Journal of Textile Research ›› 2024, Vol. 45 ›› Issue (11): 65-72.doi: 10.13475/j.fzxb.20230301101

• Textile Engineering • Previous Articles     Next Articles

Finite element modeling and simulation of cotton fiber assembly carding process based on 3-D braided and fractal theory

ZHU Lei1, LI Yong2, CHEN Xiaochuan1(), WANG Jun3   

  1. 1. College of Mechanical Engineering, Donghua University, Shanghai 201620, China
    2. College of Mechanical and Electronic Engineering, Tarim University, Alar, Xinjiang 843300, China
    3. College of Textiles, Donghua University, Shanghai 201620, China
  • Received:2023-04-01 Revised:2024-08-09 Online:2024-11-15 Published:2024-12-30
  • Contact: CHEN Xiaochuan E-mail:xcchen@dhu.edu.cn

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Abstract:

Objective Carding is the core step of cotton carding process. Its principle is to separate the fiber bundles in cotton roll into a single fiber by means of needle surface movement. In order to achieve the carding effect and prevent cotton fiber from being damaged due to excessive force at the same time, it is essential to control the carding force of cotton fiber within a reasonable range. To study the stress of cotton fiber assembly in carding process and improve the quality of cotton sliver, a new model of cotton fiber assembly was built.

Method The cotton fiber units were established based on the fractal theory, combined with the modeling idea of three-dimensional braided composite materials. The fractal cotton fiber units were arranged according to the fiber distribution in the internal single unicellular structure of three-dimensional four-way braided composite. The model was applied to simulate the carding process of cotton fiber assembly. The stress and strain variation of cotton fiber was studied by finite element method, the change of carding force over time was analyzed.

Results The carding process of cotton fiber under the fixed moisture regain was simulated by using finite element software. The cotton fiber was in the working area between cylinder and plate of the carding machine. In this process, cotton fiber was held by the needle teeth of cylinder and sorted by the needle of plate. The carding force of cotton fiber assembly, the stress and strain variation of cotton fiber over time were studied. Stress relaxation parameters shows that the stress and strain of cotton fiber first increases and then decreases as time goes on. It can be seen from assembly diagram that the stress of cotton fiber mostly occurs in the part directly in contact with the needle of plate and the part held by the needle teeth of cylinder. The effect of cotton fiber moisture regain on carding process was analyzed. The simulation parameters of cotton fiber under different moisture regain conditions were determined. The change of moisture regain will cause the change of friction coefficient of cotton fiber surface, and then affect the carding force. On the basis of the existing friction coefficient values of cotton fiber surface, the interpolation polynomial of friction coefficient and moisture regain was determined by method of undetermined coefficients. The friction coefficient values of cotton fiber under different moisture regain conditions were obtained. With the rise of moisture regain, static friction coefficient between cotton fiber and metal decreases, while dynamic friction coefficient increases. Both static friction coefficient and dynamic friction coefficient between cotton fibers increase. The stress of cotton fiber and the carding force on cotton fiber assembly increase first and then decrease with the rise of moisture regain.

Conclusion The simulation results of carding force are in agreement with the experimental results, indicating that the model of cotton fiber assembly is reasonable. As moisture regain increases, both the stress of cotton fiber and the carding force of cotton fiber assembly generally increases first and then decreases. According to the stress cotton fiber assembly under different moisture regain conditions, when the moisture regain is 6.5% and 8.5%, the stresses in both conditions are not very different and are relatively large. But the carding force is greater when the moisture regain is 6.5%, in this condition the carding effect is the best. The finite element method can better analyze the process of cotton carding, provide reference for the parameter setting of each part of the carding machine, and improve the carding efficiency and quality.

Key words: cotton fiber assembly, carding process, finite element model, sliver quality, carding force, moisture regain

CLC Number: 

  • TS11

Tab.1

IFS transform of top view of fractal cotton fiber"

i 俯视图 主视图
ωi ωi
1 x'=x+1.30 y'=y+0.75 x'=x+1.30 y'=2y+1.50
2 x'=x-1.30 y'=y+0.75 x'=x-1.30 y'=2y+1.50
3 x'=x y'=y-1.50 x'=x y'=2y

Tab.2

IFS code for top view of fractal cotton fiber"

i 俯视图 主视图
ai bi ci di ei fi ai bi ci di ei fi
1 1 0 0 1 1.30 0.75 1 0 0 2 1.30 0
2 1 0 0 1 -1.30 0.75 1 0 0 2 -1.30 0
3 1 0 0 1 0 -1.50 1 0 0 2 0 0

Fig.1

Fractal cotton fiber top view transformation process. (a)Top view; (b) Main view"

Fig.2

Fractal cotton fiber unit model"

Fig.3

Internal unicellular structure of three dimensional four-directional braided composites"

Fig.4

Solid model of cotton fiber assembly based on fractal and three-dimensional braided theory"

Fig.5

Cotton fiber assembly diagram at different times"

Tab.3

Stress and strain of cotton fiber assembly at different times"

时间/s 棉纤维应力/MPa 棉纤维应变/%
8.55×10-5 0~60.471 0~3.794
6.84×10-4 0.184~2 176 0~96.091
8.55×10-4 0.305~1 199.800 0~53.589

Tab.4

Change of carding force at different times"

时间/s 梳理力/N 时间/s 梳理力/N
1.18×10-38 0 4.70×10-4 0.272 36
4.28×10-5 0 5.13×10-4 0.290 47
8.55×10-5 0 5.56×10-4 0.267 17
1.28×10-4 0.140 72 5.99×10-4 0.215 45
1.71×10-4 0.291 39 6.41×10-4 0.297 43
2.14×10-4 0.120 31 6.84×10-4 0.270 38
2.57×10-4 0.157 69 7.27×10-4 0.344 44
2.99×10-4 0.150 29 7.70×10-4 0.166 59
3.42×10-4 0.199 98 8.12×10-4 0.696 19
3.85×10-4 0.178 00 8.55×10-4 0.661 46
4.28×10-4 0.225 62 — —

Tab.5

Stress relaxation parameters of cotton fibers under different moisture regain conditions"

回潮率/
%		 E1/
(cN·
dtex-1)		 E2/
(cN·
dtex-1)		 η1/
(cN·s·
dtex-1)		 η2/
(cN·s·
dtex-1)
5.5 158.295 27.037 681.715 19 880.471
6.5 164.095 25.883 691.573 29 091.795
8.5 159.873 25.439 671.215 27 103.253
10 150.915 24.346 608.535 21 348.383

Tab.6

Viscoelastic material parameters of cotton fibers under different moisture regain conditions"

回潮率/% 松弛时间/s G0/(cN·dtex-1) β/(s-1)
5.5 3.676 13.518 0.272 1
6.5 3.639 12.941 0.274 8
8.5 3.620 12.719 0.276 2
10 3.470 12.173 0.288 2

Tab.7

Effect of moisture regain on friction coefficient of cotton fiber"

回潮率/
%		 纤维与金属之间 纤维与纤维之间
μs μd μs μd
3.98 0.282 3 0.245 3 0.307 3 0.263 5
7.23 0.297 5 0.262 5 0.315 3 0.276 4
8.97 0.284 2 0.275 3 0.314 2 0.282 1
12.57 0.294 2 0.286 3 0.303 1 0.284 2
16.39 0.325 4 0.336 4 0.354 2 0.325 3

Tab.8

Effect of moisture regain on friction coefficient of cotton fiber"

回潮率/
%		 纤维与金属之间 纤维与纤维之间
μs μd μs μd
5.5 0.306 6 0.246 3 0.308 8 0.267 0
6.5 0.303 4 0.255 4 0.313 1 0.272 5
8.5 0.287 0 0.272 6 0.315 4 0.281 1
10.0 0.281 5 0.279 2 0.310 1 0.283 0

Fig.6

Stress-strain diagram of cotton fiber assembly under different moisture regain conditions"

Fig.7

Stress variation of cotton fiber assembly under different moisture regain conditions"

Fig.8

Change of carding force with time under different moisture regain conditions"

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