The three-dimensional model of staple yarn formation simulated from randomly assembled fibers

The modeling and simulation of the staple fiber spinning process is still a challenging concept in yarn technology due to the complexity of the process and uncontrollable parameters. This work presents a staple fiber yarn formation model based on the ideal assumptions about the configuration of the fibers and the cross-section of the sliver. The model presented utilizes a novel designed computer algorithm that randomly arranges staple fibers of defined length to simulate the typical arrangement of the fibers in a roving in the form of a fiber strand, which is then simulated in ABAQUS software to undergo the yarn formation stages, and the details are analyzed. The simulation results show the entire process of the twisting of the sliver and calculation of the configurational changes of each fiber in the strands is extracted. According to the model, the stages of the twisting of the sliver into the yarn are captured and presented, and the process of how the sliver converts to the yarn is analyzed in detail. In the real twisting experiment of the sliver, the propagation of the twist and the configurational changes of the fibers in the simulation experiment were verified. The experimental and numerical data are in good agreement and the model presents a precise mechanism for yarn formation. The work can be utilized to classify and understand fiber behavior during yarn processing, which can result in optimizing the staple fiber spinning technology.