THREE - DIMENSIONAL KNITTED FABRIC WITH … _4_Ionesi_.pdf · geometry using weft knitting...

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BULETINUL INSTITUTULUI POLITEHNIC DIN IAŞI Publicat de Universitatea Tehnică „Gheorghe Asachi” din Iaşi Tomul LVI (LX), Fasc. 3, 2010 SecŃia TEXTILE. PIELĂRIE THREE - DIMENSIONAL KNITTED FABRIC WITH TECHNICAL DESTINATION BY DORIN IONESI, RAMONA CIOBANU, ANA VIRCAN, MIRELA BLAGA and COSTEA BUDULAN Abstract. The three dimensional knitted fabrics, indifferently of the technology used, are characterised by a specific 3D geometry, with reinforcement yarns, characterized of a multiaxial directions. There are different knitting techniques to produce 3-D knitted fabric on an electronic flat-bed knitting machine: incomplete rows, the use of patterns with 3D effects, multilayer structure (sandwich), and fully- fashion. The object of this research is to obtain knitted fabrics with three-dimensional geometry using weft knitting technology on an electronic flat-bed knitting machine. This research also targets the optimization of the knitting process based on adjustments of technological parameters: stitch length, fabric take-down, carriage speed, to obtain a tight structure and a better dimensional stability of the knitted fabric. Key words: weft knits, 3D effects, technical application, electronic flat-bed knitting machine. 1. Introduction Development of three-dimensional knitted fabrics dates from the 19th- century, but their engineering applications began in the late 1960s. The three- dimensional technical textile products have been used in various fields, such as protective clothing, transportation, geo-textiles, buildings, packing materials, military equipment, medicine and sports, etc. Preforms made of knitted fabrics with complex shapes represent a group of three-dimensional materials with great applicability, mainly due to the advantage of eliminating the process of assembling before composite processing. The elimination of this operation significantly reduces the production time and allows for automation, improving whole process. Also it ensures and improves the overall quality of the finished product, by being able to control the characteristics and properties of textile performs from its design phase.

Transcript of THREE - DIMENSIONAL KNITTED FABRIC WITH … _4_Ionesi_.pdf · geometry using weft knitting...

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BULETINUL INSTITUTULUI POLITEHNIC DIN IAŞI Publicat de

Universitatea Tehnică „Gheorghe Asachi” din Iaşi Tomul LVI (LX), Fasc. 3, 2010

SecŃia TEXTILE. PIELĂRIE

THREE - DIMENSIONAL KNITTED FABRIC WITH TECHNICAL DESTINATION

BY

DORIN IONESI, RAMONA CIOBANU, ANA VIRCAN,

MIRELA BLAGA and COSTEA BUDULAN

Abstract. The three dimensional knitted fabrics, indifferently of the technology

used, are characterised by a specific 3D geometry, with reinforcement yarns, characterized of a multiaxial directions. There are different knitting techniques to produce 3-D knitted fabric on an electronic flat-bed knitting machine: incomplete rows, the use of patterns with 3D effects, multilayer structure (sandwich), and fully-fashion.

The object of this research is to obtain knitted fabrics with three-dimensional geometry using weft knitting technology on an electronic flat-bed knitting machine.

This research also targets the optimization of the knitting process based on adjustments of technological parameters: stitch length, fabric take-down, carriage speed, to obtain a tight structure and a better dimensional stability of the knitted fabric.

Key words: weft knits, 3D effects, technical application, electronic flat-bed knitting machine.

1. Introduction Development of three-dimensional knitted fabrics dates from the 19th-

century, but their engineering applications began in the late 1960s. The three-dimensional technical textile products have been used in various fields, such as protective clothing, transportation, geo-textiles, buildings, packing materials, military equipment, medicine and sports, etc.

Preforms made of knitted fabrics with complex shapes represent a group of three-dimensional materials with great applicability, mainly due to the advantage of eliminating the process of assembling before composite processing. The elimination of this operation significantly reduces the production time and allows for automation, improving whole process. Also it ensures and improves the overall quality of the finished product, by being able to control the characteristics and properties of textile performs from its design phase.

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Development of three-dimensional fabrics was stimulated by the new software design and performance modelling, and new generations of textile machines, capable of producing complex structures [2], [3].

2. Characterisation of 3D Knitted Fabrics

The concept of three-dimensional of the textile materials is not related to the

intrinsic value of dimensions found on the three axes (x, y, z), but to the relationship between them. This relation characterises the importance of the dimensions in the geometry of the material. The concepts of one, bi and three-dimensional materials are directly related to the construction of a particular fabric [5].

Thus, a one-dimensional material shows negligible dimensions compared to its length, while for a two-dimensional material thickness is considered negligible. The textiles included in one-dimensional materials are fibres and filaments. Textile materials produced by different technologies are considered to be two or three dimensions [5].

A three-dimensional fabric, regardless of the process used, is “a continuous ensemble, with fully integrated fibre, characterised by multiaxial spatial orientation” [5].

Three-dimensional knitted fabrics can be obtained with different technologies and their specific techniques. Thus, as shown in Fig. 1, creating a three-dimensional effect on knits is based on the following techniques:

I. Insertion of additional yarns along multiple directions; II. Knitting and linking independent layers in different ways; III. Spatial shaping.

Spatial shaping technique is based on three methods. First method

involves using a combination of different structures or different evolution, which presents a different arrangement. Limitations of these fabrics refer

Fig. 1 − Classification of three-dimensional knitted fabrics.

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Bul. Inst. Polit. Iaşi, t. LVI (LX), f. 3, 2010 31

to the lack of homogeneity of all the material properties and reduced diversity of forms.

A second method involves the use of dynamic density, the areas with different stitch lengths presenting different geometry. Both methods are restrictive and limiting.

For this reason, spatially shaped preforms are produced with the third method. This method is known as incomplete rows knitting technique; this technique implies a process of knitting by holding temporary the stitches on the selected needles which don’t participate to the knitting, until those are reintroduced in work- consecutive or simultaneous. The basic structures used are: single jersey structure and rib structure, the most used is single jersey structure.

3. Principles for Obtaining Three-Dimensional Knitted Fabrics

To produce three-dimensional fabrics, the knitted material can be

formed by the technique called spatial fashioning technique (also known as flechage). Three-dimensional structures can be created also by knitting stitches and loops combined with the lateral movement of the needle bed. By increasing or decreasing the number of working needles it is possible to create three-dimensional knitted items on intarsia knits. The paper approaches four different methods of producing three-dimensional articles on flat needle knitting machines. The methods of making three-dimensional items on flat knitting machines are:

1. Incomplete knitted rows technique (spatial fashioning); 2. The use of patterns with 3D effects – egg. Knitting tuck stitches

patterns combined with racking; 3. Knitting separate fabrics connected in between – sandwich/spacer fabrics; 4. Integral knitting /wholegarment.

3.1. Incomplete Rows Knitting Technique Incomplete rows knitting technique is a technique used by designers of

knits to create three-dimensional knitted items or tubular knits (Fig. 2).

Fig. 2 − Knitted fabrics with spatial geometry.

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3.2. Use of Patterned Structures with 3D Effects Three-dimensional knitted fabrics can also be created using structure patterns

with 3D effects. The most known example is the so called egg nest fabric, created by Shima Seiki [1]. The pattern is based on cardigan evolutions combined with successive racking in opposite directions. Fig. 3 exemplifies the aspect of such a fabric.

Another example is a jersey fabric with a zone with miss stitches while the carriers produce stitches on the opposite bed. When the missing stitches are discharges, the stitches produced on the opposite bed are transferred to the working bed. The effect in the fabric is illustrated in Fig. 4.

3.3. Sandwich Fabrics

A knitted layered item (sandwich) is a three-dimensional structure,

composed from two outer layers knitted together independent, connected by yarns or other knitted layers, definition illustrated in Fig. 5.

Sandwich fabrics with connection through knitted layers present a large

range of development possibilities [5]: − increase in the fabric thickness based on the length of the

connection layers; − modification of the geometry of external fabrics due to the use of

connecting layers with different length;

Fig. 3 − Knitted fabric with 3D effects. Fig. 4 – Knitted fabric with wave effect.

Fig. 5 − Principle of sandwich fabrics.

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− modification of the cross section geometry due to connecting layers with modified geometry.

3.4. Integral Knitting Technique

Integral knitting technique is an improved stage in the development of

technologies for machine flat knitting machines [1]. So far it is the most advanced knitting technology through which a garment is completely assembled on a knitting machine without the need of sewing. Seamless knitting technology is a method that cuts off waste and reduces costs. The seamless garment (Fig. 6) is very comfortable and resistant to wear.

4. Experimental Part When producing the sandwich fabrics on flat knitting machines, by

connecting the outer layers with knitted layers, the degree of fabric compactness is low, due to working on selected needles – increasing the distance between wales. The present work establishes the optimum technological parameters in order to get the best fabric compactness. The fabrics were designed on M1 pattern station and they were produced on a Stoll CMS 530, E 6.2 electronic knitting machine [4]. The fabrics are presented in Fig. 7, as principle.

Fig. 7 − Principle of sandwich structure with two connecting layers.

Fig. 6 − Seamless product – integral knitting.

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To achieve this objective a sandwich structure with two connecting layers using a 50/50% PAN/Cotton yarn, Nm 30/2 was chosen. The fabric was knitted with a 1:3 needles arrangement and is illustrated in Fig. 8.

Fig. 8 − Sandwich structure with two connecting layers. Four values were chosen for stitch density: NP=12, NP=11, NP=10

and NP=9. These structures are based on a high number of transfer stages, and in order to avoid the cast off, a low value of carriage speed was employed (0.5÷0.7 m/s), while the take-down force was selected in the interval WM=3÷3.5.

The knitted fabric with NP=12 proves a low degree of tightness, which is increasing along with the decrease of the stitch quality cam position. The minimum value for the stitch quality cam position is NP=9. Lower values cause yarns breaking. Between NP 12.0 and NP 10.0 the aspect of fabric doesn’t show significant changes, but comparison between fabrics made with NP 10.0 and NP 9.0 show significant modifications in fabric compactness (Fig. 9). The tightness is increased but fabric has poor aspect, because of the extended sinker loops. A finishing process could improve the appearance or another option concerning the structure, so further trials should further done.

The knitting scheme used for the production of the sandwich fabric with

two connecting layers is shown in Fig. 10.

Fig. 9 − Sandwich structure with two binding layers made with NP 9.0.

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Bul. Inst. Polit. Iaşi, t. LVI (LX), f. 3, 2010 35

The connection between the inside layers is made by tuck loops on the opposite layer.

The knitting of the two layers, with needle ratio 1:3.

The connection of the inside layers to the outside ones are

made by tucking.

To obtain a sandwich fabric the work should be done

with 1:3 needle selections, using two yarn carriers, one carrier for each thread. Two

layers are knitted on the front bed and two on the

rear bed. To individualize the layers it is made the

successive transfer of the stitches.

Fig. 10 − Knitting scheme and the description of knitting process.

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5. Conclusions Sandwich fabrics are three dimensional structures suitable for the

production of 3D knitted preforms used for technical purposes. If high performance yarns are used, these composites provide improved mechanical properties compared to traditional materials. The use of flat knitting machines offers great possibilities of shaping for knitted preforms.

The dimensional sandwich fabrics provide for air, heat and moisture transfer. These characteristics make them recommendable to use for medical purposes, pillows, matrices, shoes, tables for operations.

Technical solutions for fabric diversification are summarised below: − Variations of the number of layers; − Combinations between the outer fabrics, connecting layers on vertical

and horizontal position; − Engineering the thickness by modifying the length of connection layers; − Developing different structure and opacity independently on each side; − Using different materials for the two fabric sides and spacer threads; To obtain a high degree of fabric compactness for this group of fabrics,

on a machine with 6.2E, one can use Nm=30/2 yarns, knitted with a stitch depth of NP=9 and take-down force WM=3.5 or changing the thread with Nm=24/1, in combination with a stitch depth of NP=12.

The structural design of the sandwich structures is essential for the engineering of fabric properties. Especially the cross section of the fabric is responsible for the channel shape and orientation, thus for the type of resulted cells. The properties of the fabric depend on the cross-section geometry, which is determined by joint point position between layers.

A c k n o w l e d g e m e n t s. This paper is financially supported by EURODOC “Doctoral Scholarships for research performance at European level” project, financed by the European Social Found and Romanian Government. Received: August 30, 2010 “Gheorghe Asachi” Technical University of Iaşi, Department of Knitting and Ready-Made Clothing e-mail: [email protected]

R E F E R E N C E S 1. Lam J., Zhou J.Y., Principle and Development on 3D Knitted Fabrics – A Knitter`s

Perspective. the First Word Conference on 3D Fabrics and Their Aplications, Manchester (2008).

2. Blaga M., Tehnologii de tricotare pe maşini rectilinii. Edit. “Gheorghe Asachi”, Iaşi (2002).

3. Blaga M., Tehnologii neconvenŃionale de tricotare. Note de Curs, “Gheorghe Asachi” Technical University of Iaşi (2009).

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Bul. Inst. Polit. Iaşi, t. LVI (LX), f. 3, 2010 37

4. Blaga M., Proiectare asistată de calculator în tricotaje. lecture notes, “Gheorghe Asachi” Technical University of Iaşi (2008).

5. Ciobanu L., ContribuŃii la dezvoltarea şi realizarea tricoturilor cu destinaŃie tehnică. Ph. D. Diss., “Gheorghe Asachi” Technical University of Iaşi (2003).

TRICOTURI TRIDIMENSIONALE CU DESTINAłII TEHNICE

(Rezumat)

Materialele textile tridimensionale, indiferent de procesul tehnologic utilizat, reprezintă ansambluri continue, complet integrate de fibre, caracterizate prin orientarea spaŃială multiaxială. Pentru producerea tricoturilor din bătătură tridimensionale pe maşini rectilinii controlate prin microprocesor, se pot aplica diferite tehnici de tricotare, cum sunt: rândurile incomplete, ochiurile duble combinate cu deplasarea laterală a fonturii, intarsia, stratificarea, tricotarea integrală.

Scopul acestei cercetări este studiul producerii tricoturilor din bătătură cu efecte tridimensionale obŃinute prin tehnicile prezentate anterior, pe maşini rectilinii de tricotat cu selectare electronică şi comandă program.

Principalul obiectiv al acestei cercetări constă în optimizarea parametrilor tehnologici (forŃa de tragere, adâncime de buclare, viteza saniei) în vederea obŃinerii unui grad de compactitate mai mare a tricotului şi o stabilitate dimensională mai bună a asamblului tricotat.