ULTRASONIC-ASSISTED NEEDLE PENETRATION IN SEWING PROCESSES: REDUCING FABRIC PIERCING FORCE

Abstract

This study investigates the application of ultrasonic vibrations to the needle mechanism in sewing machines to reduce the fabric piercing force during the stitching process. The integration of ultrasonic oscillations (20-40 kHz) into the needle bar system demonstrates significant reduction in penetration resistance when piercing various textile materials. Experimental results show that ultrasonic-assisted sewing reduces the needle penetration force by 25-40% compared to conventional sewing methods, depending on fabric type and thickness. This reduction in piercing force leads to decreased needle wear, improved stitch quality, reduced fabric damage, and lower energy consumption. The mechanism involves superposition of high-frequency ultrasonic vibrations onto the conventional needle motion, creating micro-impacts that facilitate material separation. This technology shows particular promise for processing difficult-to-sew materials including densely woven fabrics, technical textiles, and composite materials used in modern garment manufacturing.