Textile Research Journal 2005 Mogahzy 833 45

Textile Research
Journal
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An Integrated Approach to the Analysis of Multi-Component Fiber Blending. Part III: Analysis of
Interactive Fiber Blending
Yehia El Mogahzy, Ramsis Farag, Faissal Abdelhady and Asaad Mohamed
Textile Research Journal 2005 75: 833
DOI: 10.1177/0040517505053899
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DECEMBER 2005
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An Integrated Approach to the Analysis of Multi-Component Fiber

Blending. Part III: Analysis of Interactive Fiber Blending
YEHIA EL MOGAHZY1, RAMSIS FARAG, FAISSAL ABDELHADY,
AND
ASAAD MOHAMED
Auburn University, AL 36849, U.S.A.

ABSTRACT
This paper represents the third of a three-part series in which multi-component fiber
blending was analyzed using an integrated approach. The essence of this approach is that
the phenomenon of fiber blending should be viewed on the basis of four basic modes of
blending: structural blending, attributive blending, interactive blending, and appearance
blending. In this part of the study, the focus is on interactive blending. A modified rotor
ring system is used in which the torque associated with opening and blending of a certain
mass of fibers is monitored throughout its complete run. Blends of different cotton fiber
types and blends of polyester and cotton fibers are evaluated using a number of analytical
methods such as the torque profile during opening and blending, the blend profile of torque
parameters, and the progressive change resulting from consecutive opening and blending.
The results of this study revealed that when cotton fibers of different types are blended
together, fiber length and fiber fineness can influence interactive blending in such a way
that a great deal of the initial mechanical work done is consumed in opening and blending
the longer and finer component in the blend. Large difference in fiber length and fiber
fineness can result in a nonadditive and nonlinear maximum torque associated with
blending. When cotton fibers are blended with polyester fibers, surface incompatibility
becomes a more serious issue than fiber dimensional characteristics. In this regard, a
possible failure of fiber cluster breakdown may occur, leading to nonlinear and nonadditive interactive blending. The results also reveal that the propensity to opening of different
fiber types may follow different trends in consecutive processing.
In Part I [1] of this study, we introduced different

analytical aspects that can collectively reveal the full
nature of fiber blending. In Part II of this study [3], we
discussed structural and attributive modes of blending
using blends of different cotton fiber types and blends of
polyester and cotton fibers. In this Part of the study, we
shift our attention to interactive blending. This implies
the interaction between fibers within a fiber component
and between different fiber components during the
blending process. Understanding the nature of this interaction can result in selecting appropriate fiber types and
fiber attributes for a particular process and in optimizing
machine settings for particular blends. In addition, interactive blending is often associated with many technological problems including: rough fiber flow, machine clogging, and breakage of fiber strands. These problems can
have a great impact on the consistency and quality of
blended end products [6, 8, 10].
1
To whom correspondence should be addressed; e-mail: elmogye
@eng.auburn.edu
Among all modes of fiber blending, interactive blending is the least understood. This is due to its complex
nature and the dynamic changes encountered when fibers
of different types interact together during processing. In
practice, this mode of blending is typically evaluated
through experimental trials involving actual processing
(opening, carding or drawing) of fibers and subjectively
evaluating the processing performance of fibers [7]. Most
fiber producers and machinery makers perform this type
of evaluation as an integral part of their quality control
and design programs. This is typically a time-consuming
test as it involves a great deal of trial and error adjustments and corrections. In addition, it often lacks the
quantitative measures that are necessary for product development and optimization. However, it serves as a
good quality control tool for measuring performance
consistency of fibers.
As indicated in Part I of this study [1], an optimum
interactive blending requires the fulfillment of two main
criteria: maximum breakdown of fiber clusters and appropriate cohesion between fibers. These two criteria
appear to be in conflict on the grounds that a complete
Textile Res. J. 75(12), 833 845 (2005) DOI: 10.1177/0040517505053899
2005 SAGE Publications
www.sagepublications.com
TEXTILE RESEARCH JOURNAL
834
breakdown of fiber clusters requires a smooth fiber interaction and virtually no fiber cohesion. However, an
appropriate cohesion between fibers is required to maintain the integrity of fiber flow during processing and to
allow the formation of fiber strands. It is important
therefore to analyze interactive blending in view of these
two criteria. In this part of the study, these two factors
were analyzed by measuring the propensity of a fiber
strand to opening and blending. Key questions addressed
in this part of the study include:
What measures can we use to analyze interactive blending?
How do dimensional characteristics such as fiber length
and fiber fineness influence interactive blending?
What is the impact of fiber cohesion or fiber friction on
interactive blending?
What is the extent of meeting the linear-additive rule of
interactive blending?
What is the effect of successive runs on interactive
blending?
Experimental Technique for Evaluating

Interactive Blending
In this study, we used a rotor ring unit to measure the
propensity of a fiber strand for opening and blending.
This unit was used in several studies in the past [e.g. 4,
5, 9, 11]. For the purpose of this study, the unit was
modified substantially to allow pre-opening at the feeding stage using a wired clothed feed roll, and to permit
real-time monitoring of fiber flow during the blending
process so that a complete opening and blending profile
can be generated.
As shown in Figure 1, a torque couple was mounted on
the opening roll shaft to allow measuring the resistance
of fiber flow during opening. Torque and speed signals
were acquired using a data acquisition system and LabView software system. Signal processing and analysis
resulted in a torque profile or a stick-slip pattern characterizing the behavior of fiber flow during opening and
blending. In addition, quantitative parameters such as the
mean torque and the opened web (band) width were
measured. These parameters along with the torque profile
collectively characterize the propensity to opening and
blending of the fiber sample.
Fibers in the raw or pre-opened form are fed to the
feeding roll by placing them on the feed plate and displacing them slowly until the front end of the fiber mat is
caught by the feeding roll. The feeding roll rotates clockwise at a very slow speed (4 rpm) carrying the fibers
stripped from the feed plate. A new wired feed roll was
used to allow a point-to-point opening action between
the feed roll and the opening roll. The opening roll
rotates counterclockwise and open the fibers delivered by
the feed roll. The high rotational speed of the opening
roll allows a great deal of opening. Opened fibers released from the opening roll are delivered to the inside
wall of the rotor via air suction. They are then condensed
onto the inside wall of the rotor to form a fiber ring,
which can be taken out of the rotor after completion of
the opening process to be assessed, or re-fed again to the
system for another run.
Torque Profile of Interactive Blending

As indicated above, the torque associated with opening and blending a fiber mass was monitored during the
duration of each rotor-ring run. This resulted in generating a torque profile, or a torquetime relationship. We
should point out that all blend trials performed in this
study represented intimate blending in which raw fibers
of each fiber type were manually pre-opened to form
small fiber tufts and manually pre-blended by weight
depending on the desired blend ratio. The fiber mass was
then fed to the rotor ring via a feed plate. As a result, the
initial manually blended fiber mass was in a rough form
of a discrete fiber strand, which typically consisted of
disorderly small fiber clumps. As a result, the torque
profile produced from the first rotor-ring run exhibited an
erratic and often unpredictable pattern.
The output material of the first run was a thick fiber
ring of a narrow width, when opened, resulting from the
condensation effect into the rotor. This ring was cut at
one cross-section to create a fiber strand, which was then
re-fed to the rotor-ring to perform a second run. This
procedure was repeated to perform subsequent runs
through the rotor ring. Repeated runs through the rotor
ring yielded more homogenous fiber strand and more
consistent torque profiles.
To ascertain consistency and high reproducibility,
torque profiles produced during the fifth rotor-ring run
were considered for blending analysis and comparative
analysis between different fiber types. Figure 2 shows the
general shape of the torque profiles produced during the
fifth rotor-ring runs. The initial zone of the torque profile
is a no-load zone. This begins at the moment the fiber
strand is placed on the feed plate and ends when the
fibers begin to transfer from the feed roll to the opening
roll.
After the initial zone, the torque profile can be divided
into three primary periods. The first period of the profile
(period #1) reflects the initial resistance to the opening
process by the newly fed fiber strand. The rise in torque
in this period is a result of the resistance to the progressively increasing fiber mass removed from the feed roll
DECEMBER 2005
835
FIGURE 1. Modified rotor ring.
FIGURE 2. Torque profile of fiber blending and

associated parameters.
to the opening roll. This rise continues until it reaches a

maximum point at which the maximum amount of fibers
per strand cross-section is being opened. A stick-slip
pattern in this period typically reflects a combination of
inter-fiber friction and fiber-metal friction. However, the

fiber-metal friction dominates this period. The slope (tan
), which may be termed initial opening stiffness reflects the initial resistance of fibers to opening; a high
836
angle () indicates high initial opening stiffness. The

maximum torque (Tmax) in this period reflects the initial
torque threshold of the fibers being opened.
The second period of the torque profile (period #2)
represents a quasi steady-state condition of fiber opening.
From a technological viewpoint, this is the most important period. The stick-slip pattern in this period indicates
a combination of fiber friction and fiber resiliency. The
friction component here is largely dominated by interfiber friction. This pattern is characterized by the mean
and the variance of the torque associated with opening
the fibers (Tm, 2T).
The third period of the profile (period #3) is associated
with a torque reduction resulting from clearing the feed
roll from fibers and fiber transfer from the opening roll to
the rotor. Occasionally, at the end of the second period
and as the fibers are transferred to the rotor, a significant
torque peak may exist, which in some cases may be
greater than the first peak. This peak may be a result of
high fibermetal friction with the metal being the empty
feed roll wires and the fibers are those carried by the
opening roll. In typical processing, this high torque does
not exist as a result of the continuous throughput and
transfer from one opening stage to another. Accordingly,
the second torque peak and the torque reduction period
(period #3) will be ignored in our analysis.
Results and Discussions

COTTON/COTTON BLENDS
The analysis of interactive blending involved three
types of cotton: long-fine (LF) upland cotton, short-
coarse (SC) upland cotton, and extra long staple (ELS)

Giza70 cotton. Values of fiber properties of these cottons
were presented in Part II of this study [3] and are summarized below.
ELS LF
SC
Mic
3.9
3.6
5.6
UHML 1.43 1.32 1.06
SFI
3.2
6.5 11.6
Str
48 40.4 29
Elo
4.6
4.3
5.0
Fin
148 145 200
ML
0.97 0.90 0.87
Figure 3 shows the torque profiles of the LF/SC cotton

blend. These profiles clearly indicate that the SC cotton
exhibits a torque level that is distinctly lower than that of
the LF cotton. This is largely attributed to the expected
lower inter-fiber cohesion of the SC cotton in comparison with the LF cotton as a result of its shorter length and
smaller number of fibers per cross-section of the fiber
strand. This means that dimensional characteristics of
fibers such as length and fineness can indeed influence
the propensity to opening. The extent of this influence
will be clarified later in this paper. Quantitatively, the SC
cotton has lower values of opening stiffness, maximum
torque and mean torque than the LF cotton.
At 50%LF/50%SC, there is a rapid rise in the initial
part of the torque profile leading to higher initial opening
stiffness and higher maximum torque than the individual
blend components (100%LF or 100%SC). This rapid rise
was very consistent in all the replicates made on this
blend. Based on evaluation of the appearance of blended
FIGURE 3. Torque profiles of the Long Fine/

Short Coarse (LF/SC) cotton blend.
DECEMBER 2005
837
fiber webs, this high initial torque rise was found to be

largely related to a loss of intimacy in the incoming fiber
strand with some LF and SC cotton fibers still forming
clustered groups. This explanation was supported by the
results obtained from subsequent rotor-ring runs which
showed that the initial opening stiffness of the 50%LF/
50%SC blend progressively decreased in subsequent
runs indicating an effect of interactive heterogeneity of
the two fiber types. In the second period of the profile the
50%LF/50%SC blend assumes an intermediate level between the individual blend components.
Figure 4 shows the torque profiles of the ELS/LF
cotton blend. These profiles indicate that the ELS cotton
exhibits a torque level that is distinctly higher than that
of the LF cotton. This is partially attributed to the expected higher inter-fiber cohesion of the ELS cotton in
comparison with the LF cotton as a result of its long
length. Quantitatively, the ELS cotton has higher values
of opening stiffness, maximum torque and mean torque
than the LF cotton. At 50%ELS/50%LF, the torque profile exhibits an intermediate level between those of the
individual components.
A different approach to analyze the blending performance, which was discussed in Part I of this study [1] is
to examine the deviation of torque of the actual blends
from the linear additive law of blending. Figure 5 shows
blend profiles of torque parameters for the LF/SC and
LF/ELS blends. Note that the linear additive law was
applied using the blend proportion by number as explained in Part II [3]. Figures 5a and b indicate that both
cotton blends exhibited a linearly-additive mean torque.
Since the ideal blend profile is based on the fiber proportion by number, it is clear that dimensional characteristics such as length and fineness can influence the
propensity to opening of the cotton fiber blend. Figure 5c
shows that the maximum torque of the LF/SC blend

exhibited a clear deviation from the linear-additive rule.
Figure 5d shows that the ELS/LF blend was additive but
nonlinear. This makes the mean torque more suitable for
characterizing the interactive nature of blending than
other torque parameters as it reflects the steady-state
processing condition.
Another aspect of interactive blending stems from the
effect of successive runs on the propensity to opening
and blending. Figure 6 shows the mean torque and the
opened web width at different rotor-ring runs for the two
cotton blends discussed above. These results indicate that
successive runs of cotton fiber blends result in progressive reduction in the mean torque and progressive increase in the web width. The torque results are generally
expected on the basis that consecutive runs result in more
opening, better fiber alignment, and consequently lower
resistance to opening. The progressive increase in band
width is a result of the progressive increase in the degree
of opening. This is also an indication of progressive fiber
cluster breakdown. Obviously, a larger number of fibers
and longer fiber length result in a larger width of the fiber
web.
The results of Figure 6 also indicate that the mean
torque and the web width of the 50/50 blends were
intermediate between the values of the individual components. However, the change in both the torque and the
web width was not linearly related to the blend ratio. For
instance, Figure 6a shows a bias of torque toward the SC
cotton and Figure 6c shows a bias of band width toward
the LF cotton.
In light of the above results, it follows that when
cotton fibers of different types are blended together, fiber
length and fiber fineness can indeed influence interactive
blending in such a way that a great deal of the initial
FIGURE 4. Torque profiles of the Extra Long

Staple/Long Fine (ELS/LF) cotton blend.
838
FIGURE 5. Comparison between actual and linear (by number) blend patterns of cotton blends.
mechanical work done (opening stiffness) is consumed

in opening and blending the longer and finer component
in the blended fiber strand. Large difference in fiber
length and fiber fineness (e.g. the case of LF/SC blend)
can result in a non-additive and nonlinear maximum
torque (or the torque required to initiate blending and
opening). However, the surface and crimp compatibility
of cotton fiber blends result in an additive and linear
mean torque. This means that blending of cotton fibers of
different types is largely governed by the fiber separation
mechanism. Obviously, exceptions to these findings
should be expected if one or more of the cotton components in the blend exhibit abnormal surface characteristics such as fiber stickiness or high variation in wax
percent [5].
Cotton/Polyester Blends
Following the procedures discussed above, we examined the torque profiles of some cotton/polyester blends.
Polyester fibers used are those that were examined in

Part II of this study. Values of some of the basic characteristics of these fibers are given below and their
torque profiles are shown in Figure 7.
Property
LP BP
Mean Lengthinch 1.38 1.07
Finenessmillitex 188 105
Crimp extension % 26
37
As shown in Figure 7, the two types of polyester fibers

exhibited different levels of torque parameters. The long
polyester (LP) had higher torque level than the black
polyester (BP). Based on the values of fiber characteristics of the two fibers, the BP has more fibers per unit
weight and higher crimp than the LP fibers. These should
have resulted in higher torque values. However, the LP
fiber has a longer length than the BP fiber. In addition, it
exhibited higher fiber friction as shown in Table I, which
shows values of fiber friction of the different fibers
DECEMBER 2005
839
FIGURE 6. Mean torque and band width at different rotor-ring runs of cotton blends.
examined in this study measured independently using the

Auburn Beard Friction Test [2]. This method reveals
frictional values that strictly reflect the surface behavior
of fibers, independent of fiber dimensions.
Figure 8 shows the torque profiles of the LF/LP blend.
As can be seen in this Figure, the LP fiber exhibited
substantially higher torque level than the LF cotton fiber.
This is also supported by the higher values of quantitative torque parameters of the LP fiber over those of the
LF fiber. This trend is largely attributed to the longer
length and the higher friction of LP fiber in comparison
with the LF fiber; this is despite the larger number of
fibers per unit weight of the LF fiber over that of the LP
fiber resulting from its fineness [3].
The 50%LP/50%LF blend showed an intermediate
torque level between the two individual components.
However, there was a clear bias to the LF component.
One reason for this bias is the larger number of fibers of
the LF component in comparison with the LP component

in the blend (66 to 34%). Another reason stems from the
substantially higher friction of LP fiber over that of LF
fiber. This effect is expected to hinder the cluster breakdown of LP fibers leading to a propensity to opening of
the blend that is merely a result of fiber separation of the
LF cotton fiber.
The extent of meeting the additivity and linearity
criteria is demonstrated in Figure 9 for three of the torque
parameters, namely: mean torque, torque slope and maximum torque. Note that the linear-additive law was applied using the blend proportion by number as explained
in Part II [3]. As can be seen in Figure 9, the mean torque
largely met the additivity rule, but a great deal of bias
toward the LF fiber is observed. On the other hand, the
maximum torque and the slope (or opening stiffness)
showed a clear bias to the LP component. This bias
supports the speculation made earlier regarding the effect
840
FIGURE 7. Torque profiles of two different

polyester types.
TABLE I. Beard maximum friction values of different fibers

at 6 psi lateral pressure [2].
F-F Friction (gr)

F-M Friction (gr)
LP
BP
ELS
LF
SC
68
54
50
36
34
25
35
27
36
28
LP, long polyester; BP, black polyester; ELS, extra long staple Giza70
cotton; LF, long-fine upland cotton; SC, short-coarse upland cotton.
of interfiber friction of the LP fiber since a bias in these

two parameters to one component typically implies work
consumed in attempting to break down fiber clusters.
This is particularly true when the bias is not due to

dimensional bias or a greater number of fibers per unit
weight.
The effects of successive runs on the propensity to
opening and blending of the LF/LP blend are shown in
Figure 10. The two fiber types exhibited different behaviors in successive runs through the rotor ring. While the
mean torque associated with the LF cotton fiber decreased with successive runs, the LP fiber had a tendency
to initially increase and then level off in further runs.
These trends were found to be consistent for each poly-
FIGURE 8. Torque profiles of the LP/LF

polyester/cotton blend (fifth RR run).
DECEMBER 2005
841
FIGURE 9. Linearity and additivity of different torque parameters of

the LP/LF polyester/cotton blend.
ester fiber type examined in this study. The LP/LF blend

followed the LF fiber trend and it was biased in value to
the LF fiber. The web width of the LP fiber decreased
progressively with successive rotor ring runs. On the
other hand, the LF fiber increased with successive rotor

ring runs. The LP/LF blend was biased to the LP fiber.
The second cotton/polyester blend considered in this
study was the LF/BP blend evaluated in Part II [3] in the
context of structural and attributive blending. It represents an actual fiber blend utilized in textile processing to
produce special-effect fabrics. We should point out that
the particular Black Polyester fiber used in this blend
resulted in an unexplained blending irregularity when it
was blended with cotton fibers in an actual mill operation.
Figure 11 shows the torque profiles of the LF/BP
blend measured during the fifth rotor-ring run. As can be
see in this Figure, the BP fiber exhibited lower torque
level than the LF fiber. This was somewhat surprising in
view of the fact that the BP fiber has more fibers per unit
weight and higher fiber friction than the LF fibers. Unlike
most of the fiber torque profiles examined in this study,
the BP fiber torque profile exhibited early torque peaks in
the no-load zone. Close examination of these peaks revealed that they were a result of a low coherence in the
BP fiber strand leading to few clusters of fibers accelerating through the feed roll and entering the opening roller
earlier than the remaining fiber strand. The second period
of the BP fiber torque profile was characterized by a
pronounced periodicity that almost replicated the periodicity shown in the no-load zone. In addition, the torque
level was not horizontal, as in most fiber profiles. Instead, it had an obvious nonlinear dip between the first
peak and the second peak.
Visual examination of the BP web after each run
revealed an interesting change; the web suffered progressive clustering and increase in irregularity. This indicates
that the work done to open the BP fibers was merely a
result of opening the input web into fiber clusters rather
than individual fibers. The presence of fiber clusters
resulted in a web incoherence, which was not witnessed
in other polyester and cotton fiber types.
The 50%LF/50%BP blend had an initial steep rise in
torque leading to a higher initial opening stiffness and
higher maximum torque than the individual components.
Following this initial trend, the blend was clearly biased
to the LF cotton values. Recall that the BP fiber has fiber
fineness of 105 millitex and mean fiber length of 1.07
inch and LF cotton has fiber fineness of 145 millitex and
mean fiber length of 0.90 inch. This means that the
50%LF/50%BP by weight is actually 46%LF/54%BP by
number. This clearly means that the bias of the blend to
the LF fiber was not attributed to geometrical or quantity advantage of the LF fiber. Instead, the BP fibers
failed to fully intermingle with the LF fiber leading to a
torque profile largely reflecting the LF fiber propensity to
opening.
842

Figure 12 shows the mean torque and web width of the
LF/BP blend in subsequent rotor-ring runs. As can be
seen in this Figure, after the first rotor-ring run, successive runs resulted in a continuous increase in torque and
a continuous decrease in web width of the BP fiber. The
mean torque of the 50%LF/50%BP blend was biased to
the LF fiber in all successive runs. Meanwhile, the web
width of the 50%LF/50%BP blend was biased to the BP
fiber.
The extent of meeting the additivity and linearity
criteria of the LF/BP blend is demonstrated in Figure 13
for three of the torque parameters, namely: mean torque,
torque slope and maximum torque. Again, the linear
additive law was applied using the blend proportion by
number as explained in Part II [3]. As can be seen in
Figure 13, all torque parameters showed clear violation
of the linear-additive rule.
In light of the above discussion, it follows that when
cotton fibers are blended with polyester fibers, surface
incompatibility becomes a more serious issue than fiber
dimensional characteristics. For example, the case of
LF/LP blend discussed above clearly revealed that the
high inter-fiber friction of the polyester fiber associated
with high crimp resulted in fiber clustering and persistence of polyester fibers to stick together. Indeed, appearance blending analysis showed persistent clusters of
the LP component in the final fiber strand. The substantially higher torque variance of the LP component also
supports this view. As a result, the mean torque was
largely biased to the LF component indicating that most
of the work done was consumed to individualize the
fibers in the LF component.
The LF/BP blend represented an exceptional case in
which both additivity and linearity were violated. These
trends were a result of a significant clustering effect that
was evident by the web appearance and the high torque
variance.
Closing Remarks
FIGURE 10. Average values of net torque and band width of LF/LP
blend in subsequent rotor-ring runs.
In this Part of the study, the focus was on the analysis

of interactive blending. This mode of blending primarily
reflects the propensity to opening and blending when
fibers of the same type or of different types are intimately
blended together. In theory, the process of fiber opening
involves two main mechanisms: fiber cluster breakdown
and fiber separation or individualization. These two
mechanisms are typically activated in a simultaneous
manner. Cluster break down is a result of consecutive
series of opening in which larger fiber clusters, typically
of the same type of fiber, are reduced to smaller ones.
Fiber individualization is a fine opening process in which
DECEMBER 2005
843
FIGURE 11. Torque profiles of the LF/BP blend

(fifth RR run).
the primary effects are fiber separation and reshuffling of

individual fibers of different fiber types.
The performance of these two mechanisms is largely
determined by a number of factors some of which are
machine-related and others are material-related factors.
Machine-related factors include machine settings, and
the number of consecutive operations. Material-related
factors include fiber dimensional characteristics such as
fiber length and fiber fineness, and fiber surface characteristics.
The extent of failure of fiber cluster breakdown can be
realized from the deviation of the mean torque blend
profile from the linearity and additivity criteria. High
torque variance in one of the components of the blend is
also an indication of fiber clustering. Another way to
determine the extent of cluster breakdown is through
examining the mean torque and the width of the fiber
web over a number of consecutive runs. A progressive
reduction in the mean torque accompanied by an increase
in the web width indicates a great deal of cluster breakdown and fiber individualization. On the other hand, a
dwelling effect or progressive increase in torque associated with a reduction in web width implies failure of
cluster breakdown.
Among the parameters used to characterize interactive
blending, the mean torque measured at the steady-state
condition proved to be the most reliable measure. This is
due its high reproducibility and its simulative nature of
actual opening and blending operations. Other torque
parameters such as maximum torque, initial slope, and
torque variance are useful in revealing interactive blend-
ing problems such as failure of cluster breakdown and

inconsistency in the blended fiber structure.
Based on the results of this study, it was found that
when cotton fibers of different types are blended together, fiber length and fiber fineness can influence interactive blending in such a way that a great deal of the
initial mechanical work done (opening stiffness) is consumed in opening and blending the longer and finer
component in the blended fiber strand. Large difference
in fiber length and fiber fineness (e.g. the case of LF/SC
blend) can result in a nonadditive and nonlinear maximum torque (or the torque required to initiate blending
and opening). However, the surface and crimp compatibility of cotton fiber blends result in an additive and
linear mean torque. This means that blending of cotton
fibers of different types is largely governed by the fiber
separation mechanism. Obviously, exceptions to these
findings should be expected if one or more of the cotton
components in the blend exhibit abnormal surface characteristics such as fiber stickiness or high variation in
wax percent [5].
When cotton fibers are blended with polyester fibers,
surface incompatibility becomes a more serious issue
than fiber dimensional characteristics. For example, the
case of LF/LP blend discussed in this paper clearly
revealed that the high inter-fiber friction of the polyester
fiber associated with high crimp resulted in fiber clustering and persistence of polyester fibers to stick together.
Indeed, appearance blending analysis showed persistent
clusters of the LP component in the final fiber strand. The
substantially higher torque variance of the LP component
844
FIGURE 13. Linearity and additivity of different torque parameters of

the BP/LF polyester/cotton blend.
FIGURE 12. Mean torque and band width of LF/BP blend in
subsequent rotor-ring runs.
DECEMBER 2005
845
also supports this view. As a result, the mean torque was

largely biased to the LF component indicating that most
of the work done was consumed to individualize the
fibers in the LF component.
The LF/BP blend represented an exceptional case in
which both additivity and linearity were violated. These
trends were a result of a significant clustering effect that
was evident by the web appearance and the high torque
variance.
3.
4.
ACKNOWLEDGEMENT
The authors of this series of papers would like to thank
the National Textile Center (http://www.ntcresearch.
org/) for sponsoring this research over a period of three
consecutive years. A cosponsor of this research was
Cotton Incorporated of the U.S.A. (http://www.cottoninc.
com), which sponsored this research both financially and
by providing many useful guidelines. We specifically
thank Mr Charles H. Chewning, Jr, Mr J. Berrye Worsham, III, and Dr Preston E. Sasser of Cotton Incorporated for their great support. We would also like to thank
Welman Inc. and Dr Subhas Gosh of the University of
Eastern Michigan (Former Research Director of ITT) for
providing the specially made polyester fibers used in this
study. Last, but certainly not least we would like to thank
Dr Radhakrishnaiah Parachuru of Georgia Tech and Dr
Royal Broughton, Jr. of Auburn University for their
support and guidance in this study.
5.
6.
7.
8.
9.
10.
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An Integrated Approach to the Analysis of Multi-Component Fiber

Auburn University, AL 36849, U.S.A.

In Part I [1] of this study, we introduced different

Textile Res. J. 75(12), 833 845 (2005) DOI: 10.1177/0040517505053899

2005 SAGE Publications

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