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This study is divided in to two main parts. The first part deals with the optimization of process parameters of needle-punched non-woven fabrics for achieving maximum sound absorption by employing a Box-Behnken factorial design. The influence of fibre type, depth of needle penetration and stroke frequency on sound absorption properties were studied. These parameters were varied at three levels during experimental trials. From multiple regression analysis, it was observed that the depth of needle penetration alone was the most dominant factor among the selected parameters, which was followed by the interaction between depth of needle penetration and stroke frequency. Fibre type was the least dominant parameter affecting sound absorption. A maximum sound absorption coefficient of 47% (0.47) was obtained from the selected parameters. The results showed that for a process such as needle-punching, which is influenced by multiple variables, it is important to also study the interactive effects of process parameters for achieving optimum sound absorption. The second part of the study deals with the effect of type of natural fibre (fineness), and the blending ratio (with PET fibres) on the air permeability of the needle-punched non-woven fabrics and then it proceeds to study the effect of the air-gap, type of natural fibre (fineness) and blending ratio (with PET fibres) on sound absorption of needle-punched non-woven fabrics. These parameters are tested individually and their two way interaction (synergy) effect using ANOVA. The air-gap was varied from 0mm to 25mm with 5mm increments, three natural fibre types were used and all were blended with polyester fibres at three blending ratios for each natural fibre type. The Univariate Tests of Significance shows that all three parameters have a significant effect on sound absorption together with two two-way interactions, with the exception of the Blend Ratio × Air Gap two-way interaction which was not significant. It was found that the sound absorption improves with the increase in the air-gap size up to 15mm after which sound absorption decreased slightly with the further increase in the air-gap up to 25mm.

Typescript. / Digitized by Kansas Correctional Industries

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Hydroentanglement is an important technique of bonding fibres to produce nonwovens using high velocity waterjets as the primary bonding tool. The work reported in this thesis addresses the gap in scientific knowledge and understanding, both theoretical and experimental, related to the impact forces and energy of the waterjets used in the hydroentanglement process. The current study focused on the impact forces and energy involved in, and the optimisation of, the hydroentanglement process. The results of the experimentally measured waterjet impact forces have been used to characterise the waterjets as well as to verify empirically the theoretical models currently available for explaining the mechanics of the hydroentanglement process. Since the process of supplying pressurised waterjets consumes a great deal of energy, the study of energy consumption and efficiency of the system has been critical. A method was proposed and used to determine the coefficients of velocity and water discharge of an industrial machine set-up, helping explain the mechanism of energy transfer during hydroentanglement and to concurrently optimise the process. Furthermore, a response surface experimental design was used to optimise the hydroentanglement of viscose and Polylactic acid (PLA) fibres into nonwovens. The selected Box-Behnken design, with four factors, namely the waterjet force, machine processing speed, input weight and fibre type, was employed to investigate the multivariate process factors and their interactive effects on physical and mechanical properties of nonwovens. Two sets of experiments, the later for validation, were performed to study the energy transfer efficiency. The results of the relative energy transfer to bond the fibrous web showed that it was possible to produce nonwovens using lower input energy without compromising the quality of the products. The optimum waterjet pressure and machine speed used to produce the Abstract nonwoven with the highest tensile strength for the least amount of energy supplied were identified.

This study investigated the manufacturing process of thermo-set fibreglass nonwoven composites. Techniques of manufacturing nonwoven webs from chopped strands were investigated and from the literature review it was found that the wet laid method was appropriate. The process of manufacturing paper hand sheets from pulp was modified to manufacture flat fibreglass nonwoven webs. The effects of dispersion and fibre length on the quality of these webs were investigated. It was found that the quality of these webs improved due to the dispersion.These nonwoven webs were then impregnated with epoxy resin by using the resin infusion method of vacuum bagging to make composite samples. The effects of dispersion, fibre length and multiple layering on the quality and mechanical properties of these composites were studied. It was found that it is necessary to disperse the fibreglass strands in order to manufacture composites of better quality. The quality and strength of these composites also improved due to the increase in the fibre length and multiple layering. Some initial studies were done to manufacture 3D fibreglass nonwoven webs by using the vacuum forming technique and 3D fibreglass nonwoven composites were also made using these webs. Initial investigation of the physical properties of these 3D composites was conducted and it was found that the void content decreased and the density had slightly increased due to the multiple layering process. This topic can be further investigated in the future.