chapter 4

EFFECT OF PROCESSING
VARIABLES ON PROPERTIES
OF PARTIALLY ORIENTED
POLYESTER YARN
 Results and Discussions
Effect of processing variables on Properties of
Partially Oriented Polyester Yarn

The p e r f o r m a n c e of PET fibres d e p e n d s u p o n the

molecular structure and the spatial arrangement of molecules. The

molecular structure can be established during polymerisation and

the spatial arrangements of molecules can be established during

further processing. The structural arrangement includes, morphology

and orientation of crystalline and amorphous phases. All properties

are controlled by the molecular morphology. The description of

molecular morphology and the interpretation of the properties is

most required in the manufacturing process of PET.

PET fibre has its own processing conditions. The effect of

processing condition on properties of fibre is more complex and

different authors put forward different types of processing variables

in the melt spring.

4.1 Variables in melt spinning^

l^roccssing variables are classified into three groups those

are:

42
 1. Primary variables: Predetermined technical parameters.

2. Secondary variables: Related to primary variables by the

continuity equation.

3. R e s u l t i n g v a r i a b l e s : d e t e r m i n e d by p r i m a r y a n d

secondary variables and transformation of the fibre from

one phase to another.

4.1.1 Primary variables

a. Material : chemical composition and molecular

structure.

b. Extrusion temperature

c. Spinnerrette design : diameter and no of orifices.

d. Output : mass outflow/unit time.

e. Input : take-up velocity

f. Cooling conditions: temperature, flow and nature

of the cooling medium.

g. Length of the spinning path.

43
4.1.2 Secondary variables

a. Extrusion velocity

b. Diameter and denier of the as-spun filament.

c. Spin-draw ration of deformation ratio

4.1.3 Resulting variables

a. Take-up tension.

b. Take-up stress

c. Ultimate filament temperature

d. Texture and physical properties of as-spun fibres.

Walczak ^ analysed the process variables and classified into

tw^o g r o u p s i.e., t h e o r e t i c a l a n d technological. F u r t h e r , the

technological variables may be independent or dependent variables.

44
4.1.4 Theoretical variables

The theoretical variables are as follows :

a. Number average molecular weight,

b. Shear history of the polymer,

c. Shear in the spinnerrette capilalry,

d. Degree of extension of molten polymer,

e. Effective time of crystallisation,

f. Effective rate of crystallisation,

g. Effective temperature of crystallisation,

h. Draw ratio,

i. Rate of drawing, and

j. Actual drawing temperature.

45
4.1.5 Technological variables

Technological variables can be computed from different

stages of fibre formation. These can be summarized as :

a. Resulting from polymer properties

1. Number average and weight average

molecular weight.

2. Temperature and deformation dependence of

crystallisation rate.

3. Shear s t r e s s - s h e a r rate - t e m p e r a t u r e

relationship.

b. In extrusion of polymers

1. Shear history of polymer

2. Extrusion temperature

3. Capillary diameter and length

4. Volume throughput rate

c. In the quenching zone

1. Trouton viscosity

46
 2. Length of the quench zone

3. Take-up speed

4. Flow of heat transfer agent

5. Temperature of heat transfer agent

6. Temperature profile

7. Profile of filament diameter

8. Maximum rate of extension

9. Threadline tension

Melt spinning process requires rapid a n d c o n t i n u o u s

solification of polymeric liquid. The structural development and the

resulting properties depend upon solidification induced during melt

spring operation. Industrial solidification is more controlled by means

of Quench air.

The polymer as it emerges out of spinneret bulges to a slight

extent due to release of pressure and is then drawn off from the
bottom, while getting solidified in the cooling air. The cooling of the
filament is affected by with a cross air blast, which is free from dust
and is passed through an adequate blowing chimney supplied with

47
an equalizing filter. In order to get a good even yarn the output of

the cross air must be constant and uniform. The distance between

the spinneret outlet and the cooling off through the quench air is

important. It should be such that spinnerets are maintained at even

temperature but on the other hand the air can still penetrate the

fibers. The crucial point in thread formation is the plasticizing area

below the spinneret place, namely the area where the thread passes

from the liquid to the solid state. Since during solidification the thread

is simultaneously subjected to drawing, this is the actual place where

all processes of orientation and therefore characteristics such as

tenacity, elongation, shrinkage and primarily uniformity (Uster value)

of the material are controlled.

4.2 Effect of Quench air on properties of

filaments.

Polyester yarn Polyester (POY) filaments having denier/

Filament 5 1 / 1 4 , 1 0 0 / 3 4 , 126/34 and 140/34 were produced at

different quench air velocities to study the effect of quench air flow

on yarn properties as cooling condition, temperature and Quench

zone air velocity is very important in fibre formation.

48
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4.2.1 Effect of Quench Air Velocity (QAV) on
Elongation and Draw Tension (DT)

From Table4.1 it is observed that irrespective of yarn denier

elongation decreases with increase is Air velocity. In case of 5 1 / 14
denier Elongation reached a minimum of 131.70% with 0.13 m / s e c
QAV and decreased to a minimum of 122.70% with 0.53 m / s e c QAV.
The crucial point in thread formation is the plastifying area below
the spinneret places namely the area where the thread passes from
the liquid to the solid stated Since during solidification the thread
is simultaneously subjected to drawing, this is the actual place where
all process of orientation and therefore characteristics such as
tenacity, Elongation and primarily uniformity of the material are
fixed. Draw tension increases with increase in quench air velocity.
If QAV is high solidification is also high so DT is also high.

4.2.2 Effect of QAV on Uster

The polymer jet as it emerges out of spinnerets bulges to a

slight extent due to release of pressure and is then drawn off from
the bottom while getting solidified in the cooling air'*'' The cooling
of the filaments is affected with a cross air blast which is free from
dust and is passed through an adequate blowing chimney supplied
with an equalizing filters. In order to get a good even yarn (less
uster value) the output of the cross air blast must be constant and
uniform. Table 1 shows that with small air velocity the unevenness

49
of the yarn is high i.e. higher % uster value. In the case of 5 1 / 1 4

yarn reached a maximum of 1.46%. With 0.13 m / s e c cross flow and

reached a minimum of 1.17% with 0.43 m / s e c cross flow, but with

0.53m/sec the uster value again increased to 1.21%. This clearly

indicates that the cross flow should be turbulence free. The amount

of air can be increased until the uniformity of the yarn is optimized

but if this level is exceeded, the yarn once again becomes uneven^.

In the case of 100/34 D / F uster value reached a maximum of 1.32%

with 0.23 m / s e c and minimum of 1.17% with 0.33 m / s e c . In the

case of 126/34 uster value reached a maximum of 1,27% with 0.15m/

sec and reached a minimum of 0.93% with 0.25m/sec, but U (HI)

value is 0.63%. So better flow is 0.35 m / s e c since uster is 1.07%

and U (HI) value is 0.38%. Incase of 140/34, uster value reached a

maximum of 0.94% with 0.20m/sec and minimum of 0.80% with

0.30m/sec.

4.3 Conclusion

The optimum velocities for 5 1 / 1 4 denier is 0.43 m/sec, for

100/34 denier is 0.33 m/sec, for 126/34 denier 0.35 m / s e c and for
140/34 denier 0.30 m/sec. For good even yarn the out put of the
quench Air must be constant and uniform without any dust. In order
to ensure uniform preorientation of all filaments in the yarn, filaments
must be processed under conditions which are as uniform as possible.

50
References :

1. Mishra S P, Asian Text. J., 5,6 (1995) 28.

2. Walczak Z K, Formation of Synthetic Fibres, Gordon and Breach

Science Publishers, New York (1977).

3. Riel L Chemiefasern/Textilindustrie 3 5 / 8 7 J a n (1985) 27.

4. Ziabicki A, Fundamentals of Fibre Formation J o h n Wiley and

Sons, New York (1976) 10.

5. Zimmerman J and Fleming SW, Appl Polym Symp 6 (1967) 19.

6. Mozhieko V 5, Mezhirova Sy 86 Filbert DV, Fiber Chem 10(3)

(1978) 23.

7. Zharav VB St Aleksandriski 8 8 , Fibre Chem 10(5) (1978) 26.

8. Bela von Falkai, The Indian Textile Journal, Dec (1990) 24.

51