Controlling the Fiber Stress Distribution with Variable-Frequency Step Roll for Tunable Spun Yarn Structures.

The dynamic regulation of fiber stress distribution in the yarn-forming triangle area is critical for controlling variable composite yarn structures, including siro and sirofil composite yarns. In this study, comparison analyses of the variable geometric structure and stress distribution during the yarn-forming process, which involves step rolls with asymmetrical fiber control, have been carried out using ring-spinning technology. The geometric analyses show that partly staple fibers are continuously controlled while other fibers intermittently lack stress restraint, resulting in cyclically changed helical angles and wrapping density in the yarn-forming triangle area. The yarn structure model displayed that periodically distributed staple fibers occur in siro composite yarn, while sirofil composite yarn shows gradual periodic changes with uniform thickness variations, caused by cyclical changes in the stress distribution between filaments, and the strand altered the yarn-forming zone shapes from symmetrical to offset. Then, a systematic comparison of variable composite yarns with different frequencies (high, medium and low frequency) revealed that low-frequency step roll with wider grooves resulted in an intermittent output of staple fibers with less stress restraint, resulting in more pronounced structural variation in the siro and sirofil composite yarns with a slight yarn quality deterioration.