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Journal of Industrial Textiles

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Optimization of Parameters for the Production of Needlepunched

Nonwoven Geotextiles

Amit Rawal, Subhash Anand and Tahir Shah

2008 37: 341Journal of Industrial Textiles

DOI: 10.1177/1528083707081594

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What is This?Downloaded from

OptimizationofParametersfor

theProductionofNeedlepunched

NonwovenGeotextiles

AMIT RAWAL,* SUBHASH ANAND

AND

TAHIR SHAH

TheUniversityofBolton,DeaneRoad

Bolton,BL35AB,UK

ABSTRACT: Needlepunchednonwovengeotextilesarewidelyusedforvariouscivil engineeringapplications.Theseapplicationsarerequiredtoperformmorethanone function,i.e.,filtration,separation,protection,drainage,andreinforcement. Reinforcementisacomplexphenomenonandstronglydependsuponthefabric dimensionalandmechanicalpropertiesinadditiontothesoilCgeotextileinteraction Inthisstudy,theeffectofprocessparametersincludingwebareadensity,punch density,anddepthofneedlepenetrationhasbeeninvestigatedondimensional (areadensityandthickness)andmechanical(punctureresistanceandtensile strengthsinthemachineandcross-machinedirections)propertiesofneedlepunched nonwovengeotextiles.Theseprocessparametersarethenempiricallyrelatedwiththe fabricpropertiesusingmultipleregressiontechnique.Theanisotropiccharacteristics ofneedlepunchednonwovengeotextilestensilepropertieshavealsobeendiscussed. KEYWORDS: geotextiles,needlepunchednonwoven,tensile,dimensional, mechanical,punctureresistance.

INTRODUCTION EEDLEPUNCHEDNONWOVENGEOTEXTILES arewidelyusedforvarious civilengineeringapplicationsincludingroadandrailwayconstruction,

N

*Authortowhomcorrespondenceshouldbeaddressed.

E-mail:amitrawal77@https://www.doczj.com/doc/131666197.html,,amitrawal77@https://www.doczj.com/doc/131666197.html, Figures1C12appearincoloronline:http://jit.sagepub.co

341

JOURNALOF INDUSTRIALTEXTILES, Vol.37,No.4!aApril200

1528-0837/08/040341C16$10.00/0DOI:10.1177/152808********* SAGEPublications2008

LosAngeles,London,NewDelhiandSingaporeDownloaded from

342

A.RAWALETAL.

landfills,slopestabilization,etc.Suchapplicationsrequirecertainfunctional characteristicsinthestructure,besidesbasicproperties,whicharerequired tobeengineeredbyjudiciousoptimizationoftheneedlepunchingprocess. Theseapplicationsarerequiredtoperformmorethanonefunction,

i.e.,filtration,separation,protection,drainage,andreinforcement. Anexampleofusingnonwovengeotextilesasreinforcementincludesslope stabilizationinwhichthestabilityoftheslopedependsonthestressesthat thegeotextilecansustainandtransmittheloadswithinthenonwoven structure.Theprincipleofusinggeotextilesasreinforcementistointroduce thegeotextilesintothesoilstructurethatincreasethecohesionbetweenthe grains[1].Thismodifiesthetransmissionoftheloadandtheresulting compositeisabletosustainhigherloads.Theforcesexertedonthestructure asaresultofvariousloadsaretransferredintotensilestresseswhichfurther influencesothermechanicalproperties,suchaspunctureresistance[2]. Thereinforcementisacomplexphenomenonandresultsfromthecombined behaviorofsoilCgeotextileinteractions[3C5].However,theperforman characteristicsofgeotextilesarestronglydependentuponraw-material, manufacturingprocess,anditsrelatedparametersthatalsoinfluencethe structuralmechanicsofthefabrics.Thereareseveralmaterialandprocess parameters(fiber,web,needle,needlepunching,andfinishing)thatcan

affecttheperformancecharacteristicsofgeotextiles.Inaddition,the structuralcoherenceinaneedlepunchedfabricdependsuponthefrictional characteristicsandinteractionofconstituentfibers[6C8]

Recently,RawalandAnandjiwala[9]havedemonstratedtheeffectof processparametersincludingfeedrate,strokefrequency,anddepthofneedle penetration(NP)onvariousgeometrical,mechanical,andhydraulicproper- tiesofneedlepunchednonwovengeotextiles.Inthispaper,theeffectofmore thanoneprocessparameter,namelypunchdensity(PD),webareadensity (WAD),andNPhasbeeninvestigatedondimensionalandmechanical propertiesofneedlepunchedgeotextiles.Theseprocessparametersarerelated tothedimensionalandmechanicalpropertiesofneedlepunchednonwoven structuresusingmultipleregressiontechnique.

EXPERIMENTALWORK Afullfactorialdesignwasemployedwiththreedesignfactorsat

threelevels,WAD,PD,andNPusingTaguchistechnique[10],asshow

inTable1.Here,thefactorlevelswereselectedsuchthatthelower,middle, andupperlevelscorrespondto1,0,and1,respectively.Thecodedlevels andtheactualvaluesofthesefactorsaredefinedinTable2.Following theexperimentaldesign,pre-needledcross-laidwebswereproducedusingDownloaded from

OptimizationofParametersforProductionofGeotextiles 343

Table1.Experimentaldesignforproductionof needlepunchednonwovengeotextiles.

SampleID NP PD WAD

1111

2011

3111

4101

5001

6101

7111

8011

9111

10110

11 010

12110

13100

14 0 0 0

15100

16110

17 010

18110

19111

20 011

21111

22101

23 0 01

24101

25111

26 011

27111

NPdepthofneedlepenetration;PDpunchdensity;WADweb areadensity.

Table2.Codedandactualvaluesofthe processparameters.

Parameters1012

) 400 800 1200

WAD(gm2 a

PD(cm

) 150 225 375

NP(mm)81012

WADwebareadensity;PDpunchdensity;NPdepthofneedle penetration.

a

Accordingtotheexperimentaldesign,themiddlevalueofPDshould2 correspondto262.5cm

however,problemshavebeenencounteredin producingthefabricsexperimentallyontheneedlepunchingline.Therefore,2 .Inaddition,thesevalues

thenearestvalueofPDwasfoundtobe225cm werematchedwiththeindustrialdatasets.Downloaded from

344

A.RAWALETAL.

polypropylenefibers(10dtexand100mm)atthecollaboratingcompany (GeofabricsLtd,Leeds,UK).Aseriesofneedlepunchednonwoven structureswassubsequentlyproducedonalaboratoryneedlepunchingline attheUniversityofBoltonbasedupontheexperimentaldesign,asshownin Table1.Thestandardtestswereperformedontheneedlepunched geotextilestodeterminefabricareadensity(EN965,1995),thickness

(EN964-1,1995),punctureresistance(EN-ISO12236,1996),andtensile strengthsinthemachineandcross-machinedirections(EN-ISO10319, 1996).

RESULTSANDDISCUSSION

Table3showsthedimensionalandmechanicalpropertiesofneedle- punchednonwovengeotextilesproduced,tested,andfullyanalyzedusing theexperimentalmatrix(asshowninTable1). EffectofProcessParametersonDimensionalPropertiesofNeedlepunched NonwovenGeotextiles

HearleandSultan[11]suggestedthatWADandtypeofstructurehave amajoreffectonneedlepunchedfabricareadensity(FAD)andfabric

thickness(FT).Later,themachineparameters,suchasamountofneedling andNPweretakenintoaccount[12].Rakshitetal.[13]havealsostudiedthe influenceofPDandNPonthephysicalpropertiesofneedlepunched nonwovensmadefrompolyesterandpolypropylenefibers.However,they didnotreportsimultaneousinfluenceofmorethanoneparameter.

Figure1showsthecombinedeffectofWADandNPontheFAD.Ithas beenobservedthattheNPhasanegligibleeffectontheFAD.However,the FADincreasessharplywiththeWAD.Ontheotherhand,theFADinitially increasesandsubsequentlydecreaseswithfurtherincreaseinthePDas showninFigure2.Thisisbecausehighernumberoffibersarearranged inthethicknessdirectionthatyieldshigherresistancetodraftingbetween bedandstripperplates.FurtherincreaseinthePDcausesthefiberdamage thatreducestheFAD.SimilareffectscanbeobservedforPDandNPon FADasshowninFigure3.

Ingeneral,theincreaseinFTisrelativelylessthanthecorresponding

increaseinFAD[11,12].Since,itisacombinedeffectofhigherfrictional resistanceofferedbythehigherdensitywebsandgreatereffectivefiber entanglementinthestructure.Figure4showsthecombinedeffectofWAD andNPontheFT.ItcanbeseenthattheFTdecreaseswithincreasingNPDownloaded from

OptimizationofParametersforProductionofGeotextiles 345

Table3.Dimensionalandmechanicalpropertiesof needlepunchedgeotextilesproducedonlaboratorymachine.

Parameters Property

SampleIDWADNPPDFADFTCBRTMDTXMD

1 400081505236.484.6122.6655.41

2 400101505025.435.0025.2050.08

3 400121505264.584.8624.5056.26

4 400082255406.125.3226.6550.76

5 400102255354.794.9529.8250.07

6 400122255614.004.5629.6150.90

7 400083754805.384.4324.5139.87

8 400103755684.225.4130.0943.58

9 400123756054.174.4540.0454.10

10 80008150105611.1511.4943.7581.67

11 8001015010858.5511.0446.9895.49

12 8001215010306.9610.8156.07107.58

13 8000822511989.2412.8157.9781.23

14 8001022512157.7011.8955.6198.11

15 8001222512896.6810.3865.8397.22

16 8000837511588.3611.4542.6560.01

17 8001037511456.269.9458.1075.39

18 8001237512856.217.6855.2278.90

19120008150144611.3317.5467.05100.28

20120010150167710.7119.0181.39144.64

2112001215017399.7416.8676.37148.57

22120008225176811.1617.5468.5990.25

2312001022518759.9516.1988.22126.53

2412001222518849.2215.1279.43145.82

25120008375177210.2217.3345.2259.73

2612001037518698.3014.7167.1192.16

2712001237518957.5813.5574.68123.522

WADwebareadensity(gm );NPdepthofneedlepenetration(mm);22 PDpunchdensity(cm

);FADfabricareadensity(gm );FTfabricthickness

(mm);CBRpunctureresistance(kN);TMDtensilestrengthinmachinedirection11 );TXMDtensilestrengthincrossmachinedirection(kNm ).

(kNm

atlowerWADs.AsimilarrelationshiphasbeenobservedforFTby increasingthePDatlowerWADs,asshowninFigure5.Itshouldbenoted thattheeffectofNPismoresignificantthanthePDontheFT.Figure6 illustratestheeffectofNPandPDontheFT.Sinceatlowerneedle penetrations,theneedlesmaynotbeabletoreorientatethefibersfromthe surfacelayertothethicknessdirectionwhichmayleadtothefullrecoveryof thefibersonremovaloftheneedles.Downloaded from

346 A.RAWALETAL.

2600 only

2328

¨2600

¨2328

2056

2600

2600

2328

2328

¨2056

1784

2056

2056

1512

¨1784

1784

1784

1512

1512

¨1512

1241 FAD FAD 1241 1241 968.65 968.65 ¨1241 968.65 696.79 696.79 424.92 424.92 ¨968.65 696.79 153.05 153.05 ¨696.79 424.92 12 1200

¨424.92 153.05 10

800 400

8 118.81 ¨153.05 WADNP2

FIGURE1. Effectofwebareadensity(gm )anddepthofneedlepenetration(mm)22 onfabricareadensity(gm

)atapunchdensityof225cm .

2503 only

2211¨C250

1920¨C221

2503

2503

2211

2211

1629¨C192

1920

1920

1338¨C162

1629

1629

1338FAD FAD

1338

1047¨C133

1047 1047

755.68

755.68

755.68¨C104

464.53

464.53

173.38

173.38

464.53¨C755.6

117.77

117.77

173.38¨C464.5

1200

375

117.77¨C173.3

800

225

400

150

WAD

PD22

FIGURE2. Effectofwebareadensity(gm )andpunchdensity(cm )onfabric2 areadensity(gm

)ataneedlepenetrationof10mm.Downloaded from

OptimizationofParametersforProductionofGeotextiles

347

1298 only

1237¨1298

1175¨1237

1298

1298

1237

1237

1113¨1175

1175

1175

1051¨1113

1113

1113

1051

1051FAD FAD

989.04¨1051

989.04 989.04

927.16

927.16

927.16¨989.04

865.28

865.28

803.39

803.39

865.28¨927.16

741.51

741.51

803.39¨865.28

375

12

741.51¨803.39

10

225

150

8

679.63¨741.51

NP

PD

679.63 only2

FIGURE3. Effectofpunchdensity(cm )anddepthofneedlepenetration(mm)on22 fabricareadensity(gm

)atawebareadensityof800gm .

14.62 only

13.19¨C14.6

11.76¨C13.1 14.62

14.62

13.19

13.19

10.34¨C11.7

11.76

11.76

8.912¨C10.3 10.34

10.34

8.912

8.912FT FT 7.486¨C8.91 7.486

7.486

6.059

6.059

6.059¨C

7.48 4.633

4.633

3.207

3.207

4.633¨C6.05 1.781

1.781

3.207¨C

4.63 8

1200

1.781¨C3.20

10

400

12

0.354¨C1.78

NP WAD

0.354 only2

FIGURE4. Effectofwebareadensity(gm )anddepthofneedlepenetration(mm)2 onfabricthickness(mm)atapunchdensityof225cm

.Downloaded from

348 A.RAWALETAL.

12.65 only

11.38¨12.65

10.10¨11.38

12.65 12.65

11.38

11.38

8.831¨10.10

10.10

10.10

7.559¨8.831

8.831

8.831

7.559

7.559FT FT

6.286¨

7.559

6.286

6.286

5.013

5.013¨

6.286

3.741

3.741

2.468

2.468

3.741¨5.013

1.195

1.195

2.468¨

3.741

1200

150

1.195¨

2.468

800

225

400

375

0.0774¨1.195

WAD

PD

0.0774 only22

FIGURE5. Effectofwebareadensity(gm )andpunchdensity(cm )onfabric thickness(mm)ataneedlepenetrationof10mm.

13.16 only

12.37¨C13.1

11.57¨C12.3

13.16

13.16

12.37

12.37

10.78¨C11.5

11.57

11.57

9.980¨C10.7

10.78

10.78

9.980

9.980

9.184¨C9.98 FT

FT

9.184

9.184

8.388

8.388

8.388¨C9.18 7.593

7.593

6.797

6.797

7.593¨C8.388 6.001

6.001

6.797¨C

7.59 150

8

6.001¨C6.79 225

10

12375

5.206¨C600

PD

NP

5.206 only2

FIGURE6. Effectofpunchdensity(cm )anddepthofneedlepenetration(mm)on2 fabricthickness(mm)atawebareadensityof800gm

.Downloaded from

OptimizationofParametersforProductionofGeotextiles

349 EffectofProcessParametersonMechanicalPropertiesofNeedlepunched NonwovenGeotextiles Themechanicalpropertiesincludingtensilestrengthsinthemachineand

cross-machinedirections(TMDandTXMD)andpunctureresistance(CBR) werealsostudied.ItisexpectedthatTXMDwouldbehigherthanthe correspondingstrengthinthemachinedirectionbecausethepreferential orientationoffibersisinthecross-machinedirection(cross-laidwebswere usedinallexperimentalfabrics).Inthepast,thetensilepropertiesofthe needlepunchednonwovenstructureshavebeenrelatedtothefabric dimensionalpropertiesandprocessparametersincludingNP,numberof barbs,etc.[11C13].However,itisinterestingtocharacterizetheisotropyi thetensilestrength,expressedastheratiooftensilestrengthsinthecross- machinedirectiontothemachinedirectionbaseduponthecombinedeffect ofprocessparameters.Figure7showsthecombinedeffectofWADandNP ontheratiooftensilestrengthsinthecross-machinetomachinedirections. Ithasbeenfoundthatthedesiredisotropiccharacteristicsintensile strengthscanbeachievedathigherWADwithlowerNP.Ontheother

hand,thestructurewouldbelooseastheentanglementofthefiberswould

2.831 only

2.652¨C2.83

2.473¨C2.65 2.831

2.831

2.652

2.652

2.294¨C2.47 2.473

2.473 TXMD/TMD 2.115¨C2.29 2.294

2.294

2.115

2.115

1.937¨C

2.11 1.937

1.937 TXMD/TMD 1.758 1.758 1.758¨C1.93 1.579

1.579

1.400

1.400

1.579¨C1.75 1.222

1.222

1.400¨C1.579 12

400

1.222¨C1.40

10

800

1200

8

1.043¨C1.22

WAD

NP

1.043 only2

FIGURE7. Effectofwebareadensity(gm )anddepthofneedlepenetration(mm) onratiooftensilestrengthsinthecross-machinetomachinedirectionsatapunch2 densityof225cm

.Downloaded from

350 A.RAWALETAL.

3.479 only

3.262¨C3.47

3.045¨C3.26

3.479

3.479

3.262 3.262

2.829¨C

3.04

3.045

3.045

TXMD/TMD

2.612¨C2.82

2.829

2.829

2.612

2.612

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Journal of Industrial Textiles https://www.doczj.com/doc/131666197.html,/ Optimization of Parameters for the Production of Needlepunched Nonwoven Geotextiles Amit Rawal, Subhash Anand and Tahir Shah 2008 37: 341Journal of Industrial Textiles DOI: 10.1177/1528083707081594 The online version of this article can be found at: https://www.doczj.com/doc/131666197.html,/content/37/4/341 Published by: https://www.doczj.com/doc/131666197.html, can be found at:Journal of Industrial TextilesAdditional services and information for https://www.doczj.com/doc/131666197.html,/cgi/alertsEmail Alerts: https://www.doczj.com/doc/131666197.html,/subscriptionsSubscriptions: https://www.doczj.com/doc/131666197.html,/journalsReprints.navReprints: https://www.doczj.com/doc/131666197.html,/journalsPermissions.navPermissions: https://www.doczj.com/doc/131666197.html,/content/37/4/341.refs.htmlCitations: - Mar 28, 2008Version of Record >>

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