Glass fiber with high strength, lightweight, good physical and chemical properties in new materials are more and more widely used, but in the glass fiber drawing operation, often because of position of wire drawing process, the production of machinery and equipment operating conditions of the surface, causing production of glass fibre wire drawing bundles of filaments, and filament, fuzz, bad shape etc. several situations, and now with the several problems common in glass fiber production, analysis of some solutions.
1 treatment and solution of common problems
1.1 point beam
The so-called splitting wire different in chopped strand splitting is refers to in the production of wire drawing, single glass fiber not according to a predetermined drawing technology cluster zone, but a root and root number separate cluster with. In the winding process, because of its single joint-stock beam is easy to cause the original yarn rolls cut in the process of yarn cross joint play, reduce the rate of finished products of the winding, winding process and the tow is fine, in passing the porcelain eye, winding tension is easy to break, finished yarn roll end face of wool yarn, a yarn length, serious will cause winding process because of its fracture wound on the other strand caused yarn breakage, larger influence winding process orderly, and the problem in the drawing process if we do not pay attention to, is often difficult to find and cause a large number of "return of the yarn. The reason there are several working conditions of oil shaft. Such as whether it is due to run for a long time and resulting in the coated surface of the shaft groove, groove and other, which often shaft oiling roll caused by individual raw silk slip into them, cluster effect, the formation of sub beam. The beam in the original yarn cake is often a long distance and large area dagger cluster round working condition. Drawing process in graphite cluster round for local wear groove, groove, resulting in glass fiber drawing cluster in not in the same groove, a root and a few glass filaments separate bundle drawing molding machine traverse. Such as steel wire on wear and local dirt deposition case drawing process improper position. In short, the emergence of a beam of silk, to be careful observation, to identify the reasons, at the same time, in the production of vulnerable equipment to be done timely inspection and maintenance, so that timely cleaning or replacement, the formation of institutionalized, standardized operation.
1.2 and silk
The so-called and silk, the popular understanding is drawing cable in the process of glass fiber strand cable appear to overlap of a cycle and a or a few cycles. The raw silk cake after drying after the film, due to the film forming agent are connected into a film, in the winding could easily lead to the original yarn cake back solution is difficult or impossible to degradation, or unwinding continuously in the process of yarn series with, the yarn breakage etc.. The reasons are generally
(1) bad speed ratio. Refers to the ratio in the drawing process drawing machine with synchronous traverse wheel speed ratio.
When the ratio is integer or close to integer times tends to occur and the wire, but also in the production of different varieties of raw yarn, the ratio of the level will also affect the quality of raw silk roll forming process, generally unchanged in other cases, the greater the ratio is, in a drawing during the trip, the number of wire arranging device is less, the intersection angle between the original wire stock and shares will become smaller, the contact length between stocks and shares will increase, this may be due to the infiltration of agents into film to affect the winding process, adhesion with delamination, reduce the winding speed, winding process of lead the appearance and inner quality, more serious when serious and not winding wire. Conversely, contact length, but and not the smaller the better, is too small will cause the other quality problems, and the size of the ratio, and the production of a variety of related, such as winding yarn production and chopped yarn is somewhat different, specific ratio visual product types and the process of different and make reasonable choice. At this point, through the improvement of synchronous motor gear, a winding gear tooth number of how many or replace synchronous motor to change its speed to adjust the ratio to an ideal numerical.
(2) synchronous transmission belt appear wear, tension caused by excessive belt aging deformation or too small and skid, synchronous motor gear, a winding gear appear wear, resulting in wire drawing machine speed ratio change and cause and wire, this time only need to the replacement can be.
(3) process position effect. In the production of wire drawing traverse relative drawing machine head position of drawing tension, traversing width, cable force size has certain influence, its position is too low could easily lead to cable thrust, affect the traversing width and cable effect, too high to the yarn tension produced adverse effects (the process is schematically shown in Figure 1).
(4) other effects, such as yarn in the drawing cylinder row picture size, size of the tension and wire drawing and winding mechanism have no damage, such as fibrillation reason.
1.3 filaments and forming bad
Filament produced most of the reason is the cluster round, Tu tanker, cable, etc. appear wear groove, groove or the deposition of dirt and other reasons, cause local wear serious, in the wire drawing process broken filament or a few raw silk bundle adverse, in the winding process resulting in the fracture forming yarn.
A large part of the reason for the forming bad is a steel wire arc properly and not ascending spiral curve, or cable and wire drawing machine is damaged, quiver, or process dimension bad reasons. For example "ripple" shaped surface of raw silk cake, mostly because of steel wire molding process is not good, synchronous motor belt tension caused by excessive deformation or tension of the belt caused by small slip, or wire drawing mechanism of fibrillation caused, thereby affecting the winding effect. In addition, wire drawing machine, the size of the stroke and its rationality has a direct impact on the shape of the raw silk cake, such as drawing and superposition part of two strokes to the stroke of big or small, resulting in raw silk cake forming "saddle" or "peak".
1.4 other cases
In the winding process sometimes encountered after drying of raw yarn cake at the time of winding continuously appear single strand breaks, adjusting the tension, reduce the vehicle speed does not solve the problem, if the original yarn cake raw yarn pull were observed, you will find meters or a few meters long and drawing machine of the original yarn each isolation of the law relating to the nose radius of the original yarn wear serious, which is often due to the wire drawing process, raw silk in cable of raw silk ribbon amplitude had caused by one end or two ends of the raw silk slip out of the winding machine, resulting in the formation of wear, as long as the timely replacement of cable steel
Wire and cable are often able to adjust the width of solution.
Anyway, in the production of wire drawing process, due to a part of the inspection, inspection is not in place or improper maintenance may bring hidden troubles to the normal production, resulting in production of substandard or waste, only by understanding the problems easily occurred in the production process, don't let any a trivial problem, to find the problem in the according to the problems of frequency and frequency of careful search, and in peacetime to accumulate more experience and do aware of in order to better serve the production.
Concluding remarks
There are many factors that affect the original wire winding, wherein the shape of spiral wire arranging device is reasonable or not is the key factor, also bundling groove, cable and wire drawing die relative technology position, head speed and wire speed ratio, cable reciprocating dynamic process parameters such as selection, steel wire cleaning and surface smoothness, traverse shaft concentricity has a direct impact on filament winding forming
Cause of hairiness causes and solutions in the process of glass fiber
Mao Yu phenomenon has always been an important problem in the production of glass fiber. To solve the problem of hairiness is actually a system engineering, from infiltration agent to drawing, drying, annealing solution, weaving, every procedure has many is worth to pay close attention to the details, but in the production is often easy to overlook. Glass fiber filaments that are caused by many reasons, from the perspective of production process analysis: glass melting, and to clarify the adverse, wire drawing process parameters settings is not reasonable, the drying process or raw silk conditioning process is improper. From the point of view of the wetting agent, the formula of film forming agent is not reasonable, the content of the wetting agent is low, the use of the wetting agent is improper. From the point of view of the process analysis: environmental temperature and humidity, back solution (winding) technology, raw silk conditioning process, the drying process etc.. In this paper, mainly from the infiltration agent technology, glass melting process, wire drawing process, machining environment, untwisting (winding) process, drying process analysis of producing hairiness causes and prevention.
The reason of fuzz formation and Countermeasures
2.1 of the original wire sizing agent will cause the low content of raw silk bundle bad, easy to wear off single wire sanding, the emergence of a large number of filaments.
Solution measures:
(1) in order to improve the solid content of the wetting agent, the raw silk produced in the alkali tank furnace was found to be due to the spray and so on.
(2) to improve the adhesion of the wetting agent, adding polyvinyl alcohol (PVA), polyvinyl alcohol (PVPK) and other high viscosity materials, can increase the viscosity of the wetting agent.
(3) to control the spray flow, to check the status of atomization in time.
(4) to solve the graphite size applicator roll fisheye and flower roll phenomenon, timely cleaning or replacement of oiling roller.
2.2 glass melting is not good or bad fuzz clarification, due to the presence of unmelted good glass stones, bubbles and other defects in the process caused by single fiber fragmentation and hairiness.
Solution measures:
(1) stability of the glass melting process, improve the quality of melting.(2) the clarification of glass using bubbling technology.
2.2 sizing formula of hairiness effect. Has an important influence on sizing film-forming agent, lubricant, coupling agent and other components on hairiness formation.
Solution measures:
(1) selection of appropriate film forming agent. Epoxy ester, using epoxy ester reactive groups and easy open-loop characteristics, various infiltration agent properties required for the molecular chain segment. Linear saturated polyester, in the wetting agent can also play a role in the lubrication of plastic, used as a hard yarn plasticizer, penetrate fast, not easy to migrate. Can also be used for resin type textile sizing agent, soft, smooth, cut filament. Waterborne polyurethane. Waterborne polyurethane film with high strength, good elasticity, good protection effect of glass fiber bundles, can reduce the fuzz.
(2) selection of appropriate lubricant plays a crucial role in reducing glass fiber filament and glass fiber wetting agent used in lubricant can be broadly divided into two major categories of nonionic and cationic lubricant. A non-ionic lubricant: ethylene chloro fatty acid sulfate and its derivatives, imidazoline, dimethyl silicone oil emulsion, phosphatidic acid, etc. Cationic lubricant is: fatty acid quaternary ammonium salt, fatty acid, fatty acid, fatty acid, four ethylene or amine complex, etc.. Glass fiber surface strong adsorption of water, and make water molecules, water molecules in the H+, SiO- and AlO-, strong combination, resulting in OH- outward, so the surface of the glass fiber for the anion. It is widely used in glass fiber lubricant cationic lubricant, and glass fiber with good reducing filament. The hard yarn wetting agent can be used for 3 to 2 kinds of cationic lubricant, while the soft yarn wetting agent is a kind of soft and plastic film, which is generally used as a non ionic lubricant and a cationic lubricant. The amount of lubricant in the wetting agent formula must be appropriate. General cationic wet lubricant concentration is below 0.2%, too much is easy to raw silk cylinder deformation caused by, if it is hard tube drawing will form a megaphone, soft tube drawing will cause raw silk tube collapse tube, back solution is difficult, will cause the broken filament. Stem state lubricant dosage should be controlled appropriately, multi effect yarn bundling, especially in a low glass transition temperature of film forming agent, film as a whole is too soft, back or weaving yarn easy adhesion on the parts, forming black sticky objects, will cause the broken filament.
(3) the appropriate coupling agent. Infiltration agent in the coupling agent and the surface of the glass fiber to Si-O-Si bond with and repair micro cracks on the fiber surface, preventing glass fibre in the microcrack stress concentration at fracture, can reduce hairiness. For the enhanced wetting agent, coupling agent, coupling agent modification or hydrolysis is caused by one of the factors causing adverse.
2.3 infiltration caused by improper use of Mao Yu. Because of the change of the infiltration effect caused by the change of the temperature during the use of the wetting agent, the change of the circulating oil and solid content will affect the content of the original silk wetting agent and then cause the production of Mao Yu in the process.
Solution measures:
(1) strict control of the infiltration of the small circulation of the solid content and its fluctuations (strict control of good spray angle - control of a good spray water intrusion into the wetting agent);
(2) the number of strict control of each small cycle with the oiler;
(3) strict control of the wetting agent temperature;
(4) strict control of the original moisture content of the original silk cake. The moisture content of the cake of raw silk rate reaction raw tow "eat oil" is good or bad and full extent; too much raw silk water rate will cause infiltration agent migration aggravate. Therefore, the original moisture content of the original silk cake must be strictly controlled.
2.4 wire drawing process parameters set unreasonable also easy to cause the hairiness. Drawing process parameter setting is easy to cause the formation of the original wire is not good, the tension is too large, etc..
The solution has the following points:
(1) to adjust the process position, especially control the fan monofilament in the package on the graphite roll angle and wheel position cluster. The single wrap angle as far as possible adjustment of small, generally about 3O, so it can effectively reduce the drawing tension. At the same time slot to cluster regularly turn a certain angle, otherwise it will cause the original filoselle silk mill wide, and fuzz.
(2) according to the different characteristics of the wetting agent and the choice of different winding ratio. Winding ratio = head speed / line speed. The cable rotation, rotation of the head number. The significance lies in the repeatability of winding ratio control of winding angle, filament winding, determines the degradation efficiency and cake unwinding efficiency. The higher the winding angle, the shape is stable. In order to make the silk cake smoothly, it is generally more than 6o. Such as small cake weight, small thickness, can use a smaller angle. Parallel wire will cause the time to take off. The main control speed ratio can not be integer or integer scores, generally above three decimal places.
(3) according to the varieties of raw silk to choose different steel wire. The spiral steel wire with a high speed mobile as raw silk, and according to a predetermined pattern around the original thread cylinder. Geometric forms of the spiral cable is based on the Archimedes curve and linear motion, but the performance of raw silk will change the movement and lead to wave action. Steel wire specifications (shape, material) is an important factor in deciding the effect of cable. Steel wire shape inaccurate, local excessive wear (caused by change in shape), steel wire deformation, installation not accurate to high, low-end installation exsertion size and each pair of steel wire installed symmetry, the end pins of parallelism and so on), the material is too soft (no degree of elasticity and rigidity), impure materials, smoothness (material itself inferior, burr, crack and so on).
(4) bushing of uneven temperature produced by Mao Yu. Bushing uneven temperature resulting in drawing process in single yarn tension uneven, resulting in raw silk seersucker, single fiber fracture process hairiness. By testing two cause of hairiness degree is 40%.
2.5 around the wire cylinder between raw yarn sticky and if around the drum silk raw silk around, between the upper and lower stick and unwinding a yarn exit often cause another yarn damaged, as long as there is a root or a few a single wire fracture will result in large area net yarn, sticky and serious will result in degradation, off circle. One of the most important reasons for this is also the phenomenon of fuzz.
Solution measures:
(1) the appropriate reduction of the content of the original silk wetting agent. Wetting agent content and viscosity in the original wire, causing back fracture of single fiber solution caused by hairiness.
(2) a small amount of lubricant with isolation effect can be added in the wetting agent formula. Both play a good role in lubrication, and can also play the role of isolation and effect.
2.6 original silk smooth enough, and the yarn friction coefficient of friction material is caused by the direct cause of the broken filament.
The solution is as follows:
(1) improve the smoothness and wear resistance of the yarn guide material.
(2) when the winding sliding friction into rolling friction, reducing the contact point, the coefficient of friction.
(3) improve the smoothness of the original silk. The first is to check whether the amount of dry lubricant in the wetting agent is sufficient. Second is the wetting agent formula to add an efficient lubricant. Use process should pay attention to don't need a large amount of lubricant, otherwise easily lead wire, intensifies hairiness.
2.7 static too large
Electrostatic will cause adhesion of raw silk on the friction point, and make the yarn fluffy and filoselle, increase the fuzz. Therefore, adding antistatic agent in the wetting agent to eliminate the adverse effect of static electricity. Commonly used antistatic agents are: inorganic antistatic agents such as ammonium chloride, lithium chloride, lithium nitrate, etc.; organic antistatic agent such as SN, etc.. The dosage of antistatic agent is 0.3% ~ 0.05%. When preparing the wetting agent, the antistatic agent should be fully diluted and then added into the preparation tank to avoid the high concentration of the electrolyte. Textile yarn unwinding yarn twisting machine contact parts can be cast on a thin layer of organic antistatic agent. Practice has proved that it can effectively reduce the fuzz.
2.7 the original silk tube temperature and humidity control is not good.
Solution measures:
(1) according to the different film-forming agent system modulation technology suitable, especially in textile spinning. Appropriate conditioning process is beneficial to the infiltration agent better film forming and processing can provide good protection for raw silk, thereby reducing hairiness. We in the process of production of monofilament coated yarn contrast the same batch of raw silk in different conditioning process, the degree of hairiness up to 56%.
(2) control of unwinding (winding) workshop temperature and humidity. In the process of glass fiber processing, the influence of temperature and humidity is great, and the suitable temperature and humidity can reduce the production of Mao Yu in the process. Under normal circumstances, the control of textile yarn at a temperature of about 23 degrees, the relative humidity of about 60% is more appropriate.
2.8 drying processes resulting from the improper hairiness, raw silk not completely drying or drying excessive, yarn hair crisp will cause fiberglass filaments.
Solution measures:
(1) raw silk without drying or does not meet the sizing film required drying temperature and time, infiltration agent in each phase, not fully fused into a complete film, at this time of the original wire bundle cohesion is bad, filoselle and yarns are not smooth, friction coefficient, fuzz.
(2) raw silk tube has just entered the drying room, starting temperature is not too high, and to strengthen the platoon is wet, especially the tension is too large, winding tight raw silk tube, large filament tube, directly without roving group, but also to increase humidity and air circulation.
(3) by microwave drying or microwave assisted drying, can reduce the migration, to help reduce the fuzz.
2.9 detwisting (winding) process caused by improper Mao Yu. Untwisting (winding) due to the high speed movement of the yarn, single fiber bundle easily due to excessive tension and fracture and hairiness.
Solution measures:
(1) according to the different choice of yarn forming in different ways and speed. Because the yarn tension depends very much on the speed, so the speed must be strictly controlled in a proper range, especially textile yarn and hard yarn. Hard yarn winding process easily lead to improper sizing membrane rupture, reduce yarn stiffness, cluster of bad so as to affect the use effect.
(2) to select the appropriate spinning nylon with different varieties.
A.Effect of nylon hook shape on Hairiness
According to the production practice, the author draws, curvature radius of the nylon hook of the curved surface shape is round, contact with the yarn friction is relatively small, small amplitude of the yarn bending, breaking the glass fiber little makes less hairiness. Small yarn stiffness influence; and small radius of curvature by the nylon hook surface triangular, relatively large friction force between the contact with the yarn, yarn bending amplitude, the glass fiber yarn is easily broken and hairiness and bundling of influence on yarn, the yarn stiffness decrease. As shown in figure 1.
圆形曲线 三角形曲线
Fig. 1 contact of nylon hook and yarn
Figure 2 shows the mass of 200, Mg by the nylon hook and shape are triangle surface and a circular surface, after twisting detection of hairiness distribution diagram were used to detect the hairiness of yarn inner layer, a middle layer and an outer tube. From Figure 2 we can see that triangle curved face yarn hairiness of greater impact, is not conducive to the glass fiber yarn twisting; circular curve in the face of the yarn hairiness effect is relatively small. In addition, the nylon hook in and steel collar with, due to the different shape but also the formation of yarn path space of different sizes, resulting in the different influence on yarn hairiness. Thin triangular surface, thick line for circular surface.
Figure 2
B、Effect of nylon hook material on Hairiness
Glass fiber yarn twisting machine nylon hook is a good wear resistance, nylon hook long exposed to the outside, will absorb the moisture in the air, impact nylon hook weight, thus affecting the yarn tension and easy to produce the hairiness. Therefore, the nylon hook must be transported and stored under the conditions of sealing, the use of Kaifeng after the seal must be immediately sealed.
C、Effect of the weight of the hairiness of nylon hook
If the heavy weight of nylon hook can cause small gas ring, by the yarn tension is too large, will increase the nylon hook and yarn friction, caused yarn breakage, forming hairiness and increase the probability of the. At the same time, steel collar is easy to wear, twist of the tube winding high hardness, stiffness of yarn decreased to reduce the broken end of the yarn hairiness, the winding process will produce more hairiness. If the weight of the nylon hook is too light, spinning tension is too small, unstable operation, gas ring, twist a head light, yarn jitter, balloon expansion, the nylon hook and yarn friction is relatively small, but easy to bump separator hairiness, and yarn winding hardness is too small, easily deformed, is not conducive to the unwinding.
D、Nylon hook time effect of hairiness
Through the analysis of the test data, we believe that with the increase in the use of time, nylon hooks on the wear of the steel collar increased, will increase the proportion of the production of Mao Yu. In practice, we draw the line density of the glass fiber is different, the use time of nylon hook is also different.
4 conclusion
Preparation of glass infiltration formula design, process agent and glass fiber yarn filament is closely related to the problem. This paper introduces some effective use of lubricants available, and suggested that film-forming agent selection should also consider both film and lubricity. In addition to the infiltration agent should pay attention to solve the problem of fuzz and control of glass fiber drawing tension, reduce raw silk unwinding of friction, effective control of raw silk drying condition etc. the production process control is to solve the fuzz. In addition, to strengthen the operator's responsibility, improve the management level of the enterprise, is the key to solve the problem of fuzz. Glass fiber filament is varied, the key is to through image analysis the intrinsic reason, then according to the analysis of the implementation effectively solve measures.
