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Friction twisting forms part of the false-twist texturing yarn and Y the forward velocity of the yarn. Thus the net
process for continuous filament yarns. In this process, the change in the value of N is given by:
yarn is twisted into a helical configuration, it is heat-set in
n
that state and is then cooled and untwisted. During all these dU = dL ( ~ - r ) (2)
stages, the yarn moves forward in the direction of its own
axis; the general scheme of things is outlined in Fig 1. The
The change dN can also be expressed in terms of the twist
yarn is fed into the system by the feed rollers and is taken
change d T by differentiating Eq (1) with p constant. By
away by the take-up rollers; the surface speed of these
rollers determines the forward speed of the yarn. Between
the feed rollers and the twister lie a heater and a cooling
zone which constitute the 'processing zone', and between
the twister and the take-up rollers is the 'take-up zone'.
The function of the twister is two-fold: it twists the yarn I
in the processing zone and simultaneously untwists the G Feed r o l l e r s
yarn in the take-up zone so that the yarn leaves the machine
without twist.
The present discussion is mainly concerned with the func-
tioning of the twister which rotates the yarn around its own
axis. How this is done depends on the nature of the twister
but the effect of the yarn rotation on the yarn twist in the
processing zone is common to all types of twister. It can be
Heater
described in comparatively simple mathematical terms by
Processing p
considering the balance between twist gains and losses in zoRe
the processing zone when a small yarn element of length dL
passes through the zone - twist is defined as the number of
turns per unit length of untwisted yarn and it is assumed
that the turns are uniformly distributed along the length of
the yarn in the zone.
Yarn
By def'mition, the total number of turns (N) in the process- Cooling zone
ing zone is given by:
N =pT (1)
where p is the length of the zone and T is the twist of the / Twieter
yarn in it. Entry of a length dL into the processing zone Take-up
does not affect the value of N since that yarn has no twist; zone
exit of a similar length of yarn from the twister, however, T a k e - u p rollers
causes a twist loss of TdL turns. This twist loss is compen-
sated by the rotation of the yarn which leads to a twist gain
equal to (n/Y)dL where n is the rotational speed of the
*Department of Textiles, UMIST, PO Box 88, Manchester
M60 1QD, UK Fig 1 Processing zone o f a false-twist machine
TRIBOLOGY international 0301-679X/85/030157-07 $03.00 1985 Butterworth & Co (Publishers) Ltd 157
Greenwood - friction twisting of yarns
C
Principle of friction twisting
Speed ratio
The idea of friction twisting is illustrated in Fig 3. The yarn
c is pressed against a rotating disc and twisted by frictional
contact with the moving surface. Because the disc diameter
#
O.
is very much larger than that of the yarn, the rotational
speed of the yarn is much higher than that of the disc.
I-" A disc, for instance, rotating at 10 000 r/min can generate
a yarn rotational speed in excess of 2 million r/rain. At first
sight, Fig 3 may suggest that the rotational speed of the
yarn could be calculated quite easily and accurately
provided the rotational speed of the disc and the two
Length of yarn processed relevant diameters were known. This, however, would only
be true if one could be sure that there was no significant
Fig 2 Development of twist when a pin twister is started up
slip between the yarn and the disc surfaces. In theory, it is
combining Eq (2)with the differentiated Eq (1), one possible to design and operate the system in such a way
obtains: that there is no slip, but in any practical situation, there is
no means of knowing whether slip occurs or not, and
n
dT_ 1 ( Y _T) (3) experience to date suggests that slip-free operation of a
dL p friction twister is neither possible nor desirable. So, with
The ratio of rotational to longitudinal speed of the yarn friction twisting, one has lost the simple and direct control
n / Y will be referred to as the speed ratio. Although its of twist which was possible with pin twisting.
physical nature is quite different from that of T, it has the In order to rotate and thereby twist the yarn, the twister
same dimensions. From Eq (3) it follows that the yarn must overcome the torsional rigidity of the yarn by means
twist T can only be stable when it is equal to the speed of a frictional force applied to the yarn surface. There must
ratio. therefore be a normal force pressing the yarn against the
Before the advent of friction twisting, rotation of the yarn twister, the most readily available source of such a force
was achieved by means of a device called the pin twister being the tension in the yarn. One of the major problems
whose salient property was that its rotational speed was encountered in the early days of friction twisting was the
directly adjustable and that it imparted to the yarn a need to operate at very high yarn tensions to generate the
rotational speed identical to its own. This meant that the necessary normal and frictional forces, but this tended to
rotational speed of the yarn itself and hence its speed ratio damage the yarn. To overcome this problem, attempts were
was a machine setting and therefore constant. Under these made to find alternative sources of a normal force (e.g. an
circumstances, Eq (3) can be solved by analytical methods auxiliary frictionless anvil roller) but these attempts were
leading to: soon abandoned in favour of the approach outlined in
Fig 4. Only very recently has the idea of generating an
n L independent normal force been revived but the principle
T= ~ [ 1 - e x p ( - -)] (4)
P shown in Fig 4 is still that most widely used. Underlying
this principle is the realization that the normal force
and between the yarn and the twister depends not only on the
TO = n / Y (5) yarn tension but also on the angle-of-wrap. An alternative
to increasing the yarn tension is therefore to increase the
where To is the stable value of T which, according to angle-of-wrap (provided that this itself does not lead to
Eq (4) is reached when a length L of yarn of approximately
five times the value o f p has passed through the machine.
This value is usually around 2 m and hence some 10 m of
yarn has to be processed before the twist (and hence the
yarn quality) reaches its stable value. This is a negligible
length from a commercial point of view.
Eq (4) itself has the well-known form of an exponential
equation describing the increase in T from zero to its stable
value TO as shown in Fig 2. It should be emphasized that
while Eq (3) applies to all forms of the false-twist process,
Eq (4) only applies to pin twisting. The latter had the great
advantage of a positive and simple control of twist but
because of its 1: 1 ratio of twister speed to yarn speed,
it imposed severe speed limitations on the whole process.
This will become clear when one realizes that present-day
false-twist machines require yarn rotational speeds in the
region 2 - 5 million r/rain. Nobody, however, has ever been
able to design a pin twister which could operate much Fig 3 Basic principle of a disc-type friction twister
l,
I . D cos ~k
tion and magnitude of the slip velocity Q of the twister
\ i \ surface relative to the yarn surface is found by connecting
2'rrRn~ "~/'. the end points of vectors v and D. The magnitude of Q is
comparatively unimportant but its direction is of great
importance because it is also the direction of the frictional
force d F between the yarn and the twister. This direction
dFb! ~ I is expressed in terms of the angle 3', which can be described
....... ---.I-
I O sin ~k -.. dF as the drag angle, since it expresses the direction in which
I "~ the twister 'drags' the yarn surface. The important point
It_ "~
dF,
to bear in mind here is that it is the direction of Q and
not that o l D which determines the direction of the drag.
The magnitude of 3' can be deduced from Fig 7 by simple
trigonometry and is given by:
D sin ~ - 27rRn
tan 3' = (8)
Fig 7 Velocity and force vectors at a point o f contact D cos~ - Y
between the yarn and the friction twister
The right-hand side of Eq (8) contains parameters which
to the yarn axis and opposite to the running direction of are all either machine settings or yarn properties, with the
the yarn; with the friction twister, it is inclined to the exception of the rotational speed n of the yarn. This can
yarn axis. The angle of incline tended to be approximately either be an independent or a dependent variable depending
90 with the early twisters, but in modern twisters it is on whether one is dealing with stable or with transient
usually around 65 to 70 (Fig 5). This angle will be conditions. Reference to Fig 7 shows that the numerator
of the above expression is the component at right angles
referred to as the twister angle.
to the yarn axis of the slip velocity Q. This component
Clearly, the prime reason for increasing the magnitude of must always be positive since the movement of the yarn
the twister angle from zero to the values quoted above is surface in that direction is entirely due to the action of the
to twist the yarn, which the capstan cannot do. The need twister, and the yarn surface cannot move faster than the
for a non-zero twister angle does not, however, provide twister surface. The situation is different, however, with
sufficient information for choosing the actual value ; an regard to the denominator which represents the component
angle of 90 , which appeared to be an obvious choice to o f Q parallel to the yarn axis. The movement o f the yarn
the first designers of friction twisters, proved to be a poor in this direction is due to the take-up rollers and therefore
one. The consequences of choosing a particular twister the yarn can move faster or slower than the twister or at
angle emerge clearly when one analyses the situation with the same speed. This means that the denominator can be
regard to velocities and forces along the line of contact either positive or negative and 3' can have any value between
between the yarn and the twister. zero and 180 depending on the relative velocity of the
yarn and the twister in the direction of the yarn axis.
Analysis of the velocity and force relations
Since the drag angle 3' determines the direction of the fric-
The analysis presented here is essentially the same as that tional force dE, it also determines the relative magnitude of
used by other workers in the field. 1-4 Before going into its two components dFt and d E b. The first o f these provides
detail, it will be useful to point out some basic differences the twisting action of the twister and the second its braking
between the analyses o f friction twisting and of pin twist- action, ie its effect on the yarn tension. It is this tension
ing. The pin twisting analysis follows the development of effect which needs to be considered first.
twist in the processing zone from its initial zero value to its
stable value by means of simple mathematical expressions T h e generalized capstan equation
(Eqs (4) and (5)). Until recently, however, all analyses of
In analysing the tension effect o f the friction twister, the
friction twisting confined themselves to the ultimate stable
argument leading to the capstan equation forms a useful
conditions without considering the route by which these
starting point. Recall that the normal force acting on a yarn
conditions are reached.
element within an incremental angle of wrap d a is given by
A similar approach is adopted here but the initial analysis Sdtx where S is the yarn tension. Hence the incremental
is presented in a form applicable to both stable and transient frictional force d F is equal to S/advt. In the friction twister,
conditions. Criteria for deciding whether the described however, as distinct from the capstan, it is not the whole
conditions are stable or transient are quoted and certain of this frictional force but only its component d F b which
conclusions are drawn regarding each of these cases. acts in the direction o f the yarn axis and influences the
yarn tension. From trigonometry, it follows that:
Fig 7 is a velocity and force vector diagram describing
conditions at a point of contact between the yarn and d F b = d F cos3' (9)
twister surfaces, ie within a small incremental angle of
Therefore:
wrap da. The yarn surface has a velocity component Y in
the direction of the yarn axis (Fig 7). The magnitude of dS = - d F b = - d F cos7 = -S/a cos7 d a "(10)
Integration of Eq (10) leads to: (Clearly, the larger the yarn radius, the smaller is the value
$2 = $1 e-US cos'r (11) of F t required to produce a given torque.) If, however, one
is content to confine the analysis to yarn of one radius
Eq (11) can be regarded as a generalized form of Eq (7) only, one can ignore torque and look for a direct relation-
(the capstan equation) and it reduces to this form when ship between twisting force and twist. Experimental results
the drag angle 3' equals zero or 180 , i.e. when the slip suggest that this relationship can be expressed reasonably
velocity vector Q is parallel to the yarn axis and either well over a practical range of conditions by:
positive or negative. According to Eq (8), this would be
F t = kT* (19)
the case not only when the twister is stationary (the more
probable practical case) but also when yarn and twister where k is an empirical constant involving the yarn radius.
surfaces have the same velocity component at right angles
to the yarn axis (highly improbable in practice). Eq (19) stipulates an equilibrium between the internal yarn
torque due to the torsional rigidity of the yarn and the
Twisting action of the frictional force external torque applied by the twister, and therefore (inertia
effects in the yarn being negligibly small) it must always be
The twisting action is carried out by the twisting satisfied. This means that when the twist has any given
component dFt which is given by: value T, the combination of all the parameters which deter-
dFt = dFsin3' (12) mine Ft, according to Eq (15) or (18), must be such as to
produce the value of F t derived from Eq (19). Leaving aside
As before, d F is given by Sladot but having established the Eq (18) which refers to a special case and examining
variation of yarn tension along the line of contact with the Eq (15) only, one finds that these parameters include the
twister by means of Eq (10), it is now possible to express drag angle 3' which in turn is dependent on the rotational
S in terms of the entry tension Sx by an equation similar speed n of the yarn itself (see Eq (8)). Thus, the existence
to Eq (11), ie: of a given twist level, all other variables having been fixed,
S = $1 e - ~ ' cos~' (13) determines the rotational speed of the yarn and, somewhat
paradoxically, the higher the twist, the lower must be the
where ct' represents the total angle of wrap between the rotational speed. On the other hand, stable conditions can
entry point of the yarn and the point where tension S is only exist when T = n/Y. Thus, the criterion for stability is
reached. Therefore: that the rotational speed dictated implicitly be Eq (19)
must simultaneously satisfy Eq (5). This raises and helps
dFt = Sla sinT de~ = Sl e-US' csVla sinT da (14)
answer the question as to how stable conditions are reached
By integrating Eq (14), one can determine the total twist- when the twister is started and the yarn has zero twist.
ing force Ft which is given by:
Transient conditions at the start of twisting
Ft = -$1 tan3' (e -us cosy _ 1) (15)
It is not proposed here, to present a full analysis of this
Eq (15) can also be written in the form: problem since this is the subject of another paper, s The
Ft = (St - $ 2 ) tan3' (16) problem does not, in fact, lend itself to a complete analyti-
cal solution and can only be solved numerically with the
At first sight, it may seem that F t becomes indeterminate aid of computer techniques. For the present, it is proposed
when 3' = 90 since tan7 = oo while $2 - $1 = 0 (see to confine the discussion to a qualitative description of the
Eq (1 I)).
initial development of twist from zero to its stable value.
This is not the case, however, because when 3' = 90 , the That development is governed by Eq (3) which applies both
differential equation takes the form: to pin andto friction twisters. In the case of the pin twister,
this equation can easily be solved because the speed ratio
d F t = S1/a da (17) is a constant. For the friction twister, the solution is based
and this leads to: on the fact that the rotational speed of the yarn and hence
its speed ratio n / Y is a function of T which is written here
Ft = Sl#a (18) f ( T ) as it is rather complicated. Eq (3) thus takes the form:
5. Greenwood K. and Grigg P.J. The development of twist in a n Rotational speed of yarn
false-twist texturing machine with friction twister. J. Textile
Inst. {to be published) Q Speed of twister surface relative to yarn surface
R Yarn radius
v Resultant surface velocity of yarn
Nomenclature Y Forward velocity of the yarn
D Surface speed of twister 7 Angle between the directions of Q and Y
d F Incremental frictional force between yarn and twister (drag angle)
d F t Incremental twisting component of d F Angle between the directions of D and Y
d F b Incremental braking component of d F (twister angle)