| Summary: | 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.
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