Yin Systematic Investigation Twist
Yin Systematic Investigation Twist
This is the accepted version of the publication Yin R, Tao XM and Xu BG. Systematic investigation of twist generation and propagation in a modified
ring spinning system. Textile Research Journal (vol 90, no. 3-4) pp. 367-375. Copyright © 2020 (The Author(s)). DOI: 10.1177/0040517519866950
Abstract:
Twisting is an important process to form a continuous yarn from short fibers and to determine the
structure and properties of the resultant yarn. This paper systematically examined yarn twisting
process in a modified ring spinning process based on a theoretical model proposed recently. In order
to reduce the number of experiments, response surface methodology (RSM) involving a central
composite design (CCD) in three factors of twist multiplier, speed ratio and wrap angle was
successfully employed for the study and analysis. The significant terms of the models were studied,
and it was discovered that the speed ratio and wrap angle are statistically significant for the responses
of twist efficiency, propagation coefficients of twist trapping and congestion. And more importantly,
linear relationships were found among the three responses.
Introduction
Spinning is a fundamental method to produce long strands from staple raw fibers of cotton, wool,
flax, or other material.1 Twisting is a vital process to determine the staple yarn structure and
performances like strength (tenacity), elongation, evenness and hairiness.2 Till now, ring spinning
continues to predominate in yarn manufacturing industry due to its high yarn quality and flexibility in
materials and yarn counts.3-5 According to the latest statistics, the total number of spindles around
world was astonishing 244 million.6 With the increasing demand of novel features or improving
qualities, many modifications have been developed, such as Compact7, 8, Siro 9, 10
and Solo11-14. In
recent years, a novel spinning technology, named Nu-Torque15-17, has been developed by introducing
a false-twisting unit into the conventional ring frame for producing low twist and soft handle single
yarns. The modified cotton yarns and fabrics have significant advantages in terms of soft handle,
higher yarn strength at lower twist factor, lower residual torque and low knitted fabric spirality after
washing and tumble-dry cycles. 18-24 Among over ten mills using the technology, 18 to 40% increment
in production rate has been achieved for cotton ring yarns with various versions of the technology. In
addition, a significant average energy saving of 337KWh/ton was reported by a mill producing Ne 30
and 1100 KWh/ton for another mill for spinning Ne 80 yarns.
Despite achieved low twist and soft handle single yarns, fundamental mechanism in terms of
false twisting process needs to be addressed. Twist generation and propagation25, 26, which are key
issues leading to the essence of spinning, including the amount of false-twist generated by the
false-twister, false-twisting efficiency and blockage rate, as well as the relationships between
1
false-twisting efficiency and system parameters. The false-twisting unit employed in this study is
single friction-belt with circular cross-section. It has been identified that the friction-belt generates the
false-twists into yarn, meanwhile traps the upward propagation of the real twist as well as congests the
downward propagation of the false twists. In our recent published paper , a steady-state model of
27
yarn dynamics in the modified ring spinning system has been proposed, which deals with two
important phenomena simultaneously, that is, twist generation and twist propagation. Based on the
proposed model, in this paper a systematic evaluation of twist generation and propagation in the
modified ring spinning system has been carried out to assess effects of system parameters on the
false-twisting efficiency as well as propagation coefficients. In order to minimize the number of
experiments, response surface methodology involving a central composite design in three factors of
twist multiplier, speed ratio and wrap angle has been successfully employed for the study and analysis.
The significant terms of the models were studied and relationships among three responses were
investigated.
twist generated by the moving belt, v be the delivery speed of the yarn, and vb be the moving
speed of the belt, the twist efficiency of the moving belt is expressed as
2π R0Tc v
λ= (1)
vb
The second effect is the twist trapping in the up-ward propagation of the real twist inserted by D.
To quantify this effect, let Tt be the total twist lost in zone BC, and TCD be the twist in zone CD,
2
the twist congestion is defined as
Tc
η= (3)
Tc + Th
From the kinematic point of view, the twist in zone AB in Figure 1 can be expressed as
λTBC
TAB kTCD +
= (4)
η
vb
where TBC = is the theoretical twist generated by the false-twister, and all three coefficients
2π R0 v
range from 0 to 1.
Experimental design
The experiments were conducted on a ring spinning frame (Zinser 351) by installing a moving
friction-belt with diameter of 6mm between the front rollers and the yarn guide. A cotton yarn with
linear density of Ne 32 and diameter of 0.16 mm was adopted for the experiments. Three important
parameters, twist factor (X1), speed ratio (X2), and wrap angle (X3) were chosen as the potential
influencing, and twist efficiency (Y1), propagation coefficients of twist trapping (Y2) and congestion
(Y3) were the dependent variables calculated by our proposed model27. Although yarn tension may
have a large impact on twist generation and propagation, it was not considered here for further
3
investigation not only because its value cannot be arbitrarily changed at such a wide range for industry
production, but also the fact that it is not a continuously adjustable parameter for the experiment.
Front rollers
X0 X
O
A0 A1
B0
Oo O1 B1
Y0 G0
Yarn guide
Y
In order to reduce the number of experiments needed, response surface methodology (RSM)
involving a central composite design (CCD) was employed to exam the relationships between
several input parameters and one or more response variables. The range and levels of the independent
variables investigated as listed in Table 1. Speed ratio is defined as the ratio of belt moving speed to
the yarn delivery speed. Wrap angle is defined as the angle formed by the yarn and belt, ∠AOB as
shown in Figure 2. The change of wrap angle can be achieved by adjusting belt position in the
spinning frame. The independent variables were tested in an orthogonal 23 CCD with six center
points and six-star points. Each of the independent variables was conducted at five different levels as
per CCD in three variables with a total of 20 experiments 28. The plan of CCD in coded levels of three
independent variables is shown in Table 2. The statistical significance level (p value) was set at 0.05.
The coded and actual values of the design were generated in a randomized run order using Minitab 16
4
software. Based on the RSM, quadratic polynomial regression equations are developed to fit the
experimental data, as show in the following equation,
K K K −1 K
Y =C0 + ∑ Ci X i + ∑ Cii X i2 + ∑∑ Cij X i X j + ε (i < j ) (5)
=i 1 =j 1 =i 1 =j 2
where Y is the response, C0 is constant, Ci, Cii and Cij are regression coefficients and Xi are the coded
factors, ε is the error and K is the number of independent variables.
Table 1 Coded and actual level for each variables of the CCD
Variation levels
Variables Code
-1.682 -1 0 +1 +1.682
Twist factor X1 2.51 2.91 3.50 4.09 4.49
Speed ratio X2 1.01 1.41 2.00 2.59 2.99
Wrap angle (o) X3 30.00 42.16 60.00 77.84 90.00
5
associated procedures, which is accomplished by subdividing the total variation in a dataset into
component parts allied with sources of variation for testing hypotheses on the variables of the model 29,
30
. Precision of a parameter estimation depends on the degree of freedom (DF), which equals to the
number of experiments subtract the number of additional parameters estimated for that calculation 31.
Followed by Fisher's statistical test (F test), ANOVA was employed to study the importance of each
independent variable 32. F value is calculated by the regression mean square divided by the real error
mean, which implies the influence of each controlled parameter on the model 33, 34. The ANOVA data
in Table A1 lists F value for twist efficiency, propagation coefficient of twist trapping and congestion
as 10.36, 11.16 and 11.33 respectively, suggesting that the regression equation is highly significant.
Generally, the large Fisher value denotes that the variation in the responses can be interpreted by the
model. The associated p value is an important parameter to estimate if F value is large enough to
display statistical significance 35, 36. The p values is the index of the significance of the test, whose
value below 0.05 indicates that the model and the associated terms are statistically significant at 95%
confidence level 37-39. The significance of each coefficient is also determined by the F and p values 40,
41
. ANOVA indicated that the highest significant level was shown by the wrap angle (X3), followed by
the speed ratio (X2) and lastly, the quadratic wrap angle (X3*X3), while the interaction terms (X1* X2,
X1* X3, X2* X3), the linear and quadratic twist factors (X1, X1* X1) were less significant.
Table A1 also shows multiple correlation coefficient (R2) and adjusted R2. The R2 implies the
variation of the response in the model 42.
The higher the R2, the better the model fits the data. The
values of R2 were calculated to be 90.31%, 90.95% and 91.07% for twist efficiency, propagation
coefficients of twist trapping and congestion, respectively, implying that the experimental data was
well-fitted. The adjusted R2 explains the number of predictors in the model and is useful for comparing
models with different numbers of predictors 43.
The high value of adjusted R2 supports a high
correlation between the experimental and the predicted data 30. In this study, the values of adjusted R2
for twist efficiency, propagation coefficients of twist trapping and congestion were 81.59%, 82.80%
and 83.03%, respectively, which means the regression models were statistically significant. The
lack-of-fit p value of the model for twist efficiency, propagation coefficients of twist trapping and
congestion were 0.334, 0.332 and 0.312, respectively, which were higher than 0.05, indicating that the
models fitted all the design points well.
Since there were some insignificant terms existing in the regression models, it was necessary to
simply them by eliminating insignificant terms. Decreasing the number of terms can make the model
manageable, meanwhile increase the precision of the predictors. By examining the F and p values of
each coefficient, it was found that all terms containing twist factor (X1) over the range of 2.51 to 4.49
has little impact on the responses, thus should be removed from the models. Moreover, the interaction
terms should also be removed as they are not significant for the models. The significant terms for the
models were wrap angle (X3), speed ratio (X2) and quadratic wrap angle (X3*X3). The quadratic wrap
6
angle (X2*X2) was reserved as it is significant at 10% level. Therefore, these four terms were
employed to reconstruct the regression formulas. The results of simplified model and ANOVA are
listed in Table A2, from which we can concluded that the reduced model was superior to the complete
quadratic equations because the reduced models have higher F values and lower p values than those of
previous ones. Moreover, all the four terms were statistically significant for the three responses and
the adjusted R2 were better than the previous ones, implying that the reduced regression models were
significant and adequate to depict the actual relationship between the responses and inputs.
Model validation
It is necessary to check the regression model to guarantee that adequate prediction to the actual
data is obtained 44. Diagnostic plots such as normal probability plots shown in Figure 3 enable to
judge the normal distribution of the residuals. The residual is the error between the experimental data
and the simulated value by the theoretical model. A small residual value represents a high accuracy of
the prediction by the model. In Figure 3, the data points on the figure were close to the straight line,
implying that the data was normally distributed.
The regression models were also investigated by nine sets of randomly selected data. As shown
in Table 3, the estimated results generally agreed well with the experimental data, particularly for
trapping and congestion coefficients. Errors between the estimated and experimental values for three
responses were generally less than 10%. All the above results implied that the reduced regression
equations provided sufficient accuracy for predicting the responses. Based on the analysis above, the
reduced regression models were capable of estimating and explaining the actual relationships between
twist efficiency, propagation coefficients and the various system parameters of twist factor, speed ratio
and wrap angle.
7
(a) 99 Twist efficiency
98
95
90
80
70
Percent (%) 60
50
40
30
20
10
5
2
1
-0.03 -0.02 -0.01 0.00 0.01 0.02 0.03
Residual
60
50
40
30
20
10
5
2
1
-0.03 -0.02 -0.01 0.00 0.01 0.02 0.03
Residual
8
(c) 99 Twist congestion
98
95
90
80
70
Percent (%) 60
50
40
30
20
10
5
2
1
-0.02 -0.01 0.00 0.01 0.02
Residual
Figure 3 Normal probability plots of residuals for responses
9
and similar value.
10
Figure 4 Response surface plots for (a) twist efficiency, (b) twist trapping, and (c) twist congestion
Moreover, the relationship between Y1 and Y3 are shown in Figure 5b and a linear regression
equation with a high correlation coefficient of 0.998 was indicated to explain the relationship as
below,
Y3 1.001 − 0.860Y1
= (8)
In addition, Figure 5c depicts the experimental data of propagation coefficients of twist trapping
and congestion, from which a linear relationship could be obtained with the same high correlation
coefficient. The relationship was expressed by the following linear regression formula.
Y3 0.175 + 0.825Y2
= (9)
Finally, it was concluded that the three responses have linear relationships.
11
(a) 1.00
Experimental data
Linear fitted line
0.90
0.85
1.002 − 1.042Y11
Y2Y2=1.002-1.04202Y
=
2
Adj.
Adj .RR2 =0.998
= 0.998
0.80
0.00 0.05 0.10 0.15 0.20
Twist efficiency (Y1)
(b) 1.00
Experimental data
Congestion coefficient (Y3)
0.90
0.85
1.001 − 0.860Y11
YY33=1.00118-0.86027Y
=
2
Adj.
Adj.RR 2=0.998
= 0.998
0.80
0.00 0.05 0.10 0.15 0.20
Twist efficiency (Y1)
(c)1.00
Experimental data
Congestion coefficient (Y3)
0.90
0.85
= 3 0.175 + 0.825Y22
YY3=0.17479+0.82463Y
2
Adj.
AdjR.R=0.998
2
= 0.998
0.80
0.80 0.85 0.90 0.95 1.00
Trapping coefficient (Y2)
Figure 5 Linear relationships among three responses
12
Conclusions
In this paper, a systematic investigation was carried out to study yarn twisting process in a modified
ring spinning system using central composite response surface design. It was found that the speed
ratio and wrap angle are statistically significant for the twist efficiency, propagation coefficients of
twist trapping and congestion at 5% significant level, while the twist factor has little effect on the
responses. Then, the complete quadratic regression models were further simplified by eliminating
insignificant terms, which were validated by normal probability analysis and another nine randomly
selected experiments. Finally, it was important to discover that relationships among three responses
can be expressed by linear regression equations with a high correlation coefficient of 0.998. The
findings can be used to predict yarn twist in the spinning zone under given operation parameters and
facilitate further research in improving spinning technology as well as reforming machine design.
Acknowledgment
This research was funded in part through a research grant from Innovation and Technology
Commission of the Hong Kong Special Administrative Region, China (Project No: ITP/021/17TI) and
a postgraduate scholarship by the Hong Kong Polytechnic University.
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Appendix
15
X1 1 0.000234 0.000234 1.82 0.207
X2 1 0.001745 0.001745 13.54 0.004
X3 1 0.009509 0.009509 73.79 0.000
X 1* X 1 1 0.000077 0.000077 0.60 0.458
X 2* X 2 1 0.000519 0.000519 4.02 0.073
X 3* X 3 1 0.000950 0.000950 7.37 0.022
X 1* X 2 1 0.000000 0.000000 0.00 1.000
X 1* X 3 1 0.000113 0.000113 0.87 0.372
X 2* X 3 1 0.000008 0.000008 0.06 0.808
Residual error 10 0.001289 0.000129
Lack-of-fit 5 0.000791 0.000158 1.59 0.312
Pure error 5 0.000498 0.000100
Total 19 0.014429
R2=91.07% R2(adj.)=83.03%
Seq. SS: sequential sum of squares, Adj. MS: adjusted mean squares
16