Indian Journal of Fibre & Textile Research

Vol. 29, June 2004, pp. 190-195

Optinlization of ring frame process parameters for better yam quality and
production
S M Ishtiaque", R S Rengasamy & A Ghosh
Department of Textile Technology, Indian Institute of Technology, New Delhi 110 016, India
Received 3 April 2003; accepted 16 June 2003

Ring frame process parameters, namely spindle speed, top roller pressure and traveller mass, have been optimized
using three-variable Box and Behnken design to achieve better yarn quality and production. It is observed that 15000 rpm
spindle speed with top roller pressure of 2.5 kg/cm2 and traveller mass of 50 ISO No. gives the optimum results within the
experimental zone explored. But to achieve the spindle speed of 17000 rpm, the traveller mass of 40 ISO No. with the
optimum value of top roller pressure gives acceptable running performance of the machine.
Keywords: Spindle speed, Top roller pressure, Traveller mass
IPC Code: Int. CI. 7 DOIHI/02; D02G 3/00

1 Introduction three-variable factorial design proposed by Box and

Although the new spinning technologies have
solved the problem of production and automation to a
greater extent, the ring spinning still dominates over
others and is likely to continue as a most widely used
form of spinning, because it exhibits significant
advantages in terms of yarn strength and flexibility in
comparison with the new spinning processes.
Increasing ring spindle speed with the existing
machines in consideration of yarn quality and running
performance is the cherished goal consistently sought
by every spinner for min:mizing the cost of yarn. As
ring frame cost constitutes a major portion of total
cost, the productivity at ring frame has assumed
considerable importance and every effort to maximize
production at this stage is worth exploring ' . In the
present work, an attempt has been made to optimize
ring frame process parameters, viz. spindle speed, top
roller pressure and traveller mass, to achieve better
yarn quality and production.
2 Materials and Methods
2.1 Preparation of Samples
Using the optimized speed frame parameters 2 , the
roving was prepared and used for optimization of ring
frame process parameters. The yarn samples of 30' Ne
with 3.79 twist multiplier were prepared on Lakshmi
LG/5 ring frame for all the combinations by using
"To whom all the correspondence should be addresses.
Phone: 26591410; Fax : +91-11-26581 103;
E-mail: ishtiaque54@hotmail.com
Bhenken 3 (Table 1). The actual levels of variables
were taken within the range of industrially acceptable
limits (Table 2).
2.2 Testing of Samples
Starting from the initial doff to full doff, the total
breakage was observed for each run of the samples in
ring frame. The breakage rate was calculated as the
number of end breaks / 100 spindle / h. The other
parts of yarn testing are similar as discussed earlier2.
3 Results and Discussion
Experimental results for various responses of
different yarn characteristics are given in Table 3. The
response surface equations for various spinning
performances are given in Table 4 along with the
square of correlation coefficients.
3.1 End Breakage Rate
The contour diagrams (Fig. 1) show the influence
of spindle speed, top roller pressure and traveller mass
on end breakage rate. It is found that the end breakage
rate decreases with the decrease in spindle speed.
Further, when both traveller mass and spindle speed
increase the end breakage rate also increases. This can
be explained due to the fact that the increase in
spindle speed and traveller mass increases the
spinning tension, which may often exceed the safe
spinning tension limit, resulting in more number of
end breakage. The top roller pressure has similar
influence on the end breakage rate as shown in case of
speed frame 2.
 ISHTIAQUE et al. : OPTIMIZATION OF RING FRAME PROCESS PARAMETERS 191

Table I-Box and Behnken design for three variables 3.2 Yarn Irregularity
Fig. 2 shows the influence of traveller mass and top
Experiment Levels of variables roller pressure on yarn U%. From the contour plots, it
No. x. X2 X3 is clear that yarn U% decreases with the increase in
-I -I 0 top roller pressure and traveller mass and according to
2 -I 1 0 the experimental result the influence of spindle speed
3 -I 0 on yarn U% is not appreciable. The above findings
4 1 0 can be explained on the basis of the fact that the
5 -1 0 -I
6 -I 0 increase in top roller pressure consolidates fibres
7 I 0 -I strand in the drafting zone and fibres move in a more
8 I 0 I controlled manner so that the erratic movement of
9 0 -I -I floating fibres is restricted. This reduces the yarn U%.
10 0 -I I
II 1 -I
Furthermore, with the increase in traveller mass, the
0
12 0 I I twist flow increases in the spinning zone that may
13 0 0 0 lead to better binding of edge fibres in the yarn body
14 0 0 0 and they do not eject out from the spinning triangle,
15 0 0 0 resulting in better yarn evenness.
Table 2-Actual levels corresponding to coded levels
3.3 Yarn Imperfections
Variable Coded level It can be observed from Fig. 3 that the yarn
-I o +1 imperfection level reduces with the increase in
Spindle speed (x.), rpm 13000 15000 17000 traveller mass. However, the imperfections first
Top roller pressure (X2), kg I cm 2 2.0 2.25 2.5
increase and then decrease with the increase in top
Traveller mass (X3), ISO No. 40 45 50
roller pressure. The yarn imperfections initially
ISO No. = Mass of a traveller in mg. decrease and then increase with the increase in

Table 3-Experimental results

Experiment Breakage rate U% Hairiness Yarn Tenacity Elongation-
No. breaks! 1OOspi nd1e1h index imperfections! km gttex at-break, %
I 6.0 9.28 6.03 128 15.17 4.30
2 4.7 8.62 6.14 85 16.21 4.21
3 14.6 9.41 5.88 137 16.15 3.49
4 13.4 8.73 5.94 98 16.32 3.41
5 5.8 9.34 6.32 133 15.40 4.49
6 4.3 8.72 5.79 121 16.08 4.20
7 13.8 9.44 6.28 138 15.09 3.58
8 16.3 8.87 5.71 113 16.71 3.38
9 7. 1 9.14 5.93 105 16.17 3.57
10 6.5 9.05 5.60 97 16.52 3.38
II 6.2 8.78 5.67 90 16.63 3.41
12 5.2 8.59 5.51 89 16.80 3.39
13 6.9 9.19 5.79 III 16.31 3.35
14 7.3 9.23 5.58 115 16.0S 3.40
15 8.1 9.09 5.71 114 16.37 3.42
Table 4-Response surface equations for various parameters
Parameter Response surface equation Coefficient of determination
(R2)
End breakage rale 7.185 + 4.663x. - 0.588x2 + X.X3+ 3.052 x .2 - 0.748 x/ 0.916
U% 9.126 - 0.27x2 - 0.184x3 - 0.176x/ 0.S13
Imperfections 112.154-13. 125x2 -5.75x3 + 14.981x1 2 -16.019x/ 0.S29
Hairiness index 5.684 - 0.059xl - 0. 199x3 + 0.327x1 2 0.857
Tenacity 16.411 + 0.244x2 + 0.353x3 - 0.052x / 0.703
Elongation-at-break 3.386 - O.4ISxl - 0.04X2 - 0.088x3 + O.043x2X3 0.992
192 INDIAN J. FIBRE TEXT. RES., JUNE 2004

spindle speed. As the spindle speed increases the
drafting speed also increases. Therefore, the ratio of
dynamic to static frictional force of the drafted libbon
increases. As a consequence, the floating fibres would
like to take the intermediate speed and ensure
50
shuffling of the fibres in the drafting zone4 These
factors may be responsible for the decrease in
impelfections. But, at higher spindle speed, there will
be more rubbing action between yam surface and
thread guide, balloon control ring and traveller. As a
result, long hair may get rolled up and cause neps.

--
This leads to more imperfections at higher spindle
13 speed.
11
- 9
3.4 Yarn Hairiness Index
Fig. 4 shows the effect of spindle speed, top roller
, pressure and traveller mass on yam hairiness. It is
7
very clear that hairiness index reduces with the
increase in traveller mass. This can be ascribed to the
fact that with heavier traveller the resistance to twist

C-
I-
flow past the traveller (i.e. at winding zone) increases
and thus the excessive twist flows back to the
Ia) spinning zone. This reduces the length of spinning
1.0 I
13000 15000 17000 triangle and hence the number of free ends at the edge
of the spinning triangle decreases. Again, due to the
50 11. higher twist density at the spinning zone the
-
o
z
oV)
12
10
-- peripheral fibres get twisted into the yam body. The
above phenomena are the cause of reduction in yarn
hairiness while using heavier travellers. However, as
8 the spindle speed increases the yam hairiness index
first reduces up to 15180 rpm and then increases with
- the further increase in spindle speed. This is explained
6
on the basis of the fact that with the increase in

le-
spindle speed the spinning tension increases and this
a:: faci litates better twist flow right up to the front roller
w
~ nip, resulting in shorter spinning triangle. This causes
~
w 1.0 I better binding of edge fibres, which consequently
> 13000 15000 17000
<{ reduces the yarn hairiness. But at the higher level of
a::
t-
50 50
12
10
- -~

2
8
- 0
~
\I')
6 Vl
1.5 ,....
<l
~
1.5
a:

,e-
uJ
~
~
w
>
<l
a:
Ie) t-
1.0
13000 15000 17000
SPINDLE SPEED (rpm)
Fig. I-Effect of spindle speed and traveller mass on end
breakage rate [tof, roller pressure: (a) 2 kg/cm2, (b) 2.25 kg/cm2,
and (c) 2.5 kg/cm ] Fig. 2- Contours for yarn irregularity (U%)
 ISHTIAQUE et al.: OPTIMIZATION OF RING FRAME PROCESS PARAMETERS 193

spindle speed, the size of the balloon also increases, 3.5 Yarn Tenacity
which increases the frictional contact at balloon Fig. 5 shows the influence of spindle speed, top
control ring and traveller. This may result in more roller pressure and traveller mass on yarn tenacity.
rubbing action of yarn surface, thereby leading to From the contour diagrams, it can be concluded that
higher yarn hairiness 6 . The top roller pressure has no yarn tenacity increases with the increase in top roller
significant influence on yarn hairiness. pressure and traveller mass. This can be explained on
the basis of the fact that the higher top roller pressure
increases the normal force over the fibres and this
may reduce the fibre slippage and cause some fibre
straightening. Also, with the increase in top roller
pressure there will be better control over the
movement of fibres during their sliding. These factors
are responsible for greater yarn strength. With the
increase in spindle speed the yarn strength first
increases approximately up to 15350 rpm and then
starts decreasing. This can be attributed to the fact
that as the spindle speed and traveller mass increase
the spinning tension increases. Therefore, the fibres
get straightened out as they emerge out from the front
roller nip. This increases the spinning-in-coefficient.
Again due to the higher twist density in spinning zone
at higher spindle speed, the edge fibres get twisted
into the yarn body. These factors result in higher yarn
tenacity. But at higher spindle speed, the rubbing
0
force between the yarn surface and the different
z machine parts on which it passes through increases 6
0
\J")
and hence the surface fibres are more abraded and
protrude from the yarn surface. Thus, while tensile
III testing of yarn the protruding fibres do not bear the
III
<{ load properly. These factors are responsible for lower
~
strength of yarn as the spindle speed is increased
a:: beyond a certain level.
w
...J
...J
W
>
<{ 50
a::
I-

\I')
\I')
<{

~ 1.5
a::
UJ
...J
...J
UJ

~
....a::
I. aL---~-~..I...-----'L-+---L.-----1
SPINDLE SPEED (rpm) 13000 17000
SPINDLE SPEED (rpm)
Fig. 3-Effect of spindle speed and traveller mass on yarn
imperfections [to~ roller pressure: (a) 2 kg/cm2, (b) 2.25 kg/cm2, Fig. 4-Effect of spindle speed and traveller mass on yarn
and (c) 2.5 kg/cm-] hairiness
 194 INDIAN 1. FIBRE TEXT. RES ., JUNE 2004

50~------------~~--'
(0 )

35
38
1, 0
1, 1
loO
13000 15000 17000

50 ( b)

0 0
z z
0 0
VI VI

1.5 VI
VI VI
VI <t
<t 3.6 ~
~
0:
38 w
0: ~
W 1, 0 ~
~ w
~
1, 2 >
w <t
15000 17000
~ 0:
I-
0:
l- SO ( c)

3.1,

3.6
3.8
1, 0
lo o C:~=r==~~==~l,~~~
13000 15000 17000 SPINDLE SPEED (r pm)
SPI NDLE SPEED (rpm)
Fig. 6-Effec t of spindl e speed and trave ller mass on breaki ng
Fig. 5-E ffect o f spindle speed and traveller mass o n yarn e lo nga tion [top ro ller pressure: (a) 2 kg/cm2, (b) 2.25 kg/cl1l 2, and
tenac ity [top roller pressure: (a) 2 kg/cm2, (b) 2.25 kg/c m2, and (c) (c) 2.5 kg/C I1l2]
2.5 kg/C I1l 2]
th at with the increase in spind le speed and travel ler
3.6 Yarn Elongation-at-break mass , the spinning tension increases whi ch causes
The co ntour di agrams for breakin g elongati on at straightening of fibres as rhey e merge from the fro nt
three di fferent levels of spindle speed , to p roll er roller nip, thereby reducing elongation. Again , as th e
press ure and travell er mass are show n in Fig. 6. It can top ro ll er press ure increases, the fibre ten sion in th e
be observed that w ith the increase in spindle speed , drafting zo ne increases to some extent, whi ch may
top roll er press ure and travell er mass the breaking lead to straightening o ut of fibres and hence recluce
elo ngati on dec reases. Thi s can be ascribed to th e fact the yarn breakin g elongation.
 ISHTIAQUE et al.: OPTIMIZATION OF RING FRAME PROCESS PARAMETERS
Table 5-Yarn characteri stics at different levels of traveller mass
[Spindle speed, 17000 rpm; and Top roller pressure, 2.5 kg/cm2]
Parameter Traveller mass (ISO No. )
40 45
End breakage rate 8.79 13.4
breaksll 00 spindle/h
U% 9.03 8.8 1
Hairiness index 6.27 5.94
Imperfectionslkm 115 102
Tenacity, g/tex 15.59 16.2
Elongation-at-break, % 3.78 3.52
On the basis of above findings, the optimum values
of ring frame parameters are: spindle speed, 15000
rpm (0 level) ; top roller pressure, 2.5kg/cm2 (+ 1
level) ; and traveller mass, 50 ISO No (+ 1 level).
3.7 Production Trial in Ring Frame with Optimized Process
Parameters of Speed Frame and Ring Frame
With the optimum values of top roller pressure and
traveller mass, a trial was conducted on the machine
at high spindle speed (17000 rpm). But, it was
observed that the end breakage rate increased
significantly at higher traveller mass. The lighter
traveller mass reduces the end breakage rate at this
speed and also produces yarn with acceptable quality
limit. The data as given in Table 5 for yarn properties
and end breakage rate were obtained on the ring frame
by using three combinations of traveller mass, while
the spindle speed and top roller pressure were kept at
maximum level (the roving was prepared with
optimized parameters of speed frame) . From the
above data, it can be concluded that to maintain the
spindle speed of 17000 rpm the lower traveller mass
and higher top roller pressure are required.
195
4 Conclusions
4.1 The optimum values of different parameters of
ring frame are: spindle speed, 15000 rpm; top roller
50
pressure, 2.5 kg/cm2; and traveller mass, 50 ISO No.
4.2 With the increase in spindle speed, the end
16.9 breakage rate increases and yarn elongation-at-break
9.29 decreases. However, the yarn imperfections, hairiness
5.95 index and strength initially improve and then
126 deteriorate at higher speed.
16.52 4.3 Most of the yarn properties are optimized at
3.3
higher level of top roller pressure.
4.4 Yarn U%, imperfections, hairiness index and
tenacity improve with the increase in traveller mass
but breaking elongation reduces significantly .
Furthermore, the high traveller mass at higher spindle
speed increases the end breakage rate marginally. The
lighter traveller at higher speed reduces the end
breakage rate and also produces yarn with acceptable
quality limit.
4.5 Higher values of square of correlation
coefficients between the experimental values and the
calculated values were obtained from the response
surface equations and it is found that the response
function agrees fairly well with the experimental data.
Thus, ring frame process variables influence
significantly the various yarn characteristics.
References
1 Prosino C A, Int Text Bull, (3) (1989) 69.
2 Ishtiaque S M, Rengasamy R S & Ghosh A, Indian J Fibre
Text Res, 29(2004) 39.
3 Box G E P & Bhenken D W, Technometrics, 2 (1960) 455.
4 Taylor D S, J Text Inst, 50 (1959) 652.
5 Debarr A E & Catling H, The Principles and Theory of Ring
Spinning (The Textile Institute, Manchester), 1965, 122.
6 Stalder H, Melliand Textilber, 75 (7-8) (1994) E141.