An innovative explanation of spun yarn failure mechanism has been proposed which has validity in explaining some of the anomalies encountered in the previous literatures. A novel mathematical model of yarn tenacity has been derived which can predict the strength of spun yarns produced by any spinning technology. The proposed model of yarn tenacity generates a reasonable agreement between the predicted and measured values of yarn tenacity and it provides a better understanding of the mechanism of failure process of spun yarns. Using the Weibull distribution parameters of yarn tenacity at a...