Three-dimensional simulation and experimental investigation of three-dimensional printed guiding devices on lattice-apron compact spinning

Abstract

The compact spinning system with a lattice apron utilizes air-flow dynamics to condense fibers in a bunch and enhance the yarn properties. One of the main challenges with this method is the lack of a comprehensive understanding of the air-flow field's effect in the condensing zone. This work presents a numerical and experimental investigation of the effects of three-dimensional (3D) printed guiding devices on the air-flow characteristics and yarn properties. Firstly, the 3D numerical model of the compact spinning system was set up based on the compact spinning machine geometrical dimensions. Secondly, different 3D prototypes were developed, simulated, and analyzed using computational fluid dynamics based on ANSYS software. The prototypes (A-type, B-type, and C-type), selected according to the simulation results, were then 3D printed to enable further experimental investigation. Air-flow analysis results in the air-suction flume area exhibiting a very high negative pressure, and the centerline zone was characterized by high velocity. Experimental results revealed that the three yarns spun with guiding devices had better strength, hairiness, and evenness than those spun without a guiding device. The model developed can be further improved and utilized for commercial purposes and is anticipated to improve compact spun yarn properties significantly.

Numerical and experimental approach towards an energy-efficient compact spinning system

“…24,25 The negative pressure used in the present production practice is 2000–3000 Pa, which is the main energy consumption of compact spinning. According to our previous work, 26 it requires less energy consumption to absorb the fiber bundle on the lattice apron and twist the free-end fiber around the fiber bundle, probably because the condensing zone is fully open, resulting in low airflow utilization efficiency. Based on this, the two functions are separated in order to simultaneously achieve the condensing and twisting effect under the condition of reducing the negative pressure.…”

“…The guiding device used in the simulation is shown in Figure 1, as obtained from our previous work. 26 This design illustrated a downward-sloping slot on one side of the device and two small holes at the top to allow inflow of air from one side and the top, so as to increase the transverse condensing force. The idea of designing an energy-saving collector device is to prevent the dispersion of negative pressure and increase airflow utilization efficiency.…”

A Novel Compact Spinning with Lattice Apron Achieved through Airflow Simulations

“…This technique is implemented using negative pressure airflow to condense the fiber bundle for eliminating the spinning triangle and improve the yarn qualities [1][2][3]. Compact spinning with lattice apron is the most widely used pneumatic compact spinning system at present, mainly including three-line compact spinning (TLCS) and fourline compact spinning [4][5][6][7][8]. Nevertheless, the compact spinning systems with lattice apron is considered expensive due to the high energy consumption during the spinning process [1].…”

“…incompressible and expressed by Reynolds equations. The turbulence model adopts k -Ɛ two-equation model and other equations have been expressed in our previous works[8]. In this model, the pressure outlet was assumed as the atmospheric pressure (101325 Pa).…”

“…(b),which is obtained from our previous work[8]. By using fluent software, the results of numerical simulation for a 3D flow field without a guiding device and with the guiding device in the condensing zone of the compact spinning method with a lattice apron are presented in Fig.4.…”