Numerical simulation and experimental investigation of fiber tension in staple yarn

Staple yarn is the basic element of most textiles, and the breakage mechanism of staple yarn has always been a topic of focus in the textiles field. Fiber tension in staple yarn, caused by twisting, forms the basis for exploring its breakage mechanism. In this paper, a numerical model is proposed to simulate the fiber tension in staple yarn, considering fiber properties, staple yarn parameters, and the shrinkage of fibers during twisting. To ensure the reliability of the model, several typical and commonly used staple yarns were analyzed to validate the simulated results. The results show that the fiber tension in staple yarn is related to its fiber properties and linear density. Meanwhile, the mean absolute percentage error of the numerical model is only around 5%–8%. The correlation coefficient R between the simulated results and the tested results is 0.99, proving that the model has very good accuracy and applicability. This model would provide a basis for further research on the breakage mechanism of staple yarn.