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

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

Fibres & Textiles in Eastern Europe
Volume 30 (2022): Issue 3 (October 2022)
By: Yang Xu,  Shuang Huang,  Xiaowei Sheng and  Sun Zhijun  
Open Access
|Sep 2022

Figures & Tables

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 clothFiber fineness [dtex]Density [g/m2]Thickness [mm]Length [mm]Width [mm]
Hot-air bonded nonwoven1.561100.243026
Thermo-calender bonded nonwoven1.56650.353026

Parameters of tufting needle

MaterialGauge [in]Density [g.cm−3]Length [mm]Thickness [mm]Elastic modulus [MPa]Poisson ratio
Steel0.107.836327000.28

Mechanical properties of nonwoven fabrics

Backing clothE11 [MPa]E22 [MPa]E33 [MPa]G12 [MPa]G23 [MPa]G31 [MPa]v12v23v13
Hot-air bonded nonwoven357.59140.049.80121.9850.014.860.410.410.41
Thermo-calender bonded nonwoven126.7594.5610.0087.8849.664.860.410.410.41

Mechanical properties of polypropylene woven fabric

YarnStress [MPa]StrainFracture work [mJ]
Warp249.50.0561400.00
Weft243.00.0811291.31
DOI: https://doi.org/10.2478/ftee-2022-0017 | Journal eISSN: 2300-7354 | Journal ISSN: 1230-3666
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Language: English
Page range: 9 - 17
Published on: Sep 28, 2022
Published by: Łukasiewicz Research Network, Institute of Biopolymers and Chemical Fibres
In partnership with: Paradigm Publishing Services
Publication frequency: Volume open
Keywords:
tufted carpet,
finite element model,
needle force,
deformation of backing cloth
Related 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

© 2022 Yang Xu, Shuang Huang, Xiaowei Sheng, Sun Zhijun, published by Łukasiewicz Research Network, Institute of Biopolymers and Chemical Fibres
This work is licensed under the Creative Commons Attribution 3.0 License.

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