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National Textile Center Annual Report: November 1999

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DEVELOPMENT AND EXPERIMENTAL
EVALUATION OF NONLINEAR
PHENOMENA IN HIGH-SPEED YARN
TRANSPORT SYSTEMS
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Principal Investigators
Bhuvenesh Goswami
Team Leader Textiles
Clemson University
Subhash Batra
Textiles
NC State University
Tushar Ghosh
Textiles
NC State University
Barrie Fraser
Applied Mathematics
Sydney University
Bill Oxenham
Textiles
NC State University
Christopher Rahn
Mechanical Engineering
Clemson University
http:/ / ece.clemson.edu/ crb/ research/ yarn/ ntc/ textile.htm
GOALS
This project develops and experimentally validates nonlinear models for high-speed yarn
transport systems. The research focuses on models for specific textile processes that
involve rotating balloons such as: i) unwinding from cylindrical (as in texturing) or conical
(as in warping and weaving) packages; ii) ring twisting and winding (as in ring spinning or
ply-twisting); and iii) two-for-one twisting. The computer models provide insight into and
promote understanding of the complex process dynamics. The models can also be used to
design processes that provide low, uniform tension at high speed. This maximizes the
process efficiency by minimizing yarn breaks and maximizing throughput.
ABSTRACT
During the last year of this project, our interdisciplinary, international group of researchers
developed new models for several complex yarn manufacturing processes and new, model-
verifying experiments. At North Carolina State University Subhash Batra, Tushar Ghosh,
Bill Oxenham, and their students refined models for the unwinding process and conducted
ring-spinning experiments. Barrie Fraser at the University of Sydney in Australia
developed twist models for ring-spinning and two-plying operations. Under the guidance
of Bhuvenesh Goswami (Textiles) and Chris Rahn (Mechanical Engineering), graduate
students at Clemson University refined the Unwinding Analyzer for experimental
measurement of high-speed video and tension data.
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UNWINDING THEORY (Batra and Ghosh)
The governing equations developed in our previous research on cylindrical package have
been modified to analyze the problem of unwinding from conical package, which is widely
used in the textile processes such as warping and weaving. As shown in Figure 1, the yarn
path can be divided into three regions: the balloon region (OL, region 1) where yarn flies in
the air, the drag region (LU, region 2) where yarn moves on the surface of package, and the
stationary region (US, region 3) on the surface of package where yarn tension varies due to
the static friction. The equation of motion of yarn in region1 and 2 can be written as:
F R
s
T
s
R k a R k k R D k R D m

+

= + + + ) ( } ) ( 2 {
2 2

Where, m is the mass linear density of the yarn, R is the position vector of point P, is the
angular speed of the rotating frame about z-axis, T is the yarn tension and a is the angular
acceleration. For region 1, F is the air drag force per unit length of the yarn, and for region
2, F is frictional drag force per unit length of yarn.
The above two-region analysis is sufficient to solve the problem when the tension at
unwind point is less or equal to the residual tension in the yarn package. However, if this is
not the case, a third region need to be postulated from unwind point to some further point in
the yarn package where yarn tension decayed to residual tension. This point is known as
stationary point S in Fig. 1. The tension decay is due to the static frictional force between
the yarn and package. The force equilibrium equation on P is:
0 sin cos = + +

k N e N
ds
R d
F
ds
R d
T
ds
d
r s

Where, position vector k z e H z c s R
r

+ + = ) tan ) ( ( ) (
0
, N is the normal force exerted
on the yarn element by the package,
s
F

is the static friction force.

s
F

equals to zero at the

H
u
H
s
V L
U
S
R

e e
r r
k k
e e

H
F Fi ig gu ur re e 1 1: : T Th he e o ov ve er r- -e en nd d u un nw wi in nd di in ng g o of f y ya ar rn n
( (O O: : g gu ui id de e- -e ey ye e; ; L L: : l li if ft t o of ff f p po oi in nt t; ; U U: : u un nw wi in nd d p po oi in nt t; ; S S: :s st ta at ti io on na ar ry y
p po oi in nt t; ;
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stationary point and
m
F (maximum friction force in region 3, where frictional coefficient is
) and at an arbitrary point N F
s s
= . Static frictional coefficient
s
at an arbitrary point
in region 3 is proportional to the yarn distance from stationary point S, i.e.:
( ) ( )
u s s s
s s s s = (10)
Where
u
s , s ,
s
s is the distance measured from guide eye to unwind point, a point in the
region 3 and stationary point respectively.
The equation of yarn motion can be solved as a boundary value problem if boundary
conditions at guide-eye, lift-off point, unwind point and stationary point along the yarn path
are defined. Numerical solutions of these problems have been obtained by using shooting
method [2]. Most of the observations in cylindrical package are preserved in conical
package, such as effects of wind angle, yarn-package coefficient of friction, yarn
length in the balloon and residual tension on the balloon shape and tension distribution.
Bifurcation phenomenon exists in conical package as well. However, the conicity of
conical package changes the balloon shape and tension distribution, and the tension in the
yarn path is slightly less than in cylindrical package. Other observation includes that if the
Balloon shape and tension distribution
0
1
2
3
4
5
6
0 2 4 6 8 10 12
Length from gudie eye
S
h
a
p
e

a
n
d

t
e
n
s
i
o
n
mm c 45
0
= ,

6 = ,

20 = , 0 . 1 = , ., 100den M = min, / 1000m V =

, 450mm H
u
= g T
res
78 . 0 =
Figure 2: Length from Guide Eye (Nondimensional)
Red: Unwinding from Conical Package with Conicity = 12
o
Black: Unwinding from Cylindrical Package
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balloons have the same loops, the dr/ds value at the guide eye will decrease with the
increase of the tension at the guide-eye. See Figure 2.
RING SPINNING EXPERIMENTS (Oxenham)
Earlier annual reports have shown the derivation of the theoretical models. Studies are
being conducted to validate the theoretical models in different spinning conditions and
parameters. Experiments are being conducted with different yarns and defects and the
behavior of the balloon is being studied. This will enable us to a better understanding the
validity of theoretical models.
Emphasis has been placed on the tension monitoring methods since this was shown clearly
to correlate with the observed instabilities in the spinning process (Punitha, 1998). It is
understood that the variations in yarn tension during spinning causes proportional variation
in traveler speed. It is also understood that this parameter could potentially offer basis of a
control system to enable optimum productivity. The conventional devices to measure the
variation of tension are costly and difficult to use. In order to overcome the deficiencies of
the conventional devices a new device was set-up. Four proximity sensors were mounted at
equal angular intervals around the circumference of the ring (see Figure 3). Each time the
traveler passes the sensor, an electric pulse is produced. The time elapsed between the
presence of the traveler in front of the sensors is recorded. The traveler speed in each
quarter revolution is then determined from the interval between successive pulses. This
could ultimately be used as the basis of a control system to maximize the production
capabilities of the ring frame.
This approach will be further pursued by mounting additional sensors and coupling this to a
more sophisticated image capturing system. This system will analyze two perpendicular
images to develop a 3D profile of the balloon and this will be compared with data
generated by the traveler speed measuring system. The data obtained from these
measurements will be used to clearly define unstable operating conditions.
Ring spinning experiment results
The figure 4 shows five consecutive captured frames for an experimental balloon profile
for M of 23 (traveler mass), spindle speed of 12,500 rpm, yarn count of 29 Tex, and ring
radius = 25 mm, at maximum bobbin diameter. The theoretical balloon shape (obtained
from the theoretical model) predicts the formation of one and a half balloons with
minimum radius less than that of the bobbin radius. This would cause the yarn to wrap
around the bobbin and ultimately lead to an end-break. The experimental evidence from the
photographs clearly supports this proposal.
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FRONT
BACK
SENSOR 1
SENSOR 4
SENSOR 3
SENSOR 2
Right
Separator Plate
Left
Separator Plate
Traveler
Ring
Bobbin
Spindle
Figure 3: Schematic of the traveler speed monitoring system
Figure 4: Theoretical and experimental balloon profiles
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TWISTING THEORY (Fraser and Stump (U. Queensland))
During this period the the theory for the dynamics of twist in the ring-spinning balloon was
been further developed to model strand twist variation in yarn plying processes (see papers
cited below). The major progress has been in the inclusion of the effect of twist in the yarn
package unwinding balloon theory. This work, by Clark, Fraser and Stump, has just been
written up and submitted for publication. The main new result from this work is the more
realistic model for the forces that hold the yarn in the package surface and resist the
unwinding. At present we are looking at the stability of unwinding balloon configurations.
Preliminary results from this work are expected by November next.
UNWINDING EXPERIMENTS (Goswami and Rahn)
The magnitude and uniformity of the withdrawal tension during over-end unwinding
depends on the coefficient of friction between the yarn and the package. Currently used
friction measurement techniques are not adequate for measuring package surface roughness
characteristics such as yarn-on-package friction at high speed. In research conducted this
year, a new measurement technique for yarn-on-package friction has been developed that
uses simultaneously captured tension data and images of the yarn sliding on the package
surface during actual unwinding. An algorithm combines a mathematical model of the
sliding motion with experimental data to produce estimates of the coefficient of friction of
the yarn/package. Packages of equivalent denier textured and fully drawn polyester yarns
are tested with measurement uncertainty of less than 10%.
Figure 5 shows a schematic diagram of the Unwinding Analyzer used for experimental
measurement. Yarn is withdrawn from a fixed horizontal package by a yarn drive at
transport speeds of up to 1000 meters per minute. A tension sensor installed on the stand
near the eyelet measures the yarn tension. A video camera and stroboscopes capture the
yarn path. The system is controlled and synchronized by Windows-based software on a
PC. The software package integrates data display, control and image processing functions
in one graphical user interface. The image captured by the video camera is transferred to
the PC by the video capture board and displayed. The Digital Signal Processor (DSP)
board receives signals from the speed sensor, tension sensor, and synchronization sensor.
The tension data sampled by the tension sensor is filtered and displayed on the PC.
Synchronization pulses are generated by an optical synchronization sensor at every half
revolution of the balloon and used to measure the rotation speed and control the capturing
of the image by the video camera and flashing of the stroboscopes.
The unwinding analyzer data is processed through a friction algorithm to estimate the
yarn/package friction coefficients of fully drawn and textured polyester yarn packages.
The solid curve in Fig. 6 shows the coefficient of friction for FDY packages with radii of
110 3 mm over a range of withdrawal speeds. The coefficient of friction shows marked
increase from 500 to 800 m/min that tapers off above 800 m/min. Although it is difficult to
differentiate between the effects of tension and speed because both are increasing during
the experiment, the relative insensitivity of friction coefficient to tension in previous
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experiments indicate that speed is responsible for the increasing friction. Figure 6 shows
the increase in the textured yarn coefficient of friction with increasing speed. Again, the
rate of increase seems to decrease above 800 m/min.
This research develops the first in-situ measurements of yarn/package friction during over-
end unwinding. The method combines measurements from the Unwinding Analyzer with a
computational algorithm based on the mechanics of the yarn sliding on the package
surface. The experimental results are reasonable with an overall uncertainty of less than
10%. The FDY coefficient of friction is relatively insensitive to normal force but sensitive
to withdrawal speed, increasing from 0.23 to 0.35 over the speed range of 500 - 1000
m/min. The TY packages have higher coefficients of friction than the FDY packages. The
TY coefficients also increase with speed from 0.37 to 0.48 in the range of 400 - 1000
m/min. The slopes of the coefficient of friction versus speed curves decrease above 800
m/min for both materials. We have also developed a simple measurement method using an
Instron Tensile Tester can be used for comparative coefficient of friction measurements but
provides quantitative agreement with the in-situ measurements only at low tension.
Figure 5: The Unwinding Analyzer
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REFERENCES
1. X. Ma, Dynamic Analysis of Unwinding from Cylindrical Package, Aug, 1997.
Ph.D. Theses, Burlington Textile Library, NCSU
2. W. B. Fraser,, T. K. Ghosh, S. K. Batra, On unwinding yarn from a cylindrical
package, Prod. R. So. Lond. (1992) 436, 479-498.
3. Fraser, W.B.and Stump, D.M., 1998, Yarn twist in the ring-spinning balloon. Proc.
Roy. Soc. Series A, vol. 454 pp. 707--723.
4. Fraser. W.B. and Stump, D.M., 1998, Equilibrium of rhe convergence point in two-
strand plying. Int. J. Solids and Structures. vol. 35, pp. 285--298.
5. Stump, D.M., and Fraser W.B. 1998, On the dynamical theory of twist in yarn
plying. Mathematical Engineering in Industry, vol. 7, pp. 41--56.
6. Stump, D.M., and Fraser W.B. and Gates, K.E., 1998, The writhing of circular cross-
section rods: Undersea cables to DNA supercoils. Proc. Roy. Soc. Lond. 454, 2123--
2156.
Figure 6: Coefficient of friction versus withdrawal speed: FDY
(solid) and TY (dashed). Error bars indicate the uncertainty
associated with the measurement.
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7. Fraser. W.B. and Stump, D.M., 1998, Twist in balanced ply structures. J. Textile Inst.
vol. 89, pp. 485--497.
8. Clark J.D., Fraser, W.B., Sharma, R, and Rahn, C.D., 1998, The dynamic response of
a ballooning yarn: Theory and experiment. Proc. Roy. Soc. Lond. Series A vol. 454,
pp. 2767--2789.
9. Stump, D.M. and Fraser, W.B., 1999, Bending boundary-layers in a moving strip.
Nonlinear Dynamics, (in press).
10. Champneys, A.R.and Fraser, W.B., 1999 The Indian rope trick for a parametrically
excited flexible rod: Linearized analysis. Proc. Roy. Soc. Lond. (in press)
11. Stump. D.M. and Fraser, W.B., 1999, Multiple solutions for writhed rods: implications
for DNA supercoiling. Proc. Roy. Lond. (in press).
12. Clark, J.D., Fraser, W.B. and Stump, D.M., 1999, Simulation of tension in an
unwinding yarn. Mathematical Engineering in Industry. (submitted)
13. Zhu, F., Sharma, R., and Rahn, C. D., Vibrations of Ballooning Elastic Strings,
ASME Journal of Applied Mechanics, Vol. 64, No. 3, pp. 676-683, September
1997.12.
14. Zhu, F., Hall, K., and Rahn, C. D., Steady State Response and Stability of Ballooning
Strings in Air, International Journal of Nonlinear Mechanics, Vol. 33, No. 1, pp. 33-
46, 1998.19.
15. Sharma, R., and Rahn, C., An Experimental Study of Ballooning Yarn with a Control
Ring, Journal of the Textile Institute, Part 1: Fibre Science and Textile Technology,
Vol. 89, pp. 621-634, 1998.22.
16. Kong, X., Rahn C., and Goswami, B., Steady State Unwinding of Yarn from
Cylindrical Packages, Textile Research Journal, Vol. 69, No. 4, pp. 292-306, March
1999.24.
17. Zhu, F., and Rahn, C., Limit Cycle Prediction for Ballooning Strings, International
Journal of Nonlinear Mechanics, (accepted, April 1998).25.
18. Wu, R., Yu, J., Rahn, C., and Goswami, B., Measurement of Yarn/Package Friction
During Over-end Unwinding, Textile Research Journal, (accepted, March 1999).
19. Punitha J.H., Experimental Study of Ring-Spinning, Ph.D thesis, North Carolina State
University, August (1998).