Ijartex 296
Ijartex 296
Ijartex 296
URL: http://atctex.org/ijartex
Volume 4, Issue 1, pp 62-75, September 2016
MODELING COTTON/ NATURAL BAST FIBERS BLENDS: GRAPHIC AND STATISTICAL ANALYSES OF COTTON-FLAX
BLENDED YARNS PRODUCED ON RING AND ROTOR SPINNING MACHINES
ABSTRACT
In view of their physical properties and ultimate textile products quality, natural
fibers have attracted attention to research workers and textiles experts. The
modeling of blended fibers proportions of cotton-flax yarns produced on ring
and rotor spinning machines are developed in the present study. Using
experimental design method, the effect of blend proportions, setting
parameters and spinning processes on physical properties of yarns are revealed
and related. It was fund that the quality index of cotton flax blended yarn is
largely influenced by the blended ratio of raw materials. However, three
influencing factors, the metric yarn count, the twist coefficient value and the
type of spinning system used are considered to be very critical to determinate
the resistance and the elongation of the final blended yarns.
KEY WORDS
Yarn blends; fibers blended; spinning processes; cotton-flax blends; yarn
physical properties; experimental design.
1. INTRODUCTION
Today, in the times of economics’ globalization, it is required to produce textile product of required quality
respecting the environment protection. Being an important renewable and recyclable resource, natural
fibers will play a leading role in the global economy to gradually replace petrochemical textile products. For
this purpose, the textile researchers are working on a more rational use of these fibers.
Due to their similar properties, like comfort and average rate of cellulose [Lewin, Pearce, 1998], Flax fiber
and cotton fiber were used for several yarns in spinning industries [Jonn et al.,1991], and this mixture
interest many researchers and industrialists around the word [Cierpucha at al.,2002, Sedelnik at al.,2006].
Flax fiber (Linumusitatissimum) is probably the earliest textile material and holds a great archaeological
interest [Barber, 1991]. Flax is a source of industrial fibers and, as currently processed, provides long and
short fibers. Long line fiber is used in manufacturing high value linen products, while short staple fiber has
historically been the waste from long line fiber and used for lower value products [Jhala, Hall, 2010].
Cotton fiber is an important economic fiber, representing 45 percent (23.5 Million Tone) of the total fibers
consumed in the textile industry in 2014 [Nana, 2015]. Cotton is the purest form of cellulose found in
nature and is a fiber which originates from plants of the Gossypium species [Shore, 1995]. It is the most
important cellulosic fiber and is also currently the most used of all textile fibers due to its availability and
low price [Vasconcelos ,2005, Kavkler, Demšar 2011].Several studies have been reported in the literature
on the cotton spinning OE yarns with a high proportion of flax fibers [Cierpucha et al.,2006, Kozlowski et
al.,2008, Kozłowski et al.,2012]. Rungsima [Rungsima et al 2008], shown that the different blending
processes, in the blow room (before carding), or in the drawing frame, affect the migratory behavior of the
fibers.
*
: Corresponding author. Email : [email protected]
Copyright 2016 INTERNATIONAL JOURNAL OF APPLIED RESEARCH ON TEXTILE
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Modeling cotton/ natural bast fibers blends: graphic and statistical analyses of cotton-flax blended yarns produced on
ring and rotor spinning machines
Regarding fiber properties, the differences among component length, fineness, shape of cross-section,
coefficient of fiber friction and fiber chemical type, have important effects on fiber migration, as considered
by several workers [Doraiswawy et al., 1993, Townend, Dewhirst , 1964].
In the case of coarser yarns, Mortan [Mortan , 1956] concluded that the migration tendencies of different
fibers decrease because of the fibers’ difficulties to migrate. But in the case of finer yarn counts, they may
show more staple blends, because of the greater contribution of the fiber length [Ruppenenicker et al.,
1989].
The investigation presented in this article is a continuation of our research work into modeling of natural
fibers blending carried in a previous work of this study.
The ultimate objectives for this work are to optimizing and modeling the properties (yarn evenness CVm%,
tenacity, elongation % and yarn quality index) of the manufactured yarns with the use of a ring and rotor
spinning machines from blended different natural fibers. Cotton and flax fibers were used as raw materials
for the preparation of the yarns samples in a mill operated on the cotton system.
Physical properties of yarn blends that have relations by blend ratio, nature and parameters
characterization of constituent fibers are analyzed through statistic and graphic method in order to
modeling the yarn blends model.
The cotton fibers which require different opening, cleaning and clearing are normally prepared in the mill
operated on the cotton system as shown in a bloc scheme in Figure 1.
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BOUCHRAIET, R. et al.
Flax carded sliver of 5 Ktex was prepared by using bale opener and then card machine (DK 740). For the
blending of fibers, the carding machine slivers (six slivers) with the same linear density (5Ktex) were
blended in the first passage in the drawing frame. A second passage is used to improve the homogeneity of
the slivers blends.
Two different slivers were produced in different proportions of flax/cotton blends as 16.6/83.4, and
33.3/66.7 respectively (named -1 & 1 in the plots).
Different yarns tests in the present study were produced by using Schlafhorst Autocoro rotor spinning
machine and Zinser ring spinning frame.
In this study we adopt the method of the design of experiments by using a full factorial set to get significant
results. Some researchers used this method for different textile process [Ben Hassen ,Sakli, 2005,Halimi et
al.,2008]. To statistically analyze the results, it’s necessary to use the main effects and interaction plots and
the analysis of variance (ANOVA) for each measured property of samples. This interpretations are made up
of calculating statistic parameters that show whether the determinants significantly affiliated to the
feedback data and every determinant’s relative importance: the mean sum of squares (MS) , the F-statistic
(F) and the p-value (P) in the interpretation add up to the relative importance of every determinant to the
feedback.
Whenever the null hypothesis is absolutely true, the p-value expresses the probability of rejecting it. Since
the P-value in the ANOVA table is less than 0.05, there is a statistically significant relationship between the
variables at the 95% confidence level.
A commonly used limit by rejecting value for the p-value is 0.05, such as, if the calculated p-value is less
than 0.05 the null hypothesis is not any more true. So the determinant will have a major effect in the
feedback.
Table 3 presents the combination of the spinning system, yarn count, twist factor and blend ratio of
experiments.
Yarns are produced at different blend ration and two different metric counts with is used in different twist
factors. The factors and levels used are shown in Table 2.
Level
-1 16,6/83,4 Ring 20 120
1 33,3/66,7 Open-End 34 140
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Modeling cotton/ natural bast fibers blends: graphic and statistical analyses of cotton-flax blended yarns produced on
ring and rotor spinning machines
2.2. Testing of Yarn Samples
All the samples were conditioned for 24 hours under standard atmospheric conditions of 21± 1 °C and a
relative humidity of 65 ± 2%.
The breaking strength tests of cotton/flax blended yarns produced were carried out in Uster Tensiorapid 3
whereas unevenness and uniformity were measured using the Uster Tester 3.
3. RESULTS AND DISCUSSION
Different researchers have studied various aspects of spun yarns blends quality parameters in the last
century. In textile engineering, quality index value has been considered to be the most important yarn
quality index. On the other hand yarn, textile experts at the Uster Company concluded that the physical
properties of spun yarn are the most important quality parameters of yarn [Uster, 2013]. In textile
engineering, strength has been considered to be one of the most important yarn properties [Nurwaha,
Wang, 2008]. Similarly Krifa [Krifa et al., 2001] who stated that many factors had an impact on yarn quality,
which depends on both fiber quality parameters and spinning condition. Anindya [Anindya et al., 2005]
stated that yarn strength is a principle component of yarn Quality. On the other hand yarn evenness (CVm
%) and yarn elongation significantly affect the final yarn quality [Cheng, Adams, 1995, Azzouz et al., 2005].
It has been observed that researchers gave general statement about various quality parameters of blend
yarn. There are various parameters during yarn production such as variation in mass per unit length and
tensile properties of yarns have long been the most important characteristic in textile processing and
quality control.
The present study has aimed analyzing the cotton/flax yarn blend with the combined effect of blend ratio,
spinning system, linear density and twist factor on blended yarns properties, by studying the influence of
following parameters:
Yarn evenness CVm%
Tenacity cN/tex
Yarn elongation (%)
Yarn Quality Index
The blend cotton/flax fibers is selected carefully to cover a wide knowledge domain of both fibers, whereas
blend ratio, spinning system, yarn count and twist factor are also selected according to practical yarn
spinning requirements ,which is vital for analyzing.
Table4. Table for optimization of yarn quality
Test yarn CVm% Tenacity cN/tex Elongation (%) Yarn Quality Index
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BOUCHRAIET, R. et al.
5. GRAPHIC ANALYSIS
The graphical analyses were performed using Minitab 14 software package. Each chart shows the average
effect of the factor corresponding to the answer studied when it passes from one level to another.
5.1. Analysis of CVm% of blended yarns
The main effects of factors and their interactions on the evenness CVm% of cotton/flax spun yarn are given
respectively in Figures 2 and 3.
We note from the figure 2 that the optimum values of yarn evenness (CVm%) can be obtained with a
mixture16.6/83.4 of flax/cotton fibers. The yarn count affects slightly the CVm%.The yarn evenness CVm%
increases with a decrease in linear density due to variation of the cross sectional of the blended yarn. This
finding remains consistent with the results of Klein W. [klein, 2011].We can note that the twist factor
increases the CVm%. On the other hand, the yarn evenness is mainly affected by spinning system.
M P
32
30
28
26
Mean of CVm%
24
-1 1 -1 1
Ti To
32
30
28
26
24
-1 1 -1 1
Figure 2: Main Effect Plot (data means) for CVm% of cotton/flax yarns
The deterioration of rotor-yarn evenness could be attributed to the sliver regularity because open-end
methods enabling yarn to be spun direct from sliver. On the other hand, each drafting operation increase
evenness considerably because the uniform arrangement of fibers mixed becomes more difficult. However,
evenness values of ring yarns are lower because the fibers are well bound into the structure and exhibit a
controlled movement during drafting resulting in lower evenness.
The interaction matrix (figure 3) show significant interaction between blend ratio and spinning system. The
effect of M on the CVm% is more important on rotor-yarns than ring-yarns. With more proportion of flax
fibers the evenness of open-end yarn becomes higher because the principle of draft system enabling yarn
irregularity proportionally to those of sliver. However, slightly interaction shown between P and Ti. The
interaction plot shows a non-significant interaction between M and Ti or (and) M and To.
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Modeling cotton/ natural bast fibers blends: graphic and statistical analyses of cotton-flax blended yarns produced on
ring and rotor spinning machines
-1 1 -1 1
35
30
M
M -1
25
1
35
P
30
-1
P
1
25
35
Ti
30
-1
Ti 1
25
35
To
30
-1
To 1
25
-1 1 -1 1
Figure 4 illustrates results of the influence of four factors described above on the meaning yarn tenacity.
While blend ratio of flax fibers in the raw material, the different count of the blended yarn and the spinning
process influencing much of the tenacity. Yarn tenacity decreased with increasing the ratio of flax fiber.
These results are in agreement with Krifa M. [Krifa et al., 2001] who stated that many factors had an impact
on yarn strength, which depend on both fiber quality parameters and spinning condition. Also, higher
percentage of flax fiber always decrease yarn strength. This is finding is consistent with the results of
Sevkan A. [Sevkan, Kadoglu, 2012]. On the other hand, the effect of yarn linear density is significant on yarn
tenacity. As the yarn linear density increase thin place, the number of thick and neps increase, tenacity and
elongation values decrease. However, the twist has the least effect on the meaning tenacity due to the
mechanical state of the constituent fibers ( cotton & flax) will lead to different levels of torsional stress
induced in the yarn blended [Bennet , Postle, 1979a).
From interaction matrix on blended yarn strength (Figure 5), the trend of strength has been decreased with
the increase of blend ration of flax fibers any spinning system applied, but it is more higher on the open-
end than ring spinning. Sight interaction between M and Ti on the yarn blended tenacity. This parameter
decreased with the increase in the yarn count. From interaction matrix it is also seen a significant
interaction between each other’s factors respectively: M and Ti, P and Ti also Ti and To. Negligible
interaction between M and To can be observed. It is clear from the interaction plot for tenacity that higher
interaction between independent variables indicating the significance effect on the yarn blended tenacity.
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BOUCHRAIET, R. et al.
M P
9,00
8,75
8,50
Mean of Tenacity cN/tex
8,25
8,00
-1 1 -1 1
Ti To
9,00
8,75
8,50
8,25
8,00
-1 1 -1 1
Figure 4: Main Effect Plot (data means) for tenacity of cotton/flax yarns
-1 1 -1 1
10
M
9
M -1
1
8
10
P
9 -1
P 1
8
10
Ti
-1
9
Ti 1
8
10
To
-1
9 1
To
-1 1 -1 1
Figure 5: Interaction plot for tenacity of cotton/flax yarns
5.3. Analysis of blended yarns elongation
From Figure 6, it is obvious that the raw material blended ratio(M), spinning process (P) and yarn count (Ti)
present the most significant effect on the elongation percentage of the blended yarn.
The higher the ratio of flax fiber in the mix the lower is the yarn elongation (%)“. We note that the Open-
End blended yarn over elongation is significantly lower than that produced in ring spinning. This finding is
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Modeling cotton/ natural bast fibers blends: graphic and statistical analyses of cotton-flax blended yarns produced on
ring and rotor spinning machines
consistent with the results of Klein W. [Klein,2011]. The elongation (%) is mostly influenced by yarn count.
While all factors have positive effect except twist factor, who no consistent trend was observed.
M P
6,0
5,5
Mean of Elongation (%)
5,0
-1 1 -1 1
Ti To
6,0
5,5
5,0
-1 1 -1 1
Figure 6: Main Effect Plot (data means) for Elongation of cotton/flax yarns
-1 1 -1 1
M
M 5 -1
1
4
6
P
5 P -1
1
4
6 Ti
-1
Ti 5 1
4
To
6
-1
1
5 To
4
-1 1 -1 1
Figure 7 shows the interaction plot of the input factors on blended yarn elongation. Results indicate an
important interaction between M and P. Elongation (%) of rotor-yarn blended is more influenced by
increasing the blend ratio of flax fiber in the mix than the ring-yarn blended. We can see a negligible
69
BOUCHRAIET, R. et al.
interactions reported between M and Ti and also between M and To and between P and To. On the other
hand, there is an important interaction between P and Ti; the effect of the yarn count on the elongation %
is more important at the ring system than the open-end system. It is clearly seen that there is a significant
interaction between Ti and To; the effect of the Twist factor is reversed by increasing the yarn count and
vice versa.
The effects of the input factors on Quality Index of cotton/flax yarns are shown in figure 8.Quality index of
blended yarns is predominantly influenced by the composition and the linear density of these yarns. It is
observed that the blend ratio of flax fiber in the mix has the most significant effect on the YQI. More the
proportion of flax in the blend is higher, more the quality index of yarn is low. We can state that a relatively
high proportion of flax in the blend is not recommended. While the spinning process as well as the twist of
the yarn does not have a large significant effect on the yarn quality index. The yarn count has a negative
effect on the yarn quality index. However, it is clear that the cotton /flax blend at this ratio (33.3/66.7 of
flax/cotton fibers) is recommendable for coarser yarns.
M P
2,2
2,0
1,8
Mean of Yarn Quality Index
1,6
1,4
-1 1 -1 1
Ti To
2,2
2,0
1,8
1,6
1,4
-1 1 -1 1
Figure 8: Main Effect Plot (data means) for Quality Index of cotton/flax yarns
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Modeling cotton/ natural bast fibers blends: graphic and statistical analyses of cotton-flax blended yarns produced on
ring and rotor spinning machines
-1 1 -1 1
2,0
M M
1,5
-1
1
1,0
2,0
P
P -1
1,5
1
1,0
2,0 Ti
-1
Ti
1,5 1
1,0
To
2,0
-1
To 1
1,5
1,0
-1 1 -1 1
Figure 9: Interaction plot for yarn quality index of cotton/flax yarns
From the interaction matrix (Figure 9), the interaction of different factors can be stated as follows:
significant interaction between M and P, the effect of M is more important at the ring system than the
open-end system. The interaction plot shows a non-significant interaction between M and the other
factors. However, higher linear density of blended yarn decreases the quality index at the ring spinning
than at the open-end process. It is clear that yarn count decrease strongly the quality index at the higher
twist factor. Quality index of finer blended yarns with higher levels of twist factor decrease slightly than
coarser yarn.
6. STATISTICAL ANALYSIS
The statistical analyses were performed using Minitab 14 software package. ANOVA tables for selected
responses evenness CVm%, Tenacity, yarn elongation (%) and YQI are given in Tables 5, 6, 7 and 8
respectively. The impact of all the variables on the responses is discussed separately in the following
sections:
The experimental results have been statistically evaluated by using Design Expert analysis of variance
(ANOVA).F test used to treat the interaction between design variables. For analyses of multi-variance p
value < 0.05 was applied. If it is less than 0.05 than we can state the effect is statistically significant.
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BOUCHRAIET, R. et al.
Table 5: The analysis of variance for the blended yarn CVm%
Source of Variation DF AdjMS F P
According to p-value, the factors can be classified according to the level of importance as:
Ti>M>P>To
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Modeling cotton/ natural bast fibers blends: graphic and statistical analyses of cotton-flax blended yarns produced on
ring and rotor spinning machines
at high blend ratio and at fine yarn on ring or rotor yarn. The interaction effect of spinning system and yarn
count is statistically significant. The difference between the elongation values of conventional and open-
end yarns increases as the yarn becomes coarser.
Table 7: The analysis of variance for the elongation of blended yarn
Source of Variation DF Adj MS F P
According to p-value, the factors can be classified according to the level of importance as:
M≥P>Ti>To
Table 8: The analysis of variance quality index for the blended yarn
Source of Variation DF AdjMS F P
According to p-value, the factors can be classified according to the level of importance as:
M>Ti>P≥To
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BOUCHRAIET, R. et al.
7. CONCLUSION
The target of this work was to optimize and model the yarns manufactured with the use of a ring and rotor
spinning machines from cotton/flax blended. For these reasons, physical properties of yarn blends that
have relations by blend ratio, nature and parameters characterization of constituent fibers are analyzed
through statistical and graphical methods in order to optimize the yarn blends.
To sum up, the tenacity and yarn elongation of final yarn is largely influenced by the characteristics of raw
materials and the spinning system. The blend ratio has the most significant effect on the yarn quality,
while the spinning processes as well as the twist of the yarn were found statistically significant on
yarns properties. Whereas, the linear density is not the most influencing factors on the resistance of
the yarn. On the other hand, the higher blend ratio of flax fiber in the blend composition not
recommended for fine yarn count.
From the above all discussion and results it can conclude that flax/cotton fiber ratio in the mix and its yarn
properties are influenced by fibers proportion, yarn specifications and operational parameters.
The research results concerning the selected properties served for the development of a model of the
flax/cotton blend in order to improve the quality and cost of flax/cotton yarn at the optimal blend ratio.
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