Open Access

Coupling Characteristics of Needles and Backing Cloth During the Carpet Tufting Process

Yang Xu
Yang Xu
, 
Shuang Huang
Shuang Huang
, 
Xiaowei Sheng
Xiaowei Sheng
 and 
Sun Zhijun
Sun Zhijun
   | Sep 28, 2022
Fibres & Textiles in Eastern Europe's Cover Image
About this article
Previous Article
Next Article
Cite
Article Category: Research Article
Published Online: Sep 28, 2022
Page range: 9 - 17
DOI: https://doi.org/10.2478/ftee-2022-0017
Keywords
© 2022 Yang Xu, et al., published by Sciendo
This work is licensed under the Creative Commons Attribution 3.0 Public License.

Fig. 1

Models of tufting needles. a) Individual tufting needle; b) 1/10 needle module
Models of tufting needles. a) Individual tufting needle; b) 1/10 needle module

Fig. 2

Model of polypropylene woven fabric a) model of warp, b) model of weft, c) complete model
Model of polypropylene woven fabric a) model of warp, b) model of weft, c) complete model

Fig. 3

Model of the nonwoven fabric
Model of the nonwoven fabric

Fig. 4

Meshing in the finite element model a) single needle and polypropylene woven fabric, b) single needle and nonwoven fabric, c) 1/10 needle modules and nonwoven fabric
Meshing in the finite element model a) single needle and polypropylene woven fabric, b) single needle and nonwoven fabric, c) 1/10 needle modules and nonwoven fabric

Fig. 5

Deformation of the polypropylene woven fabric at time t: a) t=1.5ms, b) t=3ms, c) t=11.25ms, d) t=15ms, e) hole in fabric in the finite element model and in the actual backing cloth (t=15ms)
Deformation of the polypropylene woven fabric at time t: a) t=1.5ms, b) t=3ms, c) t=11.25ms, d) t=15ms, e) hole in fabric in the finite element model and in the actual backing cloth (t=15ms)

Fig. 6

Deformation of the hot-air bonded nonwoven at time t: a) t=0.65ms, b) t=1.3ms, c) t=2.6ms, d) t=4.55ms, e) t=9.75ms, f) t=13ms, g) hole in fabric in the finite element model and in the actual backing cloth (t=13ms)
Deformation of the hot-air bonded nonwoven at time t: a) t=0.65ms, b) t=1.3ms, c) t=2.6ms, d) t=4.55ms, e) t=9.75ms, f) t=13ms, g) hole in fabric in the finite element model and in the actual backing cloth (t=13ms)

Fig. 7

Deformation of thermo-calender bonded nonwoven at time t: a) t=1.5ms, b) t=4.5ms, c) t=9ms, d) t=15ms, e) hole in fabric in the finite element model and the actual backing cloth (t=15ms)
Deformation of thermo-calender bonded nonwoven at time t: a) t=1.5ms, b) t=4.5ms, c) t=9ms, d) t=15ms, e) hole in fabric in the finite element model and the actual backing cloth (t=15ms)

Fig. 8

Needle forces for different backing materials
Needle forces for different backing materials

Fig. 9

Needle forces at different needle speeds
Needle forces at different needle speeds

Fig. 10

Maximum stress of the node in the backing cloth
Maximum stress of the node in the backing cloth

Fig. 11

Deformation of hot-air bonded nonwoven punctured by 1/10 needle modules at time t: a) t=0.75 ms, b) t=3 ms, c) t=3.75 ms, d) t=4.5 ms, e) t=5.25 ms, f) t=10 ms, g) actual backing cloth
Deformation of hot-air bonded nonwoven punctured by 1/10 needle modules at time t: a) t=0.75 ms, b) t=3 ms, c) t=3.75 ms, d) t=4.5 ms, e) t=5.25 ms, f) t=10 ms, g) actual backing cloth

Specification parameters of nonwoven fabrics

Backing cloth Fiber fineness [dtex] Density [g/m2] Thickness [mm] Length [mm] Width [mm]
Hot-air bonded nonwoven 1.56 110 0.24 30 26
Thermo-calender bonded nonwoven 1.56 65 0.35 30 26

Parameters of tufting needle

Material Gauge [in] Density [g.cm−3] Length [mm] Thickness [mm] Elastic modulus [MPa] Poisson ratio
Steel 0.10 7.8 36 3 2700 0.28

Mechanical properties of nonwoven fabrics

Backing cloth E11 [MPa] E22 [MPa] E33 [MPa] G12 [MPa] G23 [MPa] G31 [MPa] v12 v23 v13
Hot-air bonded nonwoven 357.59 140.04 9.80 121.98 50.01 4.86 0.41 0.41 0.41
Thermo-calender bonded nonwoven 126.75 94.56 10.00 87.88 49.66 4.86 0.41 0.41 0.41

Mechanical properties of polypropylene woven fabric

Yarn Stress [MPa] Strain Fracture work [mJ]
Warp 249.5 0.056 1400.00
Weft 243.0 0.081 1291.31
eISSN:
2300-7354
Language:
English
Publication timeframe:
6 times per year
Journal Subjects:
Business and Economics, Business Management, Business Informatics, Process Management, Industrial Chemistry, Cellulose, Paper and Textiles, Polymer Science and Technology, Materials Sciences, Biomaterials and Natural Materials
Journal RSS Feed