FIBRE CONSOLIDATION AND AGGLOMERATION IN V GROOVE ROLLER WRAP SPINNING

This theoretical study examines the fibre consolidation and agglomeration mechanisms in a novel wrap spinning system employing a V-grooved roller positioned directly after the front rollers. The spinning triangle—the critical region where individual fibres converge and receive twist—is fundamentally transformed by the V-groove geometry, which forces all fibres to converge at a single point, the groove apex. In contrast to conventional systems where edge fibres travel longer paths, creating uneven tension and poor fibre integration, the V-shaped channel induces lateral compression that reduces path-length differences and increases fibre-to-fibre friction. The narrowing groove walls promote enhanced agglomeration through geometrical confinement, compression forces, friction-based consolidation, and single-point twist insertion. Theoretical analysis indicates that yarn packing density can be increased from 70–75% in conventional wrap yarns to 80–85% with the V-groove system, yielding stronger, more uniform yarns with fewer voids. The groove apex angle, optimally maintained between 60 and 90 degrees, provides the best compromise between effective compression and fibre integrity. Expected improvements include more circular yarn cross-sections, lower hairiness, superior dye uptake, and enhanced abrasion resistance. The system demonstrates significant potential for industrial adoption with appropriate material selection (ceramic or hardened steel) and precise surface finishing to ensure consistent fibre convergence and product quality.