Numerical Simulation of The Internal Flow Field of A New Main Nozzle in An Air-Jet Loom Based On Fluent

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Original article

Textile Research Journal


2015, Vol. 85(15) 1590–1601

Numerical simulation of the internal flow ! The Author(s) 2015


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field of a new main nozzle in an air-jet DOI: 10.1177/0040517515569522
trj.sagepub.com
loom based on Fluent

Liang Chen, Zhi-hua Feng, Teng-zhong Dong, Wei-hua Wang


and Shuai Liu

Abstract
In order to decrease the turbulence influence and the backflow during weft insertion in an air-jet loom, a new main
nozzle composed of two nozzle needles connected in series is designed. The internal flow fields of the commonly used
nozzle and the new nozzle are numerically studied by means of a three-dimensional model implemented by the com-
putational fluid dynamics technique. It is observed that the turbulence strength is effectively controlled with different air
supply pressures and the backflow phenomenon at the upstream passage generated by high supply pressures can be
eliminated when the supply pressure is reasonably distributed into two inlets of the new nozzle. The drag force exerted
on the weft yarn is calculated when the velocity distribution of the internal airflow is obtained, and results show that the
drag force can be improved. Also, the numerical simulation can give some guidelines for future prototyping and
experiments.

Keywords
air-jet loom, main nozzle, flow field, Fluent

The main nozzle is a key component in the weft inser- the shape, and the size. Zhu and Zhou4 analyzed the
tion system of an air-jet loom; it works as an ejector, structure, the velocity, and the static pressure charac-
sucking the weft yarn and driving it through the warp teristics of the airflow inside the main nozzle. Mohamed
shed. It is the first step for the weft yarn to be sucked and Salam5 and Salama et al.6 researched nozzles with
into the main nozzle. Therefore, the performance of the various geometries and the corresponding weft inser-
internal airflow, especially the centerline airflow, will tion behaviors through the tubes both in experiment
directly influence the efficiency of an air-jet loom and and theory. They also dispose the influence of air
the quality of the fabric. The airflow varies under dif- supply pressure and the presence of a yarn tube on
ferent air supply pressures, which may cause a stronger the performance of the main nozzle. Recently, more
turbulence area and generate backflow phenomenon. attention has been paid to the flow field analysis and
Studies on the research and optimization of the main structural optimization of the weft insertion system by
nozzle have been intermittently dealt with over the past our research group at Soochow University. Concretely,
few decades. Xue et al.1 and Liang et al.2 studied the Yuan7 built up a two-dimensional flow field model, and
internal flow field of the main nozzle by use of compu- simulated the flow field of weft insertion by the change
tational fluid dynamics (CFD) softwares; they obtained
the velocity distribution of the airflow along the axial
and radial direction, and observed the turbulence and
backflow phenomena. Belforte et al.3 also carried out a School of Mechanical and Electric Engineering, Soochow University, China
numerical simulation to determine which physical
Corresponding author:
model could predict a better behavior of the main Zhi-hua Feng, School of Mechanical and Electric Engineering, Soochow
nozzle, and they also discussed the influence on the University, 178 East Ganjiang Road, Suzhou, 215021, China.
drag force arising from the acceleration tube length, Email: zhfeng@suda.edu.cn

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Chen et al. 1591

of parameters, such as the diameters, throat sectional models of the internal flow fields of the commonly used
areas, acceleration tube lengths of the main nozzle, and nozzle and the new nozzle are built up by use of the
air supply pressures. Guo8 modeled a three-dimen- three-dimensional software named Unigraphics NX
sional flow field, and investigated the main nozzles 8.5. Then the models are meshed by the professional
with different numbers of slots, diameters of the holes meshing software named ICEM CFD. Finally, the
for weft insertion, distances between the outlet of the numerical simulation is carried out using Fluent. In
needle and the slots and the air supply pressures. The order to evaluate the internal airflow performance,
advantage of different parameter combinations for the the drag force exerted on the weft is calculated. It is
structure of the main nozzle and the air supply pres- observed that the performance of the internal airflow of
sures was also analyzed. Lu9 provided a method to the new nozzle is optimized compared with that of the
control the velocity and pressure of the outlet of the commonly used nozzle. Naturally, these numerical
main nozzle by changing the throat area of the main simulation results can give some guidelines for future
nozzle. Xu et al.10 combined the numerical simulation prototyping and experiments.
of the airflow velocity and the density with the experi-
mental test of the drag force to obtain the friction coef-
ficients of different weft yarns. Dong et al.11 arrived at Structures and flow field models
the conclusion that the numerical simulation results for of the main nozzles
the flow field obtained by Fluent software are in good
agreement with those obtained experimentally.
The commonly used main nozzle
In this paper, a new main nozzle composed of two Structure of the commonly used main nozzle. Figure 1
nozzle needles connected in series is designed to address shows the structure of a commonly used nozzle. The
the need to control the turbulence strength and to elim- nozzle is composed of a body (1), a needle (2), a cylin-
inate the backflow phenomenon. The three-dimensional der (3) and an acceleration tube (4). Figure 2 shows the

Figure 1. Configuration of the structure of the commonly used main nozzle.

Figure 2. Internal flow passage of the commonly used main nozzle.

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1592 Textile Research Journal 85(15)

Figure 3. Three-dimensional model and boundary condition of the flow field of the commonly used main nozzle.

Figure 5, obtained by the use of Fluent, shows the


velocity distribution of the centerline of internal airflow
under different air supply pressures of the commonly
used main nozzle. Figure 6, obtained by the use of
Fluent, shows the velocity contour under 0.2 MPa air
supply pressure of the symmetric surface of the internal
flow field of the commonly used nozzle.

Figure 4. Finite element model of the flow field of the


commonly used main nozzle. A new main nozzle
Structure of the new main nozzle. In Figure 5, one can find
that there is a strong turbulence area at point ‘‘S2’’, and
internal flow passage of the commonly used nozzle. The when the air supply pressure is 0.3 MPa or more, back-
compressed air flows from air supply inlet (A) into the flow exists in the internal upstream passage of the
chamber (B) of the body. The air is rectified and accel- commonly used nozzle. Obviously, such phenomena
erated when it flows through the polar array of slots (C) are harmful for the weft yarn insertion. In order to
on the nozzle needle and the cone-shaped interior pas- overcome such shortcomings, a new main nozzle is
sage (D) of the cylinder; the velocity reaches its max- designed and is shown in Figure 7. This nozzle consists
imum at the needle tip (E), which generates a negative of a body1 (1), a needle1 (2), two cylinders (3), a body2
pressure area to cause the yarn to be sucked into the (4), a needle2 (5) and an acceleration tube (6). The
interior flow passage (F) of the needle. When the air length of the two needles and the acceleration tube is
passes away from the needle tip, a strong flow expan- the same as that of the commonly used nozzle. Figure 8
sion occurs, and the air flow is accelerated in the inter- shows the internal flow passage of the new nozzle. The
ior passage (G) of the acceleration tube. compressed air flows from inlet2 (G) into the chamber2
(H). The air gets rectified and accelerated, and then
Flow field model of the commonly used main nozzle. Figure 3 rises to the maximum velocity when the air flows
shows the three-dimensional model and the boundary through slots (I), the cone-shaped interior passage (J)
condition of the flow field of the nozzle. The external and gets to the needle tip2 (K) in the new nozzle. When
flow fields were added to the inlet and outlet of the the air passes away from the needle tip2, there is a
nozzle. The ejection flow of the outlet is cone-shaped, negative pressure area and a strong turbulence area;
in order to mesh the model more easily and decrease the thus, a strong flow expansion occurs. The compressed
number of the elements; the model of the ejection flow air flows from inlet1 (B) into the chamber1 (C). Just like
field of the outlet is cylinder-shaped in steps, including the airflow described above, the air gets rectified and
the actual ejection flow. Figure 4 shows the finite elem- accelerated, and then arrives at the maximum velocity
ent model of the flow field of the nozzle. There when the air flows through slots (D), the cone-shaped
are about 1,134,149 elements and 972,828 nodes. interior passage (E) and gets to the needle tip1 (F) in

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Chen et al. 1593

Figure 5. Velocity distribution of the centerline of internal airflow under different air supply pressures of the commonly used main
nozzle.

Figure 6. Velocity contour under 0.2 MPa air supply pressure of the symmetric surface of the internal flow field of the commonly
used nozzle.

the new nozzle; when the air passes away from the needle passage (A) of the needle1. Since the air supply pressures
tip1, there is also a negative pressure area and a strong in inlet1 and inlet2 are adjustable, different airflow can
turbulence area, and a flow expansion also occurs. After be obtained. Thus, different pressure distribution can be
the air flows into the nozzle needle2, the interior flow chosen to obtain a suitable airflow to meet the different
passage (L) works as an acceleration area. After the air needs of the manufacturing process.
from inlet1 and inlet2 meets, the mixed air will be accel-
erated in the interior passage (M) of the acceleration Flow field model of the new main nozzle. Figure 9 shows the
tube, and the weft yarn is sucked into interior flow three-dimensional model and the boundary condition

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1594 Textile Research Journal 85(15)

Figure 7. Configuration of the structure of the new main nozzle.

Figure 8. Internal flow passage of the new main nozzle.

Figure 9. Three-dimensional model and boundary condition of the flow field of the new main nozzle.

of the flow field of the new nozzle. The flow field of the Numerical simulation of two main nozzles
new nozzle is disposed like that of the commonly used
Simulation setting
nozzle. Figure 10 shows the finite element model of the
flow field of the new nozzle. There are about 754,895 To implement the simulation, some assumptions are
elements and 546,606 nodes. made as given below:

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Chen et al. 1595

Table 2. Air supply pressures for the commonly used main


nozzle

Simulation type Air supply pressure (MPa)

A-1 0.1
A-2 0.2
A-3 0.3
A-4 0.4
A-5 0.5
Figure 10. Finite element model of the flow field of the new
main nozzle.
Tables 2 and 3 for the commonly used main nozzle
and the new main nozzle, respectively.

Table 1. Air velocity at the inlet under different air supply


pressures
Simulation results
The numerical simulation is classified according to the
Air supply pressure (MPa) 0.1 0.2 0.3 0.4 0.5
total supply pressure into groups, as shown in Table 4.
Air velocity (m/s) 47.52 71.20 97.37 124.10 150.80
Figure 11 shows the comparison among different
conditions under 0.1 MPa total supply pressure.
From the figure, one can find that type ‘‘I-1’’ possesses
1. the air is assumed to comply with ideal gas law; a better performance, the turbulence strength in the
2. the air viscosity is calculated as a function of abso- downstream area at point ‘‘S2’’ in all types of the new
lute temperature T, that is,  ¼ 0  ðT=T0 Þ2=3 , where main nozzle is controlled better than that of the com-
l0 and T0 are air viscosity and temperature under monly used main nozzle, and the maximum backflow
standard conditions respectively; velocity caused by the strong turbulence area in the
3. the outlet static pressure is specified as atmosphere downstream area at point ‘‘S2’’ of the commonly used
pressure. main nozzle and the new main nozzle is about 108 and
46 m/s, respectively, which implies that the new nozzle
The k-e model is a semi-empirical model developed is suitable for the weft insertion. The velocity increases
for high-Reynolds-number flow; there are three vari- at the internal flow passage before point ‘‘S1’’ because
ants (standard, RNG and Realizable). The RNG k-e of the cone-shaped internal passage. There is not a
model can deal with the flow with high strain rate stronger turbulence area in the types ‘‘B-1’’ and
and higher curvature degree. ‘‘C-1’’, in which the fact of velocity drop is due to the
Due to the variation of the airflow at the wall, turbu- increase of the cross-section area of the airflow passage.
lent stress almost has no effect on the airflow, especially However, there is also a velocity drop area in the down-
at the viscous sublayer. Fluent provides three different stream area at point ‘‘S3’’ in the new main nozzle; for
wall treatments: standard wall function; non-equili- types ‘‘B-1’’ and ‘‘C-1’’, it is due to the strong turbu-
brium wall function; and enhanced wall treatment. lence area, whereas for other types it is due to the
Standard wall function is employed to deal with the increase of the cross-section area of the airflow passage.
airflow at the wall. In addition, the fact that inlet2 is free to the atmosphere
The airflow flux under different air supply pressures in type ‘‘H-1’’ also contributes to the velocity drop in
can be obtained by use of the flow sensor. Therefore, such a degree. Generally speaking, the airflow in the
the air velocity at the inlet under different air supply types where an inlet is closed plays better than that of
pressures can be calculated as shown in Table 1. Thus, the types where an inlet is free, because when an inlet is
some parameters, such as static pressure Ps, turbulence free, the internal airflow is obviously influenced by the
kinetic energy k, and turbulent dissipation rate e, can atmosphere through the inlet.
also be obtained. Air supply pressures in the table are Figure 12 shows the comparison among different
relative pressures. types under 0.2 MPa total supply pressure. As with
the types under 0.1 MPa total supply pressure, the vel-
ocity increases in the upstream area at point ‘‘S1’’, and
Simulation profile
also drops down in the downstream areas at points
The airflow is different due to the air supply pressure ‘‘S2’’ and ‘‘S3’’. The airflow in types ‘‘C-2’’ and ‘‘I-2’’
distributions of inlet1 and inlet2 in the new main plays better than that of other types. The maximum
nozzle. Air supply pressures are summarized in backflow velocity caused by the strong turbulence

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1596 Textile Research Journal 85(15)

Table 3. Air supply pressures for the new main nozzle Table 4. Simulation classification

Air supply pressure (MPa) Total supply pressure (MPa) Simulation type

Simulation type Inlet 1 Inlet 2 0.1 A-1


0.1 B-1
B-1 Free 0.1
0.1 C-1
B-2 Free 0.2
0.1 H-1
B-3 Free 0.3
0.1 I-1
B-4 Free 0.4
0.2 A-2
B-5 Free 0.5
0.2 B-2
C-1 Closed 0.1
0.2 C-2
C-2 Closed 0.2
0.2 D-1
C-3 Closed 0.3
0.2 H-2
C-4 Closed 0.4
0.2 I-2
C-5 Closed 0.5
0.3 A-3
D-1 0.1 0.1
0.3 B-3
D-2 0.1 0.2
0.3 C-3
D-3 0.1 0.3
0.3 D-2
D-4 0.1 0.4
0.3 E-1
E-1 0.2 0.1
0.3 H-3
E-2 0.2 0.2
0.3 I-3
E-3 0.2 0.3
0.4 A-4
F-1 0.3 0.1
0.4 B-4
F-2 0.3 0.2
0.4 C-4
G-1 0.4 0.1
0.4 D-3
H-1 0.1 Free
0.4 E-2
H-2 0.2 Free
0.4 F-1
H-3 0.3 Free
0.4 H-4
H-4 0.4 Free
0.4 I-4
H-5 0.5 Free
0.5 A-5
I-1 0.1 Closed
0.5 B-5
I-2 0.2 Closed
0.5 C-5
I-3 0.3 Closed
0.5 D-4
I-4 0.4 Closed
0.5 E-3
I-5 0.5 Closed
0.5 F-2
Note: Free indicates that the inlet is exposed to the atmosphere, and 0.5 G-1
Closed indicates that the inlet is treated as wall.
0.5 H-5
area in the downstream area at point ‘‘S2’’ of the com- 0.5 I-5
monly used main nozzle and the new main nozzle is
about 173 and 97 m/s, respectively. However, because
the air is distributed into two inlets in type ‘‘D-1’’, the
influence of the strong turbulence area is lower than as the types with 0.1 and 0.2 MPa total supply pres-
other ones; the backflow velocity in the downstream sures, the air velocity increases in the upstream area at
area at point ‘‘S2’’ is only about 52 m/s, and drops in point ‘‘S1’’. However, there still exists a backflow phe-
the downstream areas at points ‘‘S2’’ and ‘‘S3’’ due to nomenon in the whole upstream area at point ‘‘S2’’ in
the combination result of the increase of cross-section the commonly used main nozzle. However, there is not
area and strong turbulence area. The difference between a similar phenomenon in types ‘‘E-1’’, ‘‘H-3’’, and
type ‘‘D-1’’ and other types in the new main nozzle ‘‘I-3’’. The maximum backflow velocity caused by the
shows that the air distribution may improve the inter- strong turbulence area in the downstream area at point
nal air performance at the strong turbulence area. ‘‘S2’’ of the commonly used main nozzle and the new
Figure 13 shows the comparison among different main nozzle is about 282 and 133 m/s, respectively.
conditions under 0.3 MPa total supply pressure. Just There are two air distribution methods (Types ‘‘E-1’’

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Chen et al. 1597

Figure 11. Comparison among different conditions under 0.1 MPa total supply pressure.

Figure 12. Comparison among different conditions under 0.2 MPa total supply pressure.

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1598 Textile Research Journal 85(15)

Figure 13. Comparison among different conditions under 0.3 MPa total supply pressure.

and ‘‘D-2’’), and the airflow in type ‘‘E-1’’ plays better Figure 15 shows the comparison among different con-
than that in type ‘‘D-2’’ because the internal flow pas- ditions under 0.5 MPa total supply pressure. The max-
sage in needle2 works as an acceleration area, and the imum backflow velocity caused by the strong turbulence
accelerated airflow can decrease the turbulence strength area in the downstream area at point ‘‘S2’’ of the com-
in the downstream area at point ‘‘S3’’. Thus, this shows monly used nozzle and the new nozzle are about 400
that the preferred airflow may be obtained only in a and 370 m/s, respectively, whereas the maximum back-
proper air distribution method. flow velocity in some types of the new nozzle is about
Figure 14 shows the comparison among different 185 m/s, except types ‘‘B-5’’, ‘‘D-4’’, and ‘‘E-3’’.
conditions under 0.4 MPa total supply pressure. As Furthermore, there is no backflow phenomenon in the
the air supply pressure increases, the backflow phenom- upstream area at point ‘‘S1’’ in types ‘‘H-5’’ and ‘‘I-5’’.
enon is more serious, which does not happen in types The airflow in type ‘‘F-2’’ plays better than that in type
‘‘C-4’’, ‘‘H-4’’, and ‘‘I-4’’. There are three air distribu- ‘‘E-3’’, and the airflow in type ‘‘E-3’’ plays better than
tion methods (Types ‘‘D-3’’, ‘‘E-2’’, and ‘‘F-1’’): the that in type ‘‘D-4’’, which is similar to that in the types
airflow in type ‘‘F-1’’ plays better than that in type with 0.4 MPa air supply pressure. However, the airflow in
‘‘E-2’’ and the airflow in type ‘‘E-2’’ plays better than type ‘‘G-1’’ is not better than that in type ‘‘F-2’’, because
that in type ‘‘D-3’’. This is similar to the types under 0.3 the air supply pressure distributed to inlet1 has already
MPa total supply pressure. As the air supply pressure generated a stronger turbulence area, which influences the
of inlet1 is much higher than that of inlet2, the airflow airflow in the downstream area at point ‘‘S2’’.
may play much better, because the compressed air with
0.4 MPa supply pressure distributed to inlet1 does not
generate a stronger turbulence area to obviously influ- Drag force evaluation
ence the airflow in the whole upstream area at point
‘‘S2’’, and to seriously influence the airflow in the down- In order to evaluate the internal airflow performance,
stream area at point ‘‘S2’’. The maximum backflow vel- the drag force exerted on the weft is calculated. The
ocity caused by the strong turbulence area in the drag force Fdl exerted on one element of the weft
downstream area at point ‘‘S2’’ of the commonly used yarn is defined as
nozzle and the new nozzle are about 409 and 245 m/s,
respectively. However, the maximum backflow velocity
in some types of the new nozzle is about 151 m/s, except 1
Fdl ¼ Cf  dðv  uÞ2 dl ð1Þ
type ‘‘D-3’’. 2

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Chen et al. 1599

Figure 14. Comparison among different conditions under 0.4 MPa total supply pressure.

Figure 15. Comparison among different conditions under 0.5 MPa total supply pressure.

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1600 Textile Research Journal 85(15)

Table 5. Drag force of the new nozzle and commonly used


nozzle under different total air supply pressures

Drag force
per meter
Figure 16. A model of an element connected by two points. (N/m)
Simulation Air supply
type pressure (Mpa) U¼0 U ¼ 80
where Cf is the friction coefficient between air and the A-1 0.1 14,010 3261
weft yarn element, d is the diameter of the weft yarn, 
H-1 0.1 17,183 4840
is air density, v is air velocity, u is weft yarn velocity,
I-1 0.1 21,989 7189
and dl is the length of the element.
Physical parameters on a series of points, such as  A-2 0.2 25,481 8768
and v, can be obtained from numerical simulation. C-2 0.2 33,440 13,077
Figure 16 shows a model of an element connected by H-2 0.2 32,334 13,177
two points. I-2 0.2 42,160 18,495
p is a constant, and d is a constant for a kind of weft A-3 0.3 32,923 10,085
in theory. Although Cf varies with the relative velocity C-3 0.3 40,483 15,611
between the air velocity and the weft yarn velocity, it E-1 0.3 38,178 16,017
only has a small influence on the final drag force H-3 0.3 43,408 19,021
according to Guo and Chen.12 Therefore, Cf is treated I-3 0.3 56,876 25,728
as a constant. In order to simplify the evaluation, it is A-4 0.4 37,208 6234
reasonable to treat Cf, p and d as 1, and the drag force
C-4 0.4 40,649 16,930
exerted on an element is defined as
E-2 0.4 40,463 15,772
0 1 F-1 0.4 47,548 19,110
Fdl ¼ ðv  uÞ2 dl ð2Þ H-4 0.4 30,583 11,447
2
I-4 0.4 41,458 17,510
Physical parameters of the element, such as  and v, A-5 0.5 42,060 4918
are disposed as C-5 0.5 46,036 18,927
E-3 0.5 36,118 8283
 ¼ 12 ða þ b Þ, v ¼ 12 ðva þ vb Þ ð3Þ F-2 0.5 51,662 19,571
G-1 0.5 33,019 10,674
In order to compare the air performance of the new H-5 0.5 32,508 10,685
nozzle with that of the commonly used nozzle fully, two I-5 0.5 47,583 20,053
kinds of flying status of weft yarn are taken into
consideration:
to compare with those of the commonly used nozzle
1. u ¼ 0, which means one side of the weft yarn is fixed; in Table 5. Considering Equation (1), it is observed
and that the air density  and the air velocity v are the
2. u ¼ 80 m/s, which means the weft yarn maintains key factors increasing the drag force, whereas the air
normal flying status. velocity v plays a more important role. As a conse-
quence, when the air supply pressure is less than 0.3
A series of drag forces exerted on the weft elements MPa, the air velocity grows faster and so does the
can be obtained, considering that the length of the new drag force; however, when the air supply pressure is
nozzle is longer than that of the commonly used nozzle; more than 0.3 MPa, the air velocity varies towards a
therefore, total drag force can be defined as gentle gradient, and the air density grows faster, which
X results in the drag force increasing more gently. When
0
F¼ Fdl =l ð4Þ the drag forces in different types under different air
supply pressures are compared with each other, it is
where l is the total length of the main nozzle. Drag observed that a stronger turbulence area, which
force F of the new main nozzle and commonly used causes generation of the backflow phenomenon in the
nozzle under different total supply pressure is shown upstream area at point ‘‘S2’’, is generated under high air
in Table 5. supply pressure; it obviously influences the increase of
In order to describe the advantages of the new the total drag force. It also indicates that when the air is
nozzle, some better and special situations are chosen distributed reasonably into two inlets of the new nozzle,

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Chen et al. 1601

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performance.

Funding
This work was supported by the Priority Academic Program
Development of Jiangsu Higher Education Institutions.

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