Dynamics of Fibre Formation and Processing

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1 Dynamics of Fibre Formation and Processing

2 Roland Beyreuther Harald Brünig Dynamics of Fibre Formation and Processing Modelling and Application in Fibre and Textile Industry With 171 Figures 123

3 Prof. Dr.-Ing. habil. Roland Beyreuther Dr.rer.nat.HaraldBrünig Leibniz-Institut für Polymerforschung Dresden e. V. Hohe Straße Dresden, Germany RBeyreuther@t-online.de bruenig@ipfdd.de ISBN X Springer Berlin Heidelberg New York ISBN Springer Berlin Heidelberg New York DOI /b79612 Library of Congress Control Number: This work is subject to copyright. All rights reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable for prosecution under the German Copyright Law. Springer is a part of Springer Science+Business Media springer.com Springer-Verlag Berlin Heidelberg 2007 The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Product liability: The publisher cannot guarantee the accuracy of any information about dosage and application contained in this book. In every individual case the user must check such information by consulting the relevant literature. The instructions given for carrying out practical experiments do not absolve the reader from being responsible for safety precautions. Liability is not accepted by the authors. Typesetting: By the authors Production: LE-TEX, Jelonek, Schmidt & Vöckler GbR, Leipzig Coverdesign: design&production, Heidelberg Printed on acid-free paper 2/3100/YL

4 Dedicated to our wives Ute Beyreuther and Dietlinde Brünig with a warm thanks for many hours of appreciative patience

5 Preface The special subject dynamics calls forth mostly mixed feelings to students and graduates of technical fields. The first foresee and the second know the problems to reach a good or very good mark before or after an appropriate leaving examination. The reasons for this are well known and even partly understandable. Dynamics the science of changes or motions which are caused by means of energetic impulses or forces requires namely a certain amount of applicable knowledge of mathematics as well as logical abstraction and intellectual power to its understanding. These are not within reach by means of schematic memorising. But basic knowledge and field specific applications of special branches of knowledge are absolutely necessary for engineers, physicists, chemists or mathematicians, if they in practice and research intend to treat determined tasks and operation fields successfully. Such knowledges and considerations are unconditional prerequisites specifically to the analysis of technological processes, to the suppression of disturbances and to the process stabilisation by means of qualitative high-class automatic control systems. This is especially valid for many textile-technological processes. The mastery of their dynamics decisively influences the process economy as well as the product quality because these processes are often connected with a high manufacturing velocity and/or with a special disturbance sensitivity. The manufacture of textile products is one of the oldest machine technologies of mankind because it satisfies one of the elementary basic necessities, namely clothing. Many additional technical applications of textile products came along in the nearest past. The processes of manufacturing, the treatment and the processing of fibre threads have a special importance in this context because the fibres (in their multiform kind) were and are the most important basic elements for textile fabrics. Several ten-thousands of parallel single fibre formations and processing stages are realised simultaneously in a textile or man-made fibre plant. These

6 VIII Preface processes are to be organised with the lowest possible disturbance (e. g. fibre break) levels. Additionally, a strongly increased production velocity has been realised in the last decades for the natural as well as for the man made fibre manufacturing. Both the multitude of single work positions and the high production and processing velocities require an increasing knowledge and reliable mastery of the process dynamics from engineers. This presented book collects the results of industry orientated research which the authors have been carrying out during their work at the Leibniz- Institute of Polymer Research Dresden, Germany (former Institute of Technology of Fibres, until 1990). It deals with dynamic-analytical investigations of different basic processes of the yarn formation and processing for natural as well as chemical (man made) and also glass fibres. The carding processes (roller top card and stationary flat card) and also the false twist texturing process are included (Chaps. 4 and 5, Beyreuther). The main point of these investigations is the dynamic transfer and step response functions and their methodical fundamentals will be fully explained before hand in the introductory Chaps. 1 and 2 (Beyreuther). Therefore the explanations should be understandable for experts who are not skilled in the process-dynamical thinking, too. A large scale occupies the engineering modelling of the steady state man made fibre process (Chap. 3, Brünig). The presented results are based on the current knowledge of the theory of fibre formation but also on own developed description statements. They include the single filament and multifilament melt spinning processes as well as the fibre formation of the spunbonded nonwoven process. Some representations about the importance of the tensile force time function for the process stability, its measurement and evaluation conclude the book (Chap. 6, Beyreuther). All theoretical investigations and results are discussed and verified by means of numerous examples within the industrial practice. With the representation of these complex subjects the book should be qualified for natural and engineer scientists of research and education as well as of textile and man made fibre industry to extend their know-how and know-why knowledge about the processes of fibre formation and processing. The book is also recommendable for lecturers and students of appropriate technical and chemical special branches at technical universities and colleges. The authors also considered didactic experiences in the present subject representation which they have obtained during the last three decades at lectures and seminars at the Technische Universität Dresden/Germany to graduate students of textile

7 Preface IX engineering and macromolecular chemistry. We thank all collaborators from the Leibniz-Institute of Polymer Research Dresden/Germany, especially our fellow-workers of the former department Fibre Formation, for the given support and assistance with numerous experiments, for their evaluation and for many scientific discussions which were very helpful to the conception and planning of the presented book. Furthermore we are very grateful to our longterm research partners from industry, research institutes and research organisations for the financial support and many fruitful discussions to application related projects which stimulated us to the shaping of general examples into single book chapters. This particularly concerns the companies EMS Inventa AG Domat/Switzerland, DSM Research Geleen/Netherlands, Barmag AG Remscheid/Germany, Saxon Textile Research Institute Chemnitz/Germany and the German Research Association (DFG) Bonn/Germany. We warmly thank Prof. Dr. P. Offermann, Technische Universität Dresden/Germany (Institute of Textiles and Clothing), and Prof. Dr. T. Kikutani, Tokyo Institute of Technology/Japan (Department of Organic and Polymeric Materials), for their suggestions and helpful comments to the manuscript. We are very thankful last but not least to Springer Publishers for the appreciative cooperation and the possibility of publication. Dresden, October 2006 Roland Beyreuther Harald Brünig

8 Contents 1. Introduction Steady State and Non-Steady State Technological Processes Definitions TheTechnologicalProcess Dynamics,ProcessDynamics Modelling of the Steady State Melt Spinning Process Goal of Modelling BalanceEquations Example:HeatTransfer Modelling of Non-Steady State Dynamic Process SystemandSignal Model Characterisation of the Dynamic Process Behaviour DifferentialEquation Description in the Time Range; Step Response DescriptionintheFrequencyRange Correlation and Power Density Spectrum Functions Dynamic Process Analysis and Modelling MethodicalProcedure DetailedExample(DrawingProcess) Modelling of Steady State Fibre Formation Process in Melt Spinning SteadyStateSingleFibreFormationProcess Definition: What Does Fibre Formation Mean? Fundamental Balance Equations Interaction Between Fibre and Environment ResponseofthePolymerMelt StructureDevelopment MaterialPropertiesofSpinnablePolymers Practical Modelling: Simulation of Fibre Formation MultifilamentSpinning... 90

9 XII Contents PeculiaritiesinMultifilamentSpinning Models of Interaction Between the Fibre Bundle and theenvironment ContinuumTheory Example 1: Numerical Simulation of Fibre Formation in the Staple Fibre Melt Spinning Process Example 2: Modelling of Fibre Formation in the SpunbondedNonwovenProcess Summary Limits and Spinnability MaximumandMinimumFineness Visco-elastic Failure and Nonlinear Effects Dynamics of Fibre Formation Processes Task MeltSpinning ofpolymers VariableFibreFineness VariableFibreOrientation Complex Proceedings in the Fibre Formation Distance Glass Fibre Spinning; Variable Fibre Fineness Cause-Effect-Scheme FunctionalBlockDiagram EvaluationandResults Dynamics of Fibre Formation in the Spun Yarn Spinning Process Task Dynamic Transfer Behaviour of Carding Engines Dynamic Transfer Behaviour of Drafting Zones in DraftingSystems NecessaryMeasuringandGaugeLengths Dynamics of Fibre Processing Processes DynamicsoftheFibreTransport Task Dynamic Model to the Description of a Delay Thread Line Dynamic Model to the Description of a Dead Time ThreadLine Dynamic Model to the Description of a Friction Thread Line Examples of Quantitative Investigations of Fibre TransportProcesses Dynamics of the Twist Transfer at the False Twist Texturing Task Mathematic-DynamicModel

10 Contents XIII 5.3 DynamicsofFibreHeatingandCooling Task Differential Equation for the Description of Heat TransferatFibres Technological Application Examples Dynamics of the Tensile Force and its Importance for Process Stability Task Connection Between Fibre Fineness and Fibre Tensile Force Variations DynamicPropertiesofMeasuringSensors Evaluation of the Tensile Force Time Function StationaryEvaluation Dynamic Evaluation; Auto Correlation and Auto Power DensitySpectrumFunctions Combination Measurements and Evaluations TaskandMeasurements Dynamic Evaluation and Cross-Correlation Functions (CCF) References List of Symbols Index

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