strands, National Textile Centre Research
Briefs, June 2007, NTC Project F04- GT01.
14. www.bksv.com/pdf/measuring_vibration.pdf
15. www.dliengineering.com/vibman.htm
16. www.kistler.com
17. www.ni.com
18. www.sensormag.com/articles/0299/prac0299/main.shtml
42
LIST OF PUBLICATIONS