Multiple response optimization of sizing machine settings and sized yarn tensile properties using advanced method of experimental design

On a loom, the warp yarns experience exceptionally high mechanical stresses and strains, as well as significant abrasion from friction. As a result, significant yarn breakages cause loom stoppages and, hence, production and quality interruptions. To mitigate this problem, the warp yarns should be treated with a thin, strong film of an appropriate adhesive. The aim of this study is therefore, to investigate the effect of sizing machine parameters on tensile properties of the yarn and to optimize the sized yarn tensile properties. Design expert 11 software with Box-Behnken design has been employed to design the research, analyze the results of experiments, and optimize the responses. In this research, three factors, each at three levels (wet zone yarn tension (A) (340, 380, and 420 N), squeezing roller pressure (B) (13, 15, and 17 N), and sizing machine speed (C) (30, 49, and 68 m/min), as well as three response variables (gain strength, loss elongation, and stretch), are considered. 15 samples of sized yarn have been produced with various combinations of the given factors, and the values of the response variables are measured for each sample. It has been observed that wet zone yarn tension and squeezing roller pressure have a significant effect on gain strength, stretch, and loss elongation. According to the regression analysis, gain strength has a negative relationship with wet zone yarn tension and a positive relationship with squeezing roller pressure. In the other case, both wet-zone yarn tension and squeezing roller pressure have a positive and significant effect on loss elongation and yarn stretch. At 340 N wet zone yarn tension, 13 N squeezing roller pressure, and 51 m/min sizing machine speed, the optimum values of gain strength (32.7 cN/tex), loss elongation (18.5%), and stretch (1.4%) were obtained. The methodologies employed in this study revealed the empirical relationship between the factors and the responses, the interaction effects of the factors on the responses, and multiple response optimizations. The optimized result of this study can be applied to the warp yarn sizing and can improve the tensile properties of the yarn and the loom’s efficiency significantly.