DEPARTMENT OF TEXTILE ENGINEERING

Course Code : Tex-3011

Course Title : Yarn Manufacturing Technology-||

Topic Name: Friction Spinning (DREF) & Air Jet Spinning

Submitted To : Dr.Syed Atiqur Rahman

(Associate Professor & Coordinator)
Submitted By :
Name : Md. Jahangir Alam
ID : 2018000400079
Batch : 37
Sec :2
Submission Date : 21/05/2020
 CONTENTS

Friction Spinning (DREF)

 Introduction
 Principal of Friction Spinning System
 Basic Working Principle of Friction Spinning
 Types of (DREF) Friction Spinning
 Properties of Friction Spun Yarns
 Advantages of Friction Spinning System & Limitations of Friction
Spinning System
 Conclusion

Air Jet Spinning

 Introduction
 Flowchart of Air Jet
 Spinning Operation Principle of Rieter Two-Nozzel Air-Jet
Spinning
 Yarn Characteristics of Air-Jet Spin Yarn
 Advantages of Air-Jet Spinning
 Conclusion

References
 Autexrj.com
 Textileschool.com
 Textileworld.com
Introduction: The need to rotate the package at the twist insertion rate coupled
with rapid increase in spinning tension with spinning speed sets a limit to the
spindle speeds achievable in ring spinning. Open end spinning methods where
open-end of the yarn alone needs to be rotated for imparting twist was therefore,
developed to achieve high delivery rates. Rotor spinning which is one of first
methods developed on this principle has well established itself as an alternate to
ring spinning in course count range for certain end uses. Friction spinning
represents an alternate open-end spinning method to rotor spinning which holds
promise of still higher delivery rates
Principal of Friction Spinning System:
1. Fibers are delivered onto the drum surface, which transports and stacks the
fibers to the fiber bundle rotating between two surfaces moving in opposite
directions.
2. The fibers wrap around the bundle surface.
3. wrapped fiber bundle (yarn tail) is tugged by the yarn delivery roll.
4. 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.

Basic Working Principle of Friction Spinning

 The twisting rate in friction spinning is related to the drum rpm, drum
diameter and yarn diameter as indicated below.
 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 12 to yarn
end.

Types of DREF Friction Spinning

1. DREF-1
2. DREF-2
3. DREF-3
4. DREF-5
5. DREF-2000
6. DREF-3000

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-1 friction spinning system

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). 

DREF-2 friction spinning system

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. 

DREF-3 friction spinning system

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. 

DREF-5 friction spinning system

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. 

DREF-2000 friction spinning system

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.

 PROPERTİES OF FRİCTİON SPUN YARNS

 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 ringspun 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.
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. Low yarn strength and extremely poor fiber orientation made the friction
spun yarns very weak.
2. The extent of disorientation and buckling of fibers are predominant with
longer and finer fibers.
3. Friction spun yarns have higher snarling tendency.
4. High air consumption leads to high power consumption.
5. The twist variation from surface to core is quite high; this is another reason
for the low yarn strength.
6. It is difficult to hold spinning conditions as constant.
7. The spinning system is limited by drafting and fiber transportation speeds. 

Conclusion: 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 centre of the yarn. 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.
Introduction: Air-jet spinning is the latest in a string of technological
developments intended to increase production speed and flexibility. This technique
is also known as fasciated yarn spinning. Air-jet spinning system which consists of
a 3-over-3 high-speed roller drafting unit, The basic jet design is also shown. This
has a central cylindrical channel (the spinning channel) through which the fibre
ribbon from the drafting unit passes. Inclined to the channel axis but tangential to
its circumference are four nozzles through which compressed air is injected into
the channel, creating a vortex airflow. 

Twist

Each jet of compressed air entering and expanding into the channel has
two velocity components of airflow: V1, a circular motion of the air around
the channel circumference, and V2, the movement of the air to the channel outlet.
The suction at the jet inlet created by V2 gives automatic threading-up of the
spinning process. Provided the drafted ribbon is not tautly held between the front
drafting rollers and take-up rollers, the V1 component of flow rotates it, inducing a
false-twisting action via a rotating standing waveform (a spinning balloon) while
V2 assists movement of the twisted ribbon through the channel.

Flowchart of Air Jet Spinning

Operation Principle of Rieter Two-Nozzel Air-Jet Spinning: As
shown in a draw frame sliver fed from a can is passed to a drafting arrangment,
where it is attenuated by a draft in the range of 100 - 200. The fiber strand
delivered then proceeds to two air jets arranged directly after the
drafting arrangement. The second jet is the actual false-twist element.

Diagram of Air Jet Spinning

 The air vortex generated in this jet, with an angular velocity of more than 2
million rpm, twists the strand as it passes through so that the strand rotates
along a screw-thread path in the jet, achieving rotation speeds of about 250 000
rpm. The compressed air reaches the speed of sound when entering the central
canal of the false-twist element. Since the axial forces are very low during this
rotation, only low tensions arise in the yarn.

 
 Twist direction of Air Jet Spinning

 The ability of the vortex to impart torque is so high that the turns of twist in
the yarn run back to the drafting arrangement. The fiber strand is
therefore accelerated practically to full rotation speed as soon as it leaves the
front roller. 
 The edge fibers which ultimately bind the yarn together by becoming
wrapping fibers are in a minority. 
 For process reasons, they do not exceed about 5% of the total yarn mass.
These edge fibers exhibit relatively few turns of twist in the same direction as
the falsetwisted core fibers or can even be slightly twisted in the opposite
direction. This is partly ensured by causing the strand to emerge from the nip
line in a broadly spread form, but mainly by generating in the first jet a vortex
with an opposite direction of rotation to the vortex in the second jet. 
 This first vortex is in fact weaker in intensity than the second and cannot
really affect the core fibers, but can grasp the edge fibers projecting from the
strand at one end. Since the first vortex acts against the twist direction
generated by the second jet, it prevents the edge fibers from being twisted into
the core or even twists them in the opposite direction around the core fibers. As
the strand runs through the second jet, the following occurs.
 The turns of twist generated by the jet are canceled in accordance with the
falsetwist law. The core fibers, i.e. the vast majority, no longer exhibit any
twist; these fibers are arranged in parallel. On the other hand, the edge fibers
(which previously exhibited no twist, relatively little twist, or even twist in the
opposite direction) receive twist in the direction imparted by the jet, as
determined by the law of false twist; they are therefore wound around the
parallel fiber strand. They bind the body of fibers together and ensure
 coherence. A twist diagram prepared by Dr. H. Stalder demonstrates this
twisting procedure .
 The resulting bundled staple-fiber yarn passes from the take-off rollers
through a yarn-suction device and an electronic yarn clearer before being
wound onto a cross-wound package. The two nozzle air-jet spinning system
represents a very interesting process, which has already been introduced into
practical operation with some success.

Yarn Characteristics of Air-Jet spin Yarn

The yarn character is slightly different from that of ring spun yarn. It is
somewhat:
 weaker
 stiffer
 harder
The hardness can be reduced by using finer fibers and by treatment of the
finished product with a softener (e.g. with a silicone).

Advantages of Air-jet Spinning

 Less hairness & Clear appearance

 High resistance to Pilling & abrasion
 High moisture absorption
 Less shrinkage & High wash resistance
 Can be spun with various other materials such as cotton, synthetic
fiber, regenerated fiber and blended fiber.
 Yarn structure also suitable as core yarn

Conclusion: Air jet spinning has offered yarn manufacturers the

opportunity to produce yarn at relatively high production rate. Unlike other
spinning methods in which productivity is limited by the amount of twist in
the yarn, Air Jet yarns can be produced at the same production rate
regardless of yarn counts. Murata Vortex Spinners are one such leading Air
Jet spinning machines which excel at producing finer yarns (Ne 40/1-60/1),
because of the improved strength imparted to the smaller fibre bundle .