Abstract
The growing need for high-performance stretchable fabrics led scientists to innovate a new spinning technique, especially for manufacturing cotton/spandex core-spun yarns. This type of yarn is spun by using spandex monofilament or multifilament as a core, which is surrounded by a sheath of staple cotton fibers. The key covering process parameters include spindle speed, delivery roller speed, spandex drafting ratio, spandex linear density, and tension level, which simultaneously influence the core-spun yarn characteristics such as tensile properties, hairiness index, imperfection index, and fabric aesthetic and performance properties. Fine-tuning these multiple covering parameters achieves optimal performance of these types of yarns. This paper aimed at employing multi-objective optimization for the covering parameters of cotton/spandex composite yarn to maximize the yarn tensile properties and minimize both hairiness and imperfection indices using the robust Taguchi technique in conjunction with the grey relational analysis. A full factorial design composed of three factors, namely spandex monofilament drafting ratio, linear density, and core-spun yarn twist multiplier, with five, four, and two levels, was conducted. Average values of the grey relational grades of all combinations were estimated, and its highest value refers to the optimal combinations of the controllable factors, which yield the best performance of cotton/spandex core-spun yarn. This study revealed that core-spun yarn with a 4.2 twist multiplier, a 44 dtex linear density of spandex monofilament, and a 4.4 drafting ratio of spandex yielded the optimal yarn performance characteristics. This study provides a methodological breakthrough with beneficial ramifications for the textile industry seeking a multi-objective optimization of core-spun yarn manufacturing parameters.