Abdullah Al Parvez, profile picture
Uploaded byAbdullah Al Parvez
PPTX, PDF6,793 views

Friction spinning System

Friction spinning, or DREF spinning, is a textile technology that produces coarse yarns and core-wrapped yarns, suitable for applications like blankets and filters. The process involves opening and twisting fibers using friction, enabling high production rates and low manufacturing costs while allowing for various fiber types. Different DREF models (DREF-1, DREF-2, DREF-3, etc.) optimize yarn quality and count ranges, contributing to diverse applications in textiles.

Embed presentation

Downloaded 51 times
Friction Spinning Presented By : Abdullah Al Parvez Shurat Shahriar Eti Sarkar Jasim Munshi Tamanna Akter Tomu
Abstract • Friction Spinning or Dref Spinning is a textile technology that suitable for spinning coarse counts of yarns and technical corewrapped yarns. • Dref yarns are bulky, with low tensile strength making them suitable for blankets and mop yarns, they can be spun from asbestos, carbon fibres and make filters was water systems. • Yarns such as Rayon and Kevlar can be spun using this method.
INTRODUCTION • With the advent of modern spinning systems, frictional properties of fiber assemblies have gained technical importance because of the role played by inter-fiber friction. • Amongst the spinning systems, DREF provides a good platform for production of core spun yarns due its spinning principle. • It offers less spinning tension to the core and core will be positioned exactly at the center of the yarn. • Friction (DREF) spinning system is also known as an Open-end or Core sheath type of spinning system. 3
Features Of Friction Spinning • Yarn properties: low tensile strength. • Application: yarns for knitting; terry yarns; weft yarns. • Advantages: low manufacturing cost; possibility for automation; no fast-moving parts . • Features: up now no limited application possibilities; delivery speed is independent from yarn count. • Low energy expenses and low labor. • Good uniformity,high production rates.
Development of DREF # Development of DREF core-spun yarns unveils a path for new products including : • High performance textiles, sewing threads and in the apparels •due to its exceptional strength, outstanding abrasion resistance, consistence performance in sewing operation, •adequate elasticity for the stretch requirements, •excellent resistance to perspiration, •ideal wash and wear performance and permanent press. 6
Principle Of Friction (DREF) Spinning Systems The friction spinning system consists of: • Opening & individualization of fibres from slivers, • Reassembling of individualized fibres ( collecting), • Twisting (imparting the strength by twisting), • Withdrawing newly yarn formation, • Winding of yarn. ( A cross-wound package)
Basic Working Principle Of Friction (Dref) Spinning Fig.1-Individualizing of fibers on the drums • The figure 1 describes the DREF spinning principle where the opened fibres (1) made roll with an aid of a mechanical roller (2) for reassembling and twisting. • Fibers are delivered onto the drum surface (3), which transports and stacks the fibers to the fiber bundle rotating between two surfaces moving in opposite directions in fig 2.
Fig.2- SchematicView of Friction Spinning
• Friction spinning uses two friction surfaces to roll up fibres into a yarn. • The fibres flow freely to two rotating friction drums (3) (spinning drums, friction rollers, torque rollers). • The surfaces at the nip of the two drums (4) move in opposite direction to twist the fibres collected in the nip. • The yarn is formed from inside outwards, by the superimposition of twisting of individual fibres. • Therefore twists by fiber arrangement are generated. • Due to separate yarn winding and method of twist insertion, it has capability to go for high production rate.
• The twisting rate in friction spinning is related to the drum rpm, drum diameter and yarn diameter as indicated below. Twist (Count) = Drum Rpm x ( Drum Diameter ÷ Yarn Diameter ) x Twisting Efficiency • Because of the very large ratio between the drum and yarn diameters, the rotational speed of the drums need not be high, provided adequate twist efficiency is achieved. • The twist efficiency is reduced due to the slippage between the yarn in the nip and the drum surfaces. It is possible to have a twist efficiency as low as 40%. But even allowing for this, friction spinning is still the most efficient way of inserting twist to fibres, because twist is directly applied to yarn end. 12
Types of DREF Friction Spinning : 1. DREF-1 2. DREF-2 3. DREF-3 4. DREF-5 5. DREF-2000 6. DREF-3000
Technological developments of Dref system  ‘Dref’ is the trade name given to the machine based on friction spinning system, which was developed by Dr E Fehrer of Austria. This process is primarily suited to spin coarser and recycled yarns but most suitable to spin technical yarn. Today, Dref is only spinning machine, which got commercial success.  The different versions of the machine are DREF-1, DREF-2, DREF-3, DREF- 5, DREF-2000 and DREF-3000. DREF-1 friction spinning system has single friction drum (fig.A), where as DREF-2 has two friction drums (fig.B). Fig.A-Dref-1 Schematic Fig. (Single Drum) Fig.B-Dref-2 Schematic Fig. (Double Drum)
Dref -2 End-Uses Areas • Blankets for the homes, hotels, hospitals, camping, military uses, plaids etc. • Cleaning rags and mops from cotton waster and various waste-blends • Deco- and upholstery fabrics (fig.B) • Outerwear and leisure-wear • Filter cartridges for liquid filtration • Secondary carpet backing for tufting carpets • Canvas and tarpaulins for the military and civil sectors • High-tenacity core yarn for ropes, transport and conveyor belts • Asbestos substitutes for heavy protective clothing (protective gloves, aprons etc) packing, gaskets, clutch and brake-linings, flame retardant fabrics etc. • Filter yarns for the cable, shoe and carpet industries • Carpet Yarns (Berber carpets, hand-woven and hand-knotted carpets) and filler weft yarns for carpets.
 Dref-3 is a development over of Dref-2 system for improving the quality of yarn,productivity and count range came to the market in the year 1981,and this is a core-sheath type spinning arrangement and produce component yarns which can not be produce by other spinning machines(Fig.C-Dref 3 ). 23 Fig.C-Dref-3 Process Schema  Dref 5 was developed by Schalafhorst, Suessen and Fehrer after Dref 3,but this spinning system was not commercialized due to to various technical difficulties.
DREF-1 • DREF-1 friction spinning system was developed in 1973 by Dr. Fehrer. A.G. of Austria. • The fibers were opened with an opening roller and allowed to fall on a single perforated cylindrical drum slot • The rotation of the drum impart twist to fiber assembly. • The ratio of perforated drum to yarn surface is very large, hence the drum speed can be kept relatively low. • Due to the absence of positive control over the fibers assembly, slippage occurred between the fiber assembly and perforated roller, which reduced twist efficiency • Hence this development could not be commercialized
DREF-2 •DREF-2 was exhibited in the year 1975 at ITMA exhibition. •It operates on the basis of mechanical/aerodynamic spinning system with an internal suction and same direction of drums rotation. •Drafted slivers are opened into individual fibers by a rotating carding drum covered with saw tooth type wire clothing. •The individualized fibers are stripped off from the carding drum by centrifugal force supported by an air stream from the blower. •Fibers are transported into the nip of two perforated friction drums where they are held by suction helping in the removal of dust and dirt thereby contributing to production of cleaner yarn. •The fibers are sub-sequentially twisted by mechanical friction on the surface of the drums. •The low yarn strength and the requirement of more number of fibers in yarn cross-section (minimum 80-100 fibers) were restricted the DREF-2 spinning with coarser counts (0.3-6s Ne). Fig : DREF-2 friction spinning system
Advantages of the core yarns produced using DREF-2 method • Uniform breaking strength along the entire length and excellent running properties for further processing (weaving and raschel knitting process). • Excellent yarn regularity. • Good adhesion of the sheath fibers to the core. • No rewinding required due to the direct provision of the cylindrical bobbins to the weaving process in a weight range of 8- 10 kg. • Long, knot-free lengths. • High weaving effectiveness, due to the eradication of thread breaks. • High levels of area stability in the finished weave. • Retention of a textile surface character.
DREF-2 Application and Fields  Blankets for the home application range, hotels and military uses etc.  Interior decoration, wall coverings, draperies and filler yarn.  Shoes, ropes and industrial cable manufacturing.  Filler cartridge for liquid filtration  For upholstery, table cloths, wall coverings, curtains, handmade carpets, bed coverings and other decorative fabrics.  Heavy flame-retardant fabrics, conveyor belts, clutches and brake linings, friction linings for automobile industry, packets and gaskets.
DREF-3 • The DREF-3 machine is the next version of DREF-2 for improving the yarn quality came to the market in the year 1981. • Yarns up to 18s Ne. can be spun through this system. • This is a core-sheath type spinning arrangement. • The sheath fibers are attached to the core fibers by the false twist generated by the rotating action of drums. • Two drafting units are used in this system, one for the core fibers and other for the sheath fibers. • This system produces a variety of core-sheath type structures and multi-component yarns, through selective combination and placement of different materials in core and sheath. • Delivery rate is about 300 m/min Fig. Dref-3 Schematic Figure
DREF-3 Application and Fields •Backing fabrics for printing, belt inserts, electrical insulation, hoses, filter fabrics •Hot air filtration and wet filtration in food and sugar industries. •Clutch lining and brake lining for automotive industries. DREF-5 •It was developed by Schalafhorst, Suessen and Fehrer. •The range of count to be spun from this system is from 16’s to 40’s Ne. •Production speed is up to 200m/min. •This spinning system was not commercialized due to some reasons. •The individualized fibers from a single sliver are fed through a fiber duct into the spinning nip at an angle to the yarn axis. •They are stretched as far as possible, when fed into the nip. Fig : DREF-5 Fig : DREF-3
Fig.D-Dref 2000 DREF-2000 •It is the latest development in friction spinning demonstrated in ITMA 99. •DREF-2000 employs a rotating carding drum for opening the slivers into single fibers and a specially designed system being used for sliver retention. •The fibers stripped off from front the carding drum by centrifugal force and carried into the nip of the two perforated spinning drums. •The fibers are subsequently twisted by mechanical friction on the surface of the drums. •Drums are rotates in the same direction.
Advantages of DREF-2000 • Insertion of twist in ‘S’ and ‘Z’ direction is possible without mechanical alterations to the machine. •Yarns up to 14.5s Ne can be produced at speeds of 250 m/min. •Reduced yarn preparation costs due to high sliver weights (card slivers). •Dust extraction for secondary fibers. •Low energy costs due to the use of only 1 fan for 12 spinning heads. •Feeding of all types of filaments, yarns and components as yarn cores, in order to attain high yarn strength and production speeds, voluminous yarns and specific product characteristics.
DREF-2000 Application and Fields •Blankets for the homes, hotels, hospitals, camping, military uses, plaids etc. •Cleaning rags and mops from cotton waster and various waste-blends •Deco- and upholstery fabrics •Outerwear and leisure-wear •Filter cartridges for liquid filtration •Secondary carpet backing for tufting carpets •Canvas and tarpaulins for the military and civil sectors •High-tenacity core yarn for ropes, transport and conveyor belts •Asbestos substitutes for heavy protective clothing (protective gloves, aprons etc) packing, gaskets, clutch and brake-linings, flame retardant fabrics etc. •Filter Yarns for the cable, shoe and carpet industries •Carpet Yarns (Berber carpets, hand-woven and hand-knotted carpets) and filler weft yarns for carpets
DREF-3000 •In the ITMA 2003, the first public appearance of the DREF 3000 was made. •The yarn can be spun form 0.3Ne to 14.5Ne. Advantages of DREF-3000 •System Expansion of the scope of yarn and fiber utilization in the coarse yarn count range •Production of both ‘S’ and ‘Z’ yarns at any time without mechanical alterations to the machine •Reduced yarn preparation costs due to high sliver weights (card slivers) •Higher Bobbin weights through 200mm winding traverse.
DREF-3000 Application and Fields •High tenacity and FR protective clothing for civil & military sector •Fire blocker for the aviation and contract business range, cut protection textiles (protective gloves, mail-bags, seat coverings) •Fiber composite materials for the aviation, automotive, machinery, and construction industry •Tarpaulins, transport and conveyor belts as well as all kinds of technical textiles •Filter fabrics for dry and wet filtration •Upholstery fabrics for contact business range •Knitting sector, elastomeric fabrics •Outdoor textiles (eg chair and dock-chair covering)
Mechanism of Yarn Formation The mechanism of yarn formation is quite complicated. It has three distinct operations, namely: 1. Feeding, 2. Integration and 3. Twist insertion of fibers. Feeding: The individualized fibres are transported by air currents and deposited in the spinning zone. There is a definite effect of mode of feed on fibre extent and fibre configuration in yarn and on its properties. Fibre feed can be done in following methods. • Direct feed • Indirect feed.
1) Direct feed Fibers are fed directly onto the rotating fiber mass that outer part of the yarn tail. 2) Indirect feed Fibers are first accumulated on the in-going roll and then transferred to the yarn tail.
Fibers Integration •The fibers through feed tube assembles onto a yarn core/tail within the shear field, is provided by two rotating spinning drums and the yarn core is in between them. •The shear causes sheath fibers to wrap around the yarn core. •The fiber orientation is highly dependent on the decelerating fibers arriving at the assembly point through the turbulent flow. •The fibers in the friction drum have two probable methods for integration of incoming fibers to the sheath. Twist insertion •The fibers are applied twist with more or less one at a time without cyclic differentials in tension in the twisting zone. •Therefore, fiber migration may not take place in friction spun yarns. •The mechanism of twist insertion for core type friction spinning and open end friction spinning are different.
Twist insertion in core-type friction spinning •Core is made of a filament or a bundle of staple fibers is false twisted by the spinning drum. •The sheath fibers are deposited on the false twisted core surface and are wrapped helically over the core with varying helix angles. •It is believed that the false twist in the core gets removed once the yarn is emerged from the spinning drums, so that this yarn has virtually twist less core. •However, it is quite possible for some amount of false twist to remain in the fact that the sheath entraps it during yarn formation in the spinning zone. Twist insertion in Open end friction spinning •The fibers in the yarn are integrated as stacked cone. •The fibers in the surface of the yarn found more compact and good packing density than the axial fibers in the yarn. •The Figure shown the arrangement of fibers in the DREF-3 yarn as stacked cone shape .
Properties of Friction Spun Yarns •Friction spun yarns (DREF) yarns have bulky appearance (100-140% bulkier than the ring spun yarns) •The twist is not uniform and found with loopy yarn surface. •Usually weak as compared to other yarns. •The yarns possess only 60% of the tenacity of ring-spun yarns and about 90% of rotor spun-yarns. •The breaking elongation of ring, rotor and friction spun yarns is equal. •Depending on the type of fiber, the differences in strength of these yarns differ in magnitude. •100% polyester yarns-strength deficiency is 32% •100% viscose yarns-it ranges from 0-25% •In polyester-cotton blend, DREF yarns perform better than their ring-spun counterparts. •70/30% blend yarn-superior in strength by 25% •DREF yarns are inferior in terms of unevenness, imperfections, strength variability and hairiness. •The friction spun yarns are more hairy than the ring spun yarns •DREF yarns are most irregular in terms of twist and linear density while ring spun yarns are most even.
Properties of Hybrid Yarns/DREF core yarns If one yarn creates out of 2 or more single yarn components is called hybrid yarn. Hybrid yarns are used: A. For reinforced plastics Properties of the yarn • Core/Sheath structure with centric position of the reinforcing filament •Zero twisted reinforced filament gives best strength result •Definable fiber matrix proportion •Protection of the reinforcing filament through the sheath fibers B. For liquid filter cartridges Yarn Properties • Huddle fiber arrangement for best filter action •High elongation values •Long yarn length knotless •Uniform yarn with high tensile strength
C. For heat proof woven and knitted fabrics Yarn properties • Flame resistance •High temperature resistance •High tear abrasion resistance •Good wearing comfort •Good care properties •Skin friendly D. For Secondary carpet backings Yarn Properties • Steady high tensile strength •High uniformity of the yarn •Long knotless length of the yarn •Good non-rotating properties •High chemical resistance •Good thermal transfer •Dust free product •Electric insulation •Good dimension stability for carpets
E. For asbestos substitutes Yarn properties • High yarn volume •Good temperature resistance •High tensile strength •Low elongation F. Cut proof woven and knitted fabrics Yarn properties • High cut resistance •Good wearing comfort •High dimension stability
Advantages of Friction spinning system 1.It can spin yarn at very high twist insertion rates (ie.3,00,000 twist/min). 2.The yarn tension is practically independent of speed and hence very high production rates (up to 300 m/min) can be attainable. 3.Improved dirt particle retention and up to twice the filter service life. 4.Considerable reduced yarn production costs (up to 50%) due to lower yarn mass requirement, lower preparation costs, lower spinning costs and lower personnel expenses.
Limitations of Friction spinning system 1.The extent of disorientation and buckling of fibers are predominant with longer and finer fibers. 2.Friction spun yarns have higher snarling tendency. 3.High air consumption leads to high power consumption. 4.The twist variation from surface to core is quite high; this is another reason for the low yarn strength. 5.It is difficult to hold spinning conditions as constant. 6.The spinning system is limited by drafting and fiber transportation speeds. 7.Low yarn strength and extremely poor fiber orientation made the friction spun yarns very weak.
Thank You Slide Created By Abdullah Al Parvez 9th Batch , Ctec & Moderated By Rest of the members .

More Related Content

PPTX
WRAP AND FRICTION SPINNING SYSTEM
byMazbah Uddin
 
PPT
FRICTION SPINNING TECHNOLOGY, (M.S)
byKEVSER CARPET
 
PPTX
Rotor spinning
byAmit Biswas
 
PPT
Open end spinning
byAashutosh Vatsa
 
PPTX
Rotor spinning
byNishaJagani
 
PPTX
Wrap spinning
bySohail AD
 
PDF
Core yarn spinning
byAzmir Latif Beg
 
PPTX
Different Spinning Techniques
byEnamul Haque
 
WRAP AND FRICTION SPINNING SYSTEM
byMazbah Uddin
 
FRICTION SPINNING TECHNOLOGY, (M.S)
byKEVSER CARPET
 
Rotor spinning
byAmit Biswas
 
Open end spinning
byAashutosh Vatsa
 
Rotor spinning
byNishaJagani
 
Wrap spinning
bySohail AD
 
Core yarn spinning
byAzmir Latif Beg
 
Different Spinning Techniques
byEnamul Haque
 

What's hot

DOCX
Compact Spinning System
byAzmir Latif Beg
 
PPTX
Roving
byBeyene Dumecha
 
PDF
Rapier weaving
byFuad Ahmed
 
PPTX
Rapier loom
byMD SOHEL KHAN
 
PPTX
Draw frame
bySubarnaDey2
 
DOCX
Ring frame
bySadia Textile
 
PDF
Carding note
byRanita Paul
 
PDF
Yarn Manufacturing Process : Comber Part II [Modern combers]
bySVKMs, NMIMS, MPSTME, CTF, Shirpur, Dist. Dhule
 
PPTX
ROTOR SPINNING PROCESS
byMazbah Uddin
 
DOCX
Draw frame (1)
byShahriar Shovon
 
PPTX
Crease.pptx
byMdAbdullah360298
 
PPTX
Conventional loom and modern loom
byMd. Abdullah-Al-Masud
 
PDF
Blowroom
byZulker Nayen
 
DOCX
Blending of textile fibre (tcp)
byAjit Kumar Sahoo
 
PPTX
Rapier Loom
byAmit Biswas
 
PDF
Warp knitting design
byAzmir Latif Beg
 
PPTX
Comber
byMayed Rahman
 
PPTX
Machine parameter of speed frame
bysrsujandiu
 
PPTX
Differents parts of Simplex Machine and their Functions
bySadia Textile
 
DOCX
HVI- High Volume Instrument
byFaisal Ahmed Bappi
 
Compact Spinning System
byAzmir Latif Beg
 
Roving
byBeyene Dumecha
 
Rapier weaving
byFuad Ahmed
 
Rapier loom
byMD SOHEL KHAN
 
Draw frame
bySubarnaDey2
 
Ring frame
bySadia Textile
 
Carding note
byRanita Paul
 
Yarn Manufacturing Process : Comber Part II [Modern combers]
bySVKMs, NMIMS, MPSTME, CTF, Shirpur, Dist. Dhule
 
ROTOR SPINNING PROCESS
byMazbah Uddin
 
Draw frame (1)
byShahriar Shovon
 
Crease.pptx
byMdAbdullah360298
 
Conventional loom and modern loom
byMd. Abdullah-Al-Masud
 
Blowroom
byZulker Nayen
 
Blending of textile fibre (tcp)
byAjit Kumar Sahoo
 
Rapier Loom
byAmit Biswas
 
Warp knitting design
byAzmir Latif Beg
 
Comber
byMayed Rahman
 
Machine parameter of speed frame
bysrsujandiu
 
Differents parts of Simplex Machine and their Functions
bySadia Textile
 
HVI- High Volume Instrument
byFaisal Ahmed Bappi
 

Similar to Friction spinning System

PPTX
DREF Friction Spinning.pptx
byJubayer Ahammed
 
PPT
Frictionspinning
byAmit Biswas
 
PPTX
Friction spinning
byTakbir Ahmed
 
PPTX
Friction Spinning
byZubair Awan
 
PPTX
Spinning 2.pptx
byJASWANT SINGH GILL
 
PPS
Advance spinning Dr.Ash
byDr.S.Aishwariya
 
PDF
Dref Yarns for high performance cut protective gloves
byDavid Ducos
 
PPTX
Advance_spinning_System_Introduction (1).pptx
byssuser94922c
 
PDF
yarn count in friction spinning
bymurugesan venkateswaran
 
PPTX
Advance spinning techniques
bySohail AD
 
PPTX
DRAFTING IN VARIOUS SPINING MACHINE Principle of yarn manufacturing
byVijay Prakash
 
PPTX
RECENT DEVELOPMENTS IN RING SPINNING.pptx
bypeacesoul123
 
PPTX
5_Technological_developments_in_Yarn_Ind.pptx
bythiagofelix41
 
PPTX
general presentation on RSWM.pptx
bySatyakam Srivastava
 
PPTX
Fibre to yarn
byKarcahi university
 
PPTX
Spinning Systems
byDavid Sasso
 
PPTX
Spinning machinery
by Mazadul Hasan Shishir
 
PPTX
Ring Spinning Vs All technologies
byKazmee
 
PPTX
DF.pptx in yarn manufacturing department
bydejene1234567
 
PPTX
PROCESS FLOWCHART OF ROTOR SPINNING.pptx
byssusera8b220
 
DREF Friction Spinning.pptx
byJubayer Ahammed
 
Frictionspinning
byAmit Biswas
 
Friction spinning
byTakbir Ahmed
 
Friction Spinning
byZubair Awan
 
Spinning 2.pptx
byJASWANT SINGH GILL
 
Advance spinning Dr.Ash
byDr.S.Aishwariya
 
Dref Yarns for high performance cut protective gloves
byDavid Ducos
 
Advance_spinning_System_Introduction (1).pptx
byssuser94922c
 
yarn count in friction spinning
bymurugesan venkateswaran
 
Advance spinning techniques
bySohail AD
 
DRAFTING IN VARIOUS SPINING MACHINE Principle of yarn manufacturing
byVijay Prakash
 
RECENT DEVELOPMENTS IN RING SPINNING.pptx
bypeacesoul123
 
5_Technological_developments_in_Yarn_Ind.pptx
bythiagofelix41
 
general presentation on RSWM.pptx
bySatyakam Srivastava
 
Fibre to yarn
byKarcahi university
 
Spinning Systems
byDavid Sasso
 
Spinning machinery
by Mazadul Hasan Shishir
 
Ring Spinning Vs All technologies
byKazmee
 
DF.pptx in yarn manufacturing department
bydejene1234567
 
PROCESS FLOWCHART OF ROTOR SPINNING.pptx
byssusera8b220
 

Recently uploaded

PPTX
Role of In Vitro and In Vivo Testing biomedical engineering
bymarisudha1
 
PPTX
UnrealGameplayAbilitySystemPresentation.pptx
byBenHowenstein
 
PDF
ACI 318-2205_American Concrete Institute.pdf
byericaguilerasoto1
 
PPTX
How to Implement Kaizen in Your Organization for Continuous Improvement Success
byMaintWiz Technologies Private Limited
 
PPTX
ISO 14224 Compliance & CMMS Software — A Comprehensive Guide for Reliable Mai...
byMaintWiz Technologies Private Limited
 
PPTX
Emerging Trends and Research Frontiers in Chemical Engineering for Green and ...
byChemical Engineering Dept. NIT Rourkela-769008, Odisha, India
 
PPTX
MECCA Empire – Hotel Shuttle System for the 2026 FIFA World Cup
byay2432
 
PDF
Surveillance_Partner_Product_Training_20240120_KSA.pdf
byHamadaZayed1
 
PPTX
How to Create an Effective Monthly Maintenance Plan for Reliable Plant Operat...
byMaintWiz Technologies Private Limited
 
PPTX
Plant Performance Strategies: Enhanced Reliability & Operational Efficiency w...
byMaintWiz Technologies Private Limited
 
PPTX
Shutdown Maintenance Explained — Full Plant Turnaround & Best Practices with ...
byMaintWiz Technologies Private Limited
 
PDF
Lecture -06-Hybrid Policies - Chapter 7- Weeks 6-7.pdf
bysalaarmike
 
PDF
Narrows Planning Collective Transportation Capstone.pdf
bycj2392
 
PDF
Presentation-on-Energy-Transition-in-Bangladesh-Employment-and-Skills.pdf
bysyedSajib8
 
PPTX
Power point presentation on introduction of software engineering
bys6050748
 
PPTX
Track & Monitor Preventive Maintenance — Best Practices with MaintWiz CMMS
byMaintWiz Technologies Private Limited
 
PPTX
Natural Gas fundamentals and GRU for associated gas trap.pptx
byengineerhassan
 
PPTX
TPM Metrics & Measurement: Drive Performance Excellence with TPM | MaintWiz
byMaintWiz Technologies Private Limited
 
PPTX
Optimizing Operations: Key Elements of a Successful Plant Maintenance Plan — ...
byMaintWiz Technologies Private Limited
 
PPTX
Assessment 4 SRS Presentation - Final (2).pptx
byayush445302
 
Role of In Vitro and In Vivo Testing biomedical engineering
bymarisudha1
 
UnrealGameplayAbilitySystemPresentation.pptx
byBenHowenstein
 
ACI 318-2205_American Concrete Institute.pdf
byericaguilerasoto1
 
How to Implement Kaizen in Your Organization for Continuous Improvement Success
byMaintWiz Technologies Private Limited
 
ISO 14224 Compliance & CMMS Software — A Comprehensive Guide for Reliable Mai...
byMaintWiz Technologies Private Limited
 
Emerging Trends and Research Frontiers in Chemical Engineering for Green and ...
byChemical Engineering Dept. NIT Rourkela-769008, Odisha, India
 
MECCA Empire – Hotel Shuttle System for the 2026 FIFA World Cup
byay2432
 
Surveillance_Partner_Product_Training_20240120_KSA.pdf
byHamadaZayed1
 
How to Create an Effective Monthly Maintenance Plan for Reliable Plant Operat...
byMaintWiz Technologies Private Limited
 
Plant Performance Strategies: Enhanced Reliability & Operational Efficiency w...
byMaintWiz Technologies Private Limited
 
Shutdown Maintenance Explained — Full Plant Turnaround & Best Practices with ...
byMaintWiz Technologies Private Limited
 
Lecture -06-Hybrid Policies - Chapter 7- Weeks 6-7.pdf
bysalaarmike
 
Narrows Planning Collective Transportation Capstone.pdf
bycj2392
 
Presentation-on-Energy-Transition-in-Bangladesh-Employment-and-Skills.pdf
bysyedSajib8
 
Power point presentation on introduction of software engineering
bys6050748
 
Track & Monitor Preventive Maintenance — Best Practices with MaintWiz CMMS
byMaintWiz Technologies Private Limited
 
Natural Gas fundamentals and GRU for associated gas trap.pptx
byengineerhassan
 
TPM Metrics & Measurement: Drive Performance Excellence with TPM | MaintWiz
byMaintWiz Technologies Private Limited
 
Optimizing Operations: Key Elements of a Successful Plant Maintenance Plan — ...
byMaintWiz Technologies Private Limited
 
Assessment 4 SRS Presentation - Final (2).pptx
byayush445302
 

Friction spinning System

  • 1.
    Friction Spinning Presented By : AbdullahAl Parvez Shurat Shahriar Eti Sarkar Jasim Munshi Tamanna Akter Tomu
  • 2.
    Abstract • Friction Spinningor Dref Spinning is a textile technology that suitable for spinning coarse counts of yarns and technical corewrapped yarns. • Dref yarns are bulky, with low tensile strength making them suitable for blankets and mop yarns, they can be spun from asbestos, carbon fibres and make filters was water systems. • Yarns such as Rayon and Kevlar can be spun using this method.
  • 3.
    INTRODUCTION • With theadvent of modern spinning systems, frictional properties of fiber assemblies have gained technical importance because of the role played by inter-fiber friction. • Amongst the spinning systems, DREF provides a good platform for production of core spun yarns due its spinning principle. • It offers less spinning tension to the core and core will be positioned exactly at the center of the yarn. • Friction (DREF) spinning system is also known as an Open-end or Core sheath type of spinning system. 3
  • 4.
    Features Of FrictionSpinning • Yarn properties: low tensile strength. • Application: yarns for knitting; terry yarns; weft yarns. • Advantages: low manufacturing cost; possibility for automation; no fast-moving parts . • Features: up now no limited application possibilities; delivery speed is independent from yarn count. • Low energy expenses and low labor. • Good uniformity,high production rates.
  • 5.
    Development of DREF #Development of DREF core-spun yarns unveils a path for new products including : • High performance textiles, sewing threads and in the apparels •due to its exceptional strength, outstanding abrasion resistance, consistence performance in sewing operation, •adequate elasticity for the stretch requirements, •excellent resistance to perspiration, •ideal wash and wear performance and permanent press. 6
  • 6.
    Principle Of Friction(DREF) Spinning Systems The friction spinning system consists of: • Opening & individualization of fibres from slivers, • Reassembling of individualized fibres ( collecting), • Twisting (imparting the strength by twisting), • Withdrawing newly yarn formation, • Winding of yarn. ( A cross-wound package)
  • 7.
    Basic Working PrincipleOf Friction (Dref) Spinning Fig.1-Individualizing of fibers on the drums • The figure 1 describes the DREF spinning principle where the opened fibres (1) made roll with an aid of a mechanical roller (2) for reassembling and twisting. • Fibers are delivered onto the drum surface (3), which transports and stacks the fibers to the fiber bundle rotating between two surfaces moving in opposite directions in fig 2.
  • 8.
    Fig.2- SchematicView ofFriction Spinning
  • 9.
    • Friction spinninguses two friction surfaces to roll up fibres into a yarn. • The fibres flow freely to two rotating friction drums (3) (spinning drums, friction rollers, torque rollers). • The surfaces at the nip of the two drums (4) move in opposite direction to twist the fibres collected in the nip. • The yarn is formed from inside outwards, by the superimposition of twisting of individual fibres. • Therefore twists by fiber arrangement are generated. • Due to separate yarn winding and method of twist insertion, it has capability to go for high production rate.
  • 10.
    • The twistingrate in friction spinning is related to the drum rpm, drum diameter and yarn diameter as indicated below. Twist (Count) = Drum Rpm x ( Drum Diameter ÷ Yarn Diameter ) x Twisting Efficiency • Because of the very large ratio between the drum and yarn diameters, the rotational speed of the drums need not be high, provided adequate twist efficiency is achieved. • The twist efficiency is reduced due to the slippage between the yarn in the nip and the drum surfaces. It is possible to have a twist efficiency as low as 40%. But even allowing for this, friction spinning is still the most efficient way of inserting twist to fibres, because twist is directly applied to yarn end. 12
  • 11.
    Types of DREFFriction Spinning : 1. DREF-1 2. DREF-2 3. DREF-3 4. DREF-5 5. DREF-2000 6. DREF-3000
  • 12.
    Technological developments ofDref system  ‘Dref’ is the trade name given to the machine based on friction spinning system, which was developed by Dr E Fehrer of Austria. This process is primarily suited to spin coarser and recycled yarns but most suitable to spin technical yarn. Today, Dref is only spinning machine, which got commercial success.  The different versions of the machine are DREF-1, DREF-2, DREF-3, DREF- 5, DREF-2000 and DREF-3000. DREF-1 friction spinning system has single friction drum (fig.A), where as DREF-2 has two friction drums (fig.B). Fig.A-Dref-1 Schematic Fig. (Single Drum) Fig.B-Dref-2 Schematic Fig. (Double Drum)
  • 13.
    Dref -2 End-UsesAreas • Blankets for the homes, hotels, hospitals, camping, military uses, plaids etc. • Cleaning rags and mops from cotton waster and various waste-blends • Deco- and upholstery fabrics (fig.B) • Outerwear and leisure-wear • Filter cartridges for liquid filtration • Secondary carpet backing for tufting carpets • Canvas and tarpaulins for the military and civil sectors • High-tenacity core yarn for ropes, transport and conveyor belts • Asbestos substitutes for heavy protective clothing (protective gloves, aprons etc) packing, gaskets, clutch and brake-linings, flame retardant fabrics etc. • Filter yarns for the cable, shoe and carpet industries • Carpet Yarns (Berber carpets, hand-woven and hand-knotted carpets) and filler weft yarns for carpets.
  • 14.
     Dref-3 isa development over of Dref-2 system for improving the quality of yarn,productivity and count range came to the market in the year 1981,and this is a core-sheath type spinning arrangement and produce component yarns which can not be produce by other spinning machines(Fig.C-Dref 3 ). 23 Fig.C-Dref-3 Process Schema  Dref 5 was developed by Schalafhorst, Suessen and Fehrer after Dref 3,but this spinning system was not commercialized due to to various technical difficulties.
  • 15.
    DREF-1 • DREF-1 frictionspinning system was developed in 1973 by Dr. Fehrer. A.G. of Austria. • The fibers were opened with an opening roller and allowed to fall on a single perforated cylindrical drum slot • The rotation of the drum impart twist to fiber assembly. • The ratio of perforated drum to yarn surface is very large, hence the drum speed can be kept relatively low. • Due to the absence of positive control over the fibers assembly, slippage occurred between the fiber assembly and perforated roller, which reduced twist efficiency • Hence this development could not be commercialized
  • 16.
    DREF-2 •DREF-2 was exhibitedin the year 1975 at ITMA exhibition. •It operates on the basis of mechanical/aerodynamic spinning system with an internal suction and same direction of drums rotation. •Drafted slivers are opened into individual fibers by a rotating carding drum covered with saw tooth type wire clothing. •The individualized fibers are stripped off from the carding drum by centrifugal force supported by an air stream from the blower. •Fibers are transported into the nip of two perforated friction drums where they are held by suction helping in the removal of dust and dirt thereby contributing to production of cleaner yarn. •The fibers are sub-sequentially twisted by mechanical friction on the surface of the drums. •The low yarn strength and the requirement of more number of fibers in yarn cross-section (minimum 80-100 fibers) were restricted the DREF-2 spinning with coarser counts (0.3-6s Ne). Fig : DREF-2 friction spinning system
  • 17.
    Advantages of thecore yarns produced using DREF-2 method • Uniform breaking strength along the entire length and excellent running properties for further processing (weaving and raschel knitting process). • Excellent yarn regularity. • Good adhesion of the sheath fibers to the core. • No rewinding required due to the direct provision of the cylindrical bobbins to the weaving process in a weight range of 8- 10 kg. • Long, knot-free lengths. • High weaving effectiveness, due to the eradication of thread breaks. • High levels of area stability in the finished weave. • Retention of a textile surface character.
  • 18.
    DREF-2 Application andFields  Blankets for the home application range, hotels and military uses etc.  Interior decoration, wall coverings, draperies and filler yarn.  Shoes, ropes and industrial cable manufacturing.  Filler cartridge for liquid filtration  For upholstery, table cloths, wall coverings, curtains, handmade carpets, bed coverings and other decorative fabrics.  Heavy flame-retardant fabrics, conveyor belts, clutches and brake linings, friction linings for automobile industry, packets and gaskets.
  • 19.
    DREF-3 • The DREF-3machine is the next version of DREF-2 for improving the yarn quality came to the market in the year 1981. • Yarns up to 18s Ne. can be spun through this system. • This is a core-sheath type spinning arrangement. • The sheath fibers are attached to the core fibers by the false twist generated by the rotating action of drums. • Two drafting units are used in this system, one for the core fibers and other for the sheath fibers. • This system produces a variety of core-sheath type structures and multi-component yarns, through selective combination and placement of different materials in core and sheath. • Delivery rate is about 300 m/min Fig. Dref-3 Schematic Figure
  • 20.
    DREF-3 Application andFields •Backing fabrics for printing, belt inserts, electrical insulation, hoses, filter fabrics •Hot air filtration and wet filtration in food and sugar industries. •Clutch lining and brake lining for automotive industries. DREF-5 •It was developed by Schalafhorst, Suessen and Fehrer. •The range of count to be spun from this system is from 16’s to 40’s Ne. •Production speed is up to 200m/min. •This spinning system was not commercialized due to some reasons. •The individualized fibers from a single sliver are fed through a fiber duct into the spinning nip at an angle to the yarn axis. •They are stretched as far as possible, when fed into the nip. Fig : DREF-5 Fig : DREF-3
  • 21.
    Fig.D-Dref 2000 DREF-2000 •It isthe latest development in friction spinning demonstrated in ITMA 99. •DREF-2000 employs a rotating carding drum for opening the slivers into single fibers and a specially designed system being used for sliver retention. •The fibers stripped off from front the carding drum by centrifugal force and carried into the nip of the two perforated spinning drums. •The fibers are subsequently twisted by mechanical friction on the surface of the drums. •Drums are rotates in the same direction.
  • 22.
    Advantages of DREF-2000 •Insertion of twist in ‘S’ and ‘Z’ direction is possible without mechanical alterations to the machine. •Yarns up to 14.5s Ne can be produced at speeds of 250 m/min. •Reduced yarn preparation costs due to high sliver weights (card slivers). •Dust extraction for secondary fibers. •Low energy costs due to the use of only 1 fan for 12 spinning heads. •Feeding of all types of filaments, yarns and components as yarn cores, in order to attain high yarn strength and production speeds, voluminous yarns and specific product characteristics.
  • 23.
    DREF-2000 Application andFields •Blankets for the homes, hotels, hospitals, camping, military uses, plaids etc. •Cleaning rags and mops from cotton waster and various waste-blends •Deco- and upholstery fabrics •Outerwear and leisure-wear •Filter cartridges for liquid filtration •Secondary carpet backing for tufting carpets •Canvas and tarpaulins for the military and civil sectors •High-tenacity core yarn for ropes, transport and conveyor belts •Asbestos substitutes for heavy protective clothing (protective gloves, aprons etc) packing, gaskets, clutch and brake-linings, flame retardant fabrics etc. •Filter Yarns for the cable, shoe and carpet industries •Carpet Yarns (Berber carpets, hand-woven and hand-knotted carpets) and filler weft yarns for carpets
  • 24.
    DREF-3000 •In the ITMA2003, the first public appearance of the DREF 3000 was made. •The yarn can be spun form 0.3Ne to 14.5Ne. Advantages of DREF-3000 •System Expansion of the scope of yarn and fiber utilization in the coarse yarn count range •Production of both ‘S’ and ‘Z’ yarns at any time without mechanical alterations to the machine •Reduced yarn preparation costs due to high sliver weights (card slivers) •Higher Bobbin weights through 200mm winding traverse.
  • 25.
    DREF-3000 Application andFields •High tenacity and FR protective clothing for civil & military sector •Fire blocker for the aviation and contract business range, cut protection textiles (protective gloves, mail-bags, seat coverings) •Fiber composite materials for the aviation, automotive, machinery, and construction industry •Tarpaulins, transport and conveyor belts as well as all kinds of technical textiles •Filter fabrics for dry and wet filtration •Upholstery fabrics for contact business range •Knitting sector, elastomeric fabrics •Outdoor textiles (eg chair and dock-chair covering)
  • 26.
    Mechanism of YarnFormation The mechanism of yarn formation is quite complicated. It has three distinct operations, namely: 1. Feeding, 2. Integration and 3. Twist insertion of fibers. Feeding: The individualized fibres are transported by air currents and deposited in the spinning zone. There is a definite effect of mode of feed on fibre extent and fibre configuration in yarn and on its properties. Fibre feed can be done in following methods. • Direct feed • Indirect feed.
  • 27.
    1) Direct feed Fibersare fed directly onto the rotating fiber mass that outer part of the yarn tail. 2) Indirect feed Fibers are first accumulated on the in-going roll and then transferred to the yarn tail.
  • 28.
    Fibers Integration •The fibersthrough feed tube assembles onto a yarn core/tail within the shear field, is provided by two rotating spinning drums and the yarn core is in between them. •The shear causes sheath fibers to wrap around the yarn core. •The fiber orientation is highly dependent on the decelerating fibers arriving at the assembly point through the turbulent flow. •The fibers in the friction drum have two probable methods for integration of incoming fibers to the sheath. Twist insertion •The fibers are applied twist with more or less one at a time without cyclic differentials in tension in the twisting zone. •Therefore, fiber migration may not take place in friction spun yarns. •The mechanism of twist insertion for core type friction spinning and open end friction spinning are different.
  • 29.
    Twist insertion incore-type friction spinning •Core is made of a filament or a bundle of staple fibers is false twisted by the spinning drum. •The sheath fibers are deposited on the false twisted core surface and are wrapped helically over the core with varying helix angles. •It is believed that the false twist in the core gets removed once the yarn is emerged from the spinning drums, so that this yarn has virtually twist less core. •However, it is quite possible for some amount of false twist to remain in the fact that the sheath entraps it during yarn formation in the spinning zone. Twist insertion in Open end friction spinning •The fibers in the yarn are integrated as stacked cone. •The fibers in the surface of the yarn found more compact and good packing density than the axial fibers in the yarn. •The Figure shown the arrangement of fibers in the DREF-3 yarn as stacked cone shape .
  • 30.
    Properties of FrictionSpun Yarns •Friction spun yarns (DREF) yarns have bulky appearance (100-140% bulkier than the ring spun yarns) •The twist is not uniform and found with loopy yarn surface. •Usually weak as compared to other yarns. •The yarns possess only 60% of the tenacity of ring-spun yarns and about 90% of rotor spun-yarns. •The breaking elongation of ring, rotor and friction spun yarns is equal. •Depending on the type of fiber, the differences in strength of these yarns differ in magnitude. •100% polyester yarns-strength deficiency is 32% •100% viscose yarns-it ranges from 0-25% •In polyester-cotton blend, DREF yarns perform better than their ring-spun counterparts. •70/30% blend yarn-superior in strength by 25% •DREF yarns are inferior in terms of unevenness, imperfections, strength variability and hairiness. •The friction spun yarns are more hairy than the ring spun yarns •DREF yarns are most irregular in terms of twist and linear density while ring spun yarns are most even.
  • 31.
    Properties of HybridYarns/DREF core yarns If one yarn creates out of 2 or more single yarn components is called hybrid yarn. Hybrid yarns are used: A. For reinforced plastics Properties of the yarn • Core/Sheath structure with centric position of the reinforcing filament •Zero twisted reinforced filament gives best strength result •Definable fiber matrix proportion •Protection of the reinforcing filament through the sheath fibers B. For liquid filter cartridges Yarn Properties • Huddle fiber arrangement for best filter action •High elongation values •Long yarn length knotless •Uniform yarn with high tensile strength
  • 32.
    C. For heatproof woven and knitted fabrics Yarn properties • Flame resistance •High temperature resistance •High tear abrasion resistance •Good wearing comfort •Good care properties •Skin friendly D. For Secondary carpet backings Yarn Properties • Steady high tensile strength •High uniformity of the yarn •Long knotless length of the yarn •Good non-rotating properties •High chemical resistance •Good thermal transfer •Dust free product •Electric insulation •Good dimension stability for carpets
  • 33.
    E. For asbestossubstitutes Yarn properties • High yarn volume •Good temperature resistance •High tensile strength •Low elongation F. Cut proof woven and knitted fabrics Yarn properties • High cut resistance •Good wearing comfort •High dimension stability
  • 34.
    Advantages of Frictionspinning system 1.It can spin yarn at very high twist insertion rates (ie.3,00,000 twist/min). 2.The yarn tension is practically independent of speed and hence very high production rates (up to 300 m/min) can be attainable. 3.Improved dirt particle retention and up to twice the filter service life. 4.Considerable reduced yarn production costs (up to 50%) due to lower yarn mass requirement, lower preparation costs, lower spinning costs and lower personnel expenses.
  • 35.
    Limitations of Frictionspinning system 1.The extent of disorientation and buckling of fibers are predominant with longer and finer fibers. 2.Friction spun yarns have higher snarling tendency. 3.High air consumption leads to high power consumption. 4.The twist variation from surface to core is quite high; this is another reason for the low yarn strength. 5.It is difficult to hold spinning conditions as constant. 6.The spinning system is limited by drafting and fiber transportation speeds. 7.Low yarn strength and extremely poor fiber orientation made the friction spun yarns very weak.
  • 36.
    Thank You Slide CreatedBy Abdullah Al Parvez 9th Batch , Ctec & Moderated By Rest of the members .