The design of metallic card clothing, which is one of the most important devices in the textile industry, has always been based on operational experience. With the development of types of fibers and the requirements for the quality of yarns, those principles concluded by engineers seem to be losing their efficiency. Recent research found that airflow played an important role in the card process, which means airflow should be carefully studied. Computational fluid dynamics (CFD) simulation greatly helps in the analysis of airflow because the gauge between carding elements is too narrow to put in any measuring device. In the present study, with the help of CFD simulation, the air around different carding clothing with varied tooth depth was analyzed. It was concluded that the carding efficiency improvement in card clothing with lower tooth depth may be related to more concentrated air velocity at the tooth tips. This resulted in more probabilities that fibers would get through the cylinder surface at the teeth tips, so that the fibers could be caught by flat-top needles more efficiently. With this assumption, a new generation of card clothing called “double teeth” containing two teeth in a single section has been invented. The new configuration design of card clothing was then applied in several spinning mills on an industrial scale for experiments. The results showed about a 30% improvement in production at the same quality level as conventional card clothing, which implied the usefulness of the newly applied principles related to airflow. Despite the difficulty in the study of the complex carding process, the new airflow analysis method has shown an optional and worthwhile way of thinking that could make a difference in future research in the textile industry.

金属针布是纺织行业最重要的设备之一，其设计始终以操作经验为基础。随着纤维种类的发展和对纱线质量的要求，工程师总结的那些原则似乎正在失去效力。最近的研究发现气流在制卡过程中发挥了重要作用，这意味着应该仔细研究气流。计算流体动力学 (CFD) 模拟极大地有助于分析气流，因为梳理元件之间的厚度太窄而无法放入任何测量设备。在本研究中，借助 CFD 模拟，分析了具有不同齿深的不同梳理针布周围的空气。得出的结论是，较低齿深的针布梳理效率的提高可能与齿尖处更集中的气流速度有关。这导致纤维在齿尖穿过圆柱表面的可能性更大，因此纤维可以更有效地被平顶针捕获。有了这个假设，就发明了一种称为“双齿”的新一代针布，在一个截面中包含两个齿。针布的新配置设计随后被应用于几家工业规模的纺纱厂进行实验。结果表明，在与传统针布相同的质量水平下，产量提高了约 30%，这意味着与气流相关的新应用原理非常有用。