Optimisation of fibre denier specific carding parameters to modulate the structure of needle-punched nonwoven

Fibre denier specific carding parameters, such as feeder speed, cylinder speed and doffer speed, have been optimised to modulate the structure of needle-punched nonwoven. Polyester fibres of 3 denier, 4 denier and 6 denier are used to prepare nonwoven fabrics at different carding parameters. Box Behnken three factors three levels factorial design is used to prepare the nonwoven samples. Fibre orientation is measured with the help of Lindsley’s and image analysis techniques in terms of indices, like proportion of curved fibre ends, coefficient of relative fibre parallelisation and anisotropy of fibre inclination angle respectively. A non-linear regression technique has been developed to establish a relationship between tortuosity factor and measured values of fibre diameter, proportion of curved fibre ends, coefficient of relative fibre parallelisation, anisotropy of fibre inclination angle and mean flow pore size. The findings show the significance of carding parameters to modulate the orientation of fibres in carded web to enhance the functional properties of needle-punched nonwoven.