Yarn Manufacture I : Principal of Carding & Drawing

Prof. R. Chattopadhyay
Department of Textile Technology
Indian Institute of Technology, Delhi

Lecture – 07
Card Clothing

So we are going to discuss Card Clothing today. Card clothing means that the bear
cylinder, the doffer the licker in these elements of the carding machines needs to be
completely clothed with large number of pins or teeth.

(Refer Slide Time: 00:39)

And hence the term clothing has come the way we dress ourselves; card clothing could
be of 2 types flexible and rigid. So, depending upon the organs we decide which type of
clothing should go to that particular organ. We can see if we study a machine we will
find the large number of saw tooth type of teeth or pins on surfaces of licker in cylinder
flat doffer and also on pre and post carding segments; we will first discuss licker in
clothing.
(Refer Slide Time: 01:31)

Licker in clothing we have strong metallic wire points on the surface of the licker-in, the
tooth of a given profile is cut into a rolled wire by a high precision cutting tool; cutting is
immediately followed by hardening.

The important parameters of the wire or the tooth are its height, width of his base angle
of inclination between a line normal to the base of the tooth and the leading edge alpha
and the tooth density that is T which is teeth per inch.

(Refer Slide Time: 02:16)

Here we can see in the diagram, the profile of licker in tooth as well as is specifications
that is height width the inclination angle alpha as shown in the diagram and the number
of teeth per unit length.

Generally what we see is that the heights of the teeth are 5.5 millimeter, the width of the
base is around 12; 1 not the 1.5 mm and the number of teeth per unit length varies
between 3 to 5.

(Refer Slide Time: 03:06)

To clothe the licker in 4 to 8 helical grooves are cut into its surface; each having a lead of
1 inch. You can see it in the diagram the helical grooves shown by different colors; see if
we have a 6 inch start 6 start licker in then we will have 6 parallel grooves ones sixth of
an inch apart. In the present case we can see there are the start is 4; that means, in inch
there are 4 grooves which are cut.

Now, the metallic wire is then forced into the groove during the winding operation on the
licker in. The tip distribution, over the surface becomes more homogeneous with more
number of starts. If g stands for lead between 2 adjacent windings regardless whether
single or multi start and small t as shown is the pitch in millimeter, the tooth density will
be T d is 100 by small t into g.
(Refer Slide Time: 04:20)

The typical tooth density or licker in could be between 25 to 40 per square inch, the life
time of a licker in wire is about half of that cylinder and doffer. The nature of wear on the
wires is such here the wire means the tooth or the pins on it; that these wires cannot be
ground to bring them back to normal working again hence they need replacement when
damage is beyond repair.

So, the licker in teeths are much robust in nature because they have to tease out the
unopened couplets that we are feeding to the machine. Hence they are much stronger in
comparison to the kind of teeths which are used on cylinder, flat or duffer. From licker in
clothing we go to now flat clothing.
(Refer Slide Time: 05:32)

Flat clothing is flexible in nature; what does it mean flexible? That the pins which is
which are there they can easily bend that is why there are flexible. Now here long pins
having round or oval cross section shapes are inserted into a backing, these pins are bent
into a U shape along with a knee as shown in the diagram. That a knee is here; here is the
knee pins are inserted into an elastic backing made of 5 plies of cloth. So, these are this
is the cloth on which the pins are inserted.

And these plies are joined together by vulcanizing; these permits the points to bend
easily under the influence of stress beyond a certain limit, that whenever the force,
opening force will be acting on these pins the pins can easily bend that is the advantage
that we have.
(Refer Slide Time: 07:14)

And why do you need this flexible wire points on flats or flexible teeth on flats? Fibres
will experience intense force while getting carded between cylinder and flats. If the flat
wire points can bend where the carding force become excessive then the stress level on
the fibre will reduce. And therefore, the damage to the fibres can be avoided that is the
reason why we need flexible pins on flats; the pins on cylinder are quite rigid in nature.

(Refer Slide Time: 08:00)

The other question that may come to our mind is why the pins need to be bent? Now here
in the diagram we see that the diagram first diagram a pin is shown by a line and let us
say this has no knee; it is a straight pin going from here to there.

And in the other case we see a pin which is bent at the knee here and going up to this
point. Now if a force acts on it because of the carding action; the pin is going to move,
when this pin moves along the arc shown here and if it is comes exactly on the top of his
base; the rise in height in this case is going to be around x 2 because this will move in a
arc whose radius is going to be like in this case O; let us say A this point which will
move along a arc with the radius QA.

Whereas in the second case if this is O this is a let us say this is B represents the knee
point. In this case if a similar force acts on the pin, it will also move in a arc, but the arc
will have a radius equivalent to A B. And therefore, if we compare the rise in height in
both the cases; then we will see the rise of tip of the straight wire point or straight tooth
will be much greater and the rise by similar tooth with bent knee that is x 2 is greater
than x 1.

These rise may even cause the pins of the interacting surfaces to collide that is when the
cylinder and the flat pins an interacting together on fibres; in the rise of the pins are too
much there is a chance that the tip of the flat teeths will collide or will come into the
contract with the teeth of the cylinder and therefore, they might get damage this we want
to avoid.

So, the knee will ensure limited rise of the wire point. So, wire point and tooth are
basically same in the industry; the wire point term is more frequently used. So, the wire
point with knee will ensure limited rise when strained by the carding force. And hence
the possibilities of collision between the metallic teeth of the cylinder and flats can be
avoided.
(Refer Slide Time: 11:25)

Now, there are semi rigid clothing on flats are also available; now why semi rigid
clothing or what could be there problems with flexible clothing?

Now, flexible clothing with knees get choked with fibres very quickly this is a problem.
Because during carding action part of the force will force the fibres to move along the
base or towards the base of the wire point and as a result lot of fibres will go and
accumulate near the base and hence it gets choked or gets filled up with fibres very
quickly. So, that will gradually reduce the opening capability of the carding action and
hence so much flexibility may not be good especially with high production carding
machines.

Now, here what we do? The teeths are not so flexible; they are semi rigid in nature. Now
for this the backing contains 7 or more plies of cloth and plastic layers; resin bonded
together the base becomes stronger, it does not yield easily. So, here this is the base and
there are 1 2 3 4 5 6 or 7 layers of cloth as well as some plastic, some resins. So, the
teeths are inserted here and therefore, the base become relatively rigid in comparison to
what we have in the case of flexible clothing of flats. See the base does not yield easily
the rise of the tip point will be less.

Then in this backing we insert the teeth as we have done in the previous case. So, these
diagrams are showing how the teeths will look like inside the base; the wire points are
made of carbon steel with 0.6 to 0.6 percent of carbon. So, the carbon steel will make it
very very you know resistance to abrasive forces or abrasive actions because the pins
will be continuously acted by the fibres.

So, there is always lot of abrasion which is going on between the fibres of the teeth and
with time the teeths will get damaged. And hence we need to make sure that the teeths
are made by such material which can resist the abrasive forces of the fibres.

(Refer Slide Time: 14:37)

Now, the cross sectional shape of the tooth; the flat wire points or flat teeths are
generally upto basic shapes, double convex or elliptical type or rectangular these are the
2 types of shapes. So, one is something like this and other one is something like this; so,
this is rectangular and this is elliptical in nature.

For elliptical wire the major axis remains in the direction of the material flow in another
important point and for rectangular wires the length faces the material flow directions.
So, material flow directions shown by these arrows; so, this is the direction in which the
teeths will be actually placed into the base of the flats. In the case of flat wire cross
section, sharpening operation broadens the working surface of the point tip hence
reduces its effectiveness.

Therefore flat wires can be sharpened only once or twice; however, with lateral
sharpening; it can be carried out more number of times. This is why flat wire points
cannot be sharpened too many times and in comparison to what we can do with cylinder
or doffer wire points.

(Refer Slide Time: 16:26)

Now, comes the setting pattern, how when the when the pins or the teeth are inserted
then what kind of pattern it takes? There are 4 type of patterns which could be there plain
twill setting pattern number 1; that is if we concentrate on the tip of the teeth then we
find that they are following a twill setting. Here they what is going to be advantage or
disadvantage with this? Varying point densities when the surface is examined in smaller
segments.

So, this is what is a disadvantage with the plain twill setting. Then it comes staggered
twill setting; the twill is broken after every 3 staples to be offset by half the staple and it
gives more uniform distribution of the pins on the surface of the flat. The other one is
progressive point density; the points on an individual flat top are distributed in 2
sections, one with wider and the other with closer point density. That is part of the same
flat part of it will have higher point density the other part will have lower point density.

The point density which is less will face the incoming fibres; as a result what happens?
Points with wider spacings are supposed to act on large trash particles and fibre tufts; a
narrower spacing provides intensive action or remaining finer tufts and neps. So,
basically by having this progressive point density; we try to achieve a gradual increase in
intensity of the carding action over a particular flat also. At the same time a larger trash
particles will find spaces to get lost in the in between these spaces, where the point
density is less. Point density is too high and the space is smaller on the size of the trash
particle then the trash particle will not be able to penetrate or get into the teeth and hence
they will not get lost and will move forward.

So, that is the possibilities which are there with point densities are exactly same all over
the flat. And that could be combinational setting, which is the combinations of the 2 that
we have discussed earlier; this would mean to deliver the advantages of both; so, this
could be also there.

(Refer Slide Time: 19:56)

So, these are the different types of patterns that is followed and here in this table we see;
the flat wire points geometrical parameters that is its height at the angle; that means, they
are inclined and the point densities what we see here depending upon the type of fibre
that we are going to process, the height angle and the point densities are to be changed
that is what is recommended by the machine manufacturers.

So, what is important to see here that the height is more or less constant which is close to
8 millimeter. The angle of inclination is 70 to 80 degree and the point densities may
range between 330 to 520 degree; 520 points per square inch for long and fine cotton.
But, if we go for synthetics or if we go for short and dirty cotton the values are close to
270 points per square inch PPSI stands for Points Per Square Inch and PPCM stands for
Points Per square Centimeter.
So, we can see that all these important parameters of the wire points which are found in
the flats of put a carding machines. After discussing the flat wire points, we will now
move to cylinder and doffer clothing, what is special about cylinder clothing?

(Refer Slide Time: 21:50)

Now, these wire points should be designed in such a way so that there is lesser tendency
to load by fibres. So, the height is the angle and the thickness all these have to be
designed in such way that the cylinder wire points should not get loaded by fibres. The
fibres should not get lost in between these spaces of the teeth which are there on the
cylinder. There has to be high efficiency of fibre transferred from cylinder to doffer; this
point also we have to take care of.

And the last point is the longer life that is they should not get abraded too fast also or
they should not get bent easily. These are the important requirements of the cylinder
clothing, the other thing is easy transfer of fibres from cylinder to doffer; since fibres
remains on the teeth surface. The way the clothing is designed we will see that the fibre
transfers become easy from cylinder to doffer. Because most of the time the fibres will
remain on the surface of the teeth.

There were lesser tendency to get loaded with fibres also and we need infrequent
grinding the way we choose the material part of the wires; that they will not get blunt to
fast and it must have a longer life as has been told earlier. So, these are the important
points that we have to remember.
(Refer Slide Time: 24:25)

Keeping in mind these requirements; the cylinder clothing is all metallic in nature and
there rigid also. So, they are not flexible like we have seen in the case of flats.

(Refer Slide Time: 24:44)

Now, what are the clothing parameters; a typical teeth is shown in the diagram and there
are so many parameters geometrical parameters which will define the complete geometry
of the teeth that we have on cylinder or doffer; geometrically there very very similar to
each other.
So, what are the parameters? There is a base width a 1, there is a tooth thickness a 2;
tooth thickness at the tip a 3, overall height is h 1 height of the base is h 2, depth of the
tooth is h 3, tooth pitch shown here is small t, carding angle is this angle which is alpha
and wedge angle that is this angle which is gamma thus they. So, many parameters are
there which will actually define the tooth geometry of cylinder or doffer wire points.

(Refer Slide Time: 25:59)

Now if we try to see the geometry carefully, then we can establish relationship between
the geometrical parameters of tooth. So, in the diagram a simple profile is shown with
the necessary parameters; like here is the profile of the tooth.

And we have a carding angle alpha, then back angle called beta, wedge angle which is
gamma, depth of the tooth is h and the pitch is t. Now, if we see this diagram and then we
can establish the following relationship first of all tan alpha is d by h; hence d is h tan
alpha, tan beta is h by d plus t. And the summation of alpha, beta and gamma is 90
degree because if this is angle beta; then this angle is also going to be beta and therefore,
sum up alpha, gamma and beta is always going to be 90 degree.

So, alpha, beta, gamma are actually bound together and the sum of them has to be 90. So,
from here if we try to find out what is the pitch t; then we can write that t is h by tan beta
minus d. Or if we take the relationship put the value of d from equation l; then we can
write t is h cot beta minus tan alpha where h is the common. So, this is how the angles,
the pitch and the height of a tooth are connected together. And these simple equations
can help us to understand that if we want to change point density, what if we want to
change some other parameter what will happen to the other parameters?

(Refer Slide Time: 28:29)

A reduction in pitch t, if we want to have more teeth per unit length of the wire. So, that
we want to increase the point density that is number of points per unit area; then this
would been a decrease in h, height has to go down immediately.

While alpha and beta remains unchanged that is if we want to keep the alpha unchanged;
beta also unchanged because alpha is going to affect the intensity of the carding process.
But without compromising alpha if we want to have more and more pins on the surface.
Then one way of doing this is to reduce t and while doing so, we have to reduce basically
h. That is I mean basically if I want to do this if I draw a line parallel to this the front
face has shown by this diagram then; obviously, the height is going to be here; so, height
h is going to go down.

Now, it will be less and; obviously, in this case the t has to t will go down. So, t will
reduce, but simultaneously height is also going to reduce. And the same point height is
also possible by increasing alpha or by decreasing beta that also is possible. Therefore, in
that case if you want to do not want to change the height; we have to keep it constant
then we have to play with alpha and beta.
(Refer Slide Time: 30:34)

Significance of the clothing parameters, let us say pitch a reduction in pitch t will
increase basically point density that is the purpose to play with t, but tooth height will
decrease as shown by the previous equations.

Points per squaring or the point density can be given by this simple equation it is 645 by
base width and pitch as shown in the equation. How the value 645 is coming? 645 is
nothing, but 2.54 into 2.54 into 100 or 254, 25.4, 25.4 that is 1 inch that is in centimeter
2.54; another inch in the cross directions and 1 inch in the length directions is this
centimeter.

And if we convert them into millimeter we have to multiplied by 100. So, if you do this
value will be 645 the 645 by the base divided by the base width multiplied by the pitch,
will give you the points per unit area where the unit is expressed by inch.
(Refer Slide Time: 32:16)

The carding angle alpha; this angle actually decides the intensity of the carding actions
and the transfer efficiency of fibres from cylinder to doffer.

The carding angle alpha and inclination angle beta the inclination angle this beta is
inclination of the back edge of the tooth is 90 degree minus carding angle. With lesser
carding angle or more inclination angle that if you reduce alpha; fibre transferred is
facilitated whereas, carding intensity will reduce. And if we go for lesser carding angle
then fibre transferred will be more from cylinder surface to doffer because the holding
power of the cylinder tooth on the fibres will be less. And hence they are transferred
from cylinder wire points or cylinder tooth to doffer tooth will be little easier.

The carding angle may be positive or negative or neutral that is 0 in depending upon the
situation, but generally it is not equal to 0.
(Refer Slide Time: 33:59)

Typically, the carding angle of cylindered and doffers are shown now in this table. This
cylinder it varies between 10 degree to 40 degree and doffer is varies between 20 degree
to 40 degree; it is not minus 40, this is plus 40.

Sometimes we go for negative angle, but this negative angle is chosen in the case of
licker in tooth. Because when we need to process synthetic fibres, then we want to go for
negative angle because in that case the licker in we will facilitate transport of fibres from
licker in teeth to the cylinder easily; synthetic fibres are generally long and their friction
in the teeth is also much more in comparison to what we find in the case of cotton.
Therefore, to facilitate they are transferred from licker in to cylinder we go for negative
rake angle of the licker in teeth.

At the same time, the negative rake angles will also help in reducing the stress level on
the fibres; that also especially when the fibres has too weak or very fine then also we
may go for negative break angle. But generally the negative rake angle we go for
synthetic fibres and that too only for licker in not for cylinder and doffer. A lesser carding
angle facilitates ejection of trash that is the advantage we may get that the trash particles
can easily escaped from the teeth towards the flat wire points when the angle is less.

The other important point is with higher carding angle; a smaller flat surface at that tooth
tip is created for same depth of grinding and hence it impairs carding capacity. Now this
point we have to going to study now key what is the role of carding angle in creations
small flat surface at the tooth tip while we are grinding our teeth.

(Refer Slide Time: 36:52)

See the teeth of the cylinder and doffer needs to be sharpened time to time. So, there is
interval of sharpening actions with possessing of fibres over a certain period of time the
teeth will get abraded.

So, we need to then grind it and in the grinding process there is a little reduction in
height. We will see that and that reduction will lead to what that question comes to the
mind; let us look at this diagram and try to understand what happens when you go for
grinding actions. You see that; we will come to that point little later it has passed now
discuss the height h and its role.

Height has a strong influence, height of the tooth on carding intensity and transfer
efficiency in the case of cylinder clothing. Lesser the height more difficult it becomes for
the fibres to escape carding action; this point is important. Because whenever the forces
are acting on the fibres; fibres will have a tendency to move towards the base and if there
are sufficient space available they will go and settle there. So this possibilities can be
reduced; if we do not allow space to be there and hence lesser the height, lesser will be
the space. And therefore, the proportion of fibres which will remain near the tip of the
wire point will be more; if the tooth height is reduced.
Therefore, with shorter tooth height intensity of the carding action will be much more
intensive. Because whatever fibres are held by particular tooth; most of it will be
exposed to carding action. And will little part of those fibres held by particular tooth will
be towards the base and will escape carding actions. Short tooth will also facilitate
transfer of fibres to doffer, there is another important thing that it can facilitate because
most of the fibres would remain on the top of the tooth or pins.

The other important thing is height will also influence the point density which was
discussed earlier that if you want to increase point density we have to reduce the height.

(Refer Slide Time: 39:50)

Overall height of the cylindered and doffer another parameters of the tooths are shown
here. What we find we compare these parameters between cylinder and doffer. Then we
see that height for the doffer wires are generally more than the cylinders. This is one
important differences; the other differences we have seen in the we will see that in the
case of point density it is also there is a difference cylinder arc point density will be
much more in compression to doffer.

Doffer teeths are generally longer than cylinder since doffer has to carry must thicker
fibre layer on its surface. This point is to be noted that the fibres which are transfer to
doaffer; these fibres have to be retained by the doffer. And therefore, the height of the
teeth on doffer surface is generally much more than the cylinder. Because they have to
hold and retain lot of fibres to create and wave that we ultimately when we strip the
doffer you find a wave, but a wave consists of large number of fibres in the cross section.

Further, it has to allow the air current generated by the cylinder to escape through the
teeth. So, as to facilitate fibre transfer and to improve their orientation on the doffer that
is another reason why the dropper tooth has to be little longer than the cylinder tooth.
That is we have to allow air current to pass through and this will also help in transferring
fibres from cylinder surface to doffer surface; that means, that the transfer process is both
mechanical in nature that is physical transfer because of the interaction of the teeth of
cylinder and doffer on the fibres it is also aided by the air current which will generated.
The other important point or parameter is the base width.

(Refer Slide Time: 42:28)

Now, base width mainly influences basic point density; lesser the width more points can
be accommodated across the width of the cylinder and doffer and correspondingly point
density will increase. If we look at this the equation that we have shown it earlier, you
see the points per square inch, the denominator we have base width and also pitch. So,
the base width is reduced; point density is going to increase. Then we will be able to
accommodate more wires per unit length across the width of the cylinder.

And hence when you want to increase point density; we also reduce the base width of the
individual wire points. Generally the base width is 0.65 per cylinder and 0.70 to 0.94
doffer, but it may vary from manufacturer to manufacturers. If we go to the literature the
different manufacturers of the carding wires then we will find that there is little
differences are there between manufacture to manufacturers; on an average we can say a
typical values at 0.65 for cylinder and 0.70 to 0.9 for doffer.

For high production card it has been reduced to point 5 mm because we have to
accommodate more teeths per unit area. When the production rate is very high we have
to tackle large number of fibres per unit time. So, when you have to tackle more fibres
per unit time; this cylinder surface remains still same. There is a limit to the increase of
speed of the cylinder; so therefore, what we do at we want to increase the point density
on the cylinder surface. And that is what can be done by reducing the base width of the
wire on which the teeths are cut.

(Refer Slide Time: 44:52)

So, point density if we see now point density is basically number of teeth per unit area
this also we have discussed earlier. It has a mark influence on carding intensity; however,
point density and speed needs to be considered together. This point is important here that
point density and speed needs to be considered together.

It is the number of wire points available per unit time which is really important. The
combination of low speed with high point density or high speed with low point density
may be expected to give same results. So, depending upon the attainable speed by the
cylinder on a given machine; we have to decide what should be the point density there.
And accordingly we have to choose the wire point because point density and speed has to
be taken together.

(Refer Slide Time: 46:03)

Various alternatives to increase point density; alternative way already discussed, but I am
going to repeat it again to make the things clear. A reduction in pitch would associate a
decrease in h that is height while alpha and beta remains unchanged. This is one way of
changing point density that will reduce the pitch; as well as height together without
compromising on angle, alpha, beta, gamma angles will remain same.

The other alternative is to increase angle alpha or decrease beta; keeping point height
same if we do not want to compromise on height, we want to retain the same height then
we can change or play with alpha beta this alpha and this is beta. These 2 also we can
play that will also change the pitch and thereby point density also. So, point density wise
if we compare the 2 surfaces of cylinder and dropper; then we find that point density on
cylinder for cotton it can vary between 240 to 1000 doffer; it is 380 to 440.

So, we see that on the doffer the points are much less for synthetics on cylinder; it is
typically 400 to 450 and for the doffered it is 350 to 520. This is how the point densities
are chosen when exact values may vary from manufacturer to manufacturers. And
depending upon the will also depends upon the type of fibres were going to process
whether cotton or synthetic if cotton was is a trash cotton or not. So, all those points
needs to be taken into account while deciding the exact value of point density on cylinder
or doffer. Now, this point which we I told you earlier that this will take up later.

(Refer Slide Time: 48:26)

Now, let us go to let us look into this point relationship between grinding depth, carding
angle, wedge angle and length of flat surface.

A geometry of a typical truth is shown here and x is the grinding depth, when you grind
the surface of the teeth of cylinder let us say there is going to be a reduction in the height
also. If we take a simple case where one typical tooth is shown; x is the grinding depth, l
is the length of the land. So, if we grind it as we grind this will be the top surface of the
teeth will look like flat. To begin the ostrich is flat; it is not shown here it is not really a
pointed tip, actually it is also flat at the top, but if we grind it this flat surface is going to
be flattened more and more.

So, let us look at this to understand what is; this is point A, this is point B, this is point C
and AC is x tan alpha plus gamma; BC is x tan alpha. So, what is l? L is basically length
of the land. So, l is AC l is basically AB; that means, AC minus BC and therefore, if we
put the values of AC and BC, you get this; is a function of grinding depth x and function
of alpha and gamma. That is this angle alpha is carding angle and the wedge angle
gamma these 2 are important in this particular case.
If the carding angle alpha is increased keeping beta same; we have to read it carefully
then angle gamma has to decrease so that alpha plus gamma remains same to the earlier
value. If we angle alpha if we increase; then gamma has to decrease; obviously, it has to
decrease, but total summation of alpha plus gamma will remain same.

Therefore, tan alpha plus gamma is not going to change because summation of alpha plus
gamma will not going to change. But tan alpha value is going to increase as will increase
alpha; that means, if we look at this equation l; then as we increase alpha, this part is
going to be more whether this part is not going to change; x is going to increase as we go
for more and more grinding depth. So, what will happen? The total value is going to
increase, l is going to increase as we go for more and more grinding.

Hence for the same grinding depth even if we keep x same and compared between 2
teeth in case of one tooth having what value of alpha and another tooth having a greater
value of alpha; then we will find that for the same grinding depth increase in alpha there
is the tooth having higher value of alpha will reduces the length of the flat surface. L will
reduce a reduction in flat surface will reduce carding capacity; that is the you know
situation that we will get. And this is how the length of this land is connected to grinding
depth and the 2 important card tooth parameters which is alpha and gamma.

(Refer Slide Time: 53:05)

Distribution of cylinder and doffer wire points as they look like; so here an impression of
the wire points was taken on a piece of paper, that the piece of paper was pressed against
the doffer surface and against the cylinder surface.

And this is the distribution of the wire point that we see here is very important to ensure
that the chance do not form between the successive rows of wire points along the length
directions. That is we must not form channels the way the points would be finally,
distributed that there should not be a predominant line; where we do not find any wire
point that we have to avoid. If it is there; if we find its channels where no wire point exist
and the fibres will go and settle there. And these fibres will keep epilating and at some
point of point, they will be released and they will move as a cluster and they will go to
this fibre as well without getting properly open.

Therefore it is a constant no effort by the machine manufactures; especially the card wire
manufacturers to ensure that channels are not formed on the surface of the doffer or
cylinder. So distribution of the tips of the tips are very important.

(Refer Slide Time: 54:49)

Tooth leading edge as I told you the tip of the tooth is not really point, but there is a little
land as soon here. The leading edge of the cylinder tooth is extremely important for
efficient carding and nep removal. It should be straight and sharp; look at this land it is
straight and this here it is very very sharp.
The area below the leading edge are less importance here this areas are less important.
The land area gives support to the leading edge and provides the essential datum to allow
a worn leading edge to be corrected through grinding actions. The land area should be
small as it keeps on increasing with every grinding operations as we discussed earlier. As
we grind we go from this side to this side of an with land area will increase.

A large land area reduces the ability of the tooth to penetrate into the tufts and his is
relative power will decrease. And there could there is a limit to which we can go for
grinding and once we reach that limit; we say that the this particular wire points cannot
be used and we have to recloth the carding cylinder or doffer.

(Refer Slide Time: 56:16)

Tooth base 3 types of bases are can be seen; normal, locked and chained. As shown here
if you look at the bases this is the base, these are the bases, these are the bases. The tooth
base is slightly broader than the tooth point this is necessary to address the number of
wire points in the crosswise directions and provide adequate strength needed for winding
the wire under tensions. See these wire points are basically cut on a as already discussed
is cut on a thin strip.

And the strip is then wound on the cylinder, on the doffer, on the licker in. And therefore,
it has to bend it should have little flexibility; at the same time this would get lodged to
each other somehow this should be locked to each other. And therefore, strength is also
required since they have to be wound under tension. And hence the bottom part of the
tooth has to be little wider; normal profile for licker in and cylinder can be wound by
forcing it into the groove, cut into the surface of licker in or cylinder. That is we cut
grooves on the cylinder and then we lost these wires into those grooves and when we are
winding it winding under tension.

(Refer Slide Time: 58:01)

Preopening bars or carding segments; so, these segments also will have lot of teeths,
tooth points of these segments are designed in such a way that they do not need any
cleaning. The way they are designed the tufts and the trash particles hardly adhere to it;
here the angles are chosen in such a way that nothing is going to be retained by those
segments; it typical no.

Tooth densities are shown here for preopening bar and for carding segments. Depending
upon type of cotton you see find cottons more coarse cotton less find means more fibres;
they are finer in nature; we need more wire points per unit area this is very very obvious.
(Refer Slide Time: 58:45)

Now, some facts remember before we wind up coarser fibres are easy to individualize
and therefore, needs fewer points than finer fibres. That is there point density could be
little less; for a given fibre high point density gives better results up to a certain point
density level, beyond which the effect may be just opposite.

This is due to the fact that fibres get so tightly packed into the cylinder clothing the
transfer to doffer becomes difficult; resulting no further individualization of fibres. For
cotton a high point density not concomitant to the level of trash present may cause the
teeth to be loaded with particles in short time instead of releasing them to the flats.

So, we have to be very careful in choosing the point density; while processing cotton
fibres, we have to remembered what is the level of trash in the cotton and accordingly
you have to decide the point density.
(Refer Slide Time: 60:13)

The other points are for doffer; a long tooth with acute angle is preferred since it ensures
effective removal of fibre from the cylinder. Too acute angle makes the fibre transfer so
efficient the recycling of fibres or cylinder that is doubling effect is reduced resulting
short term irregularity present in feed material to pass to the carded web showing
patchiness or sliver unevenness; nep content in the sliver is also likely to be less.

Now, the angle is too acute in the case of doffer; fibre transfer will be faster as a result
send load will go down. So, nep content will be less, but the negative aspect is doubling
effect or recycling effect of the fibre layers; on the cylinder is going to be less. On the
contrary higher angle of the teeth reduces transfer of fibres on it; which will cause fibre
load on cylinder to increase and therefore, nep generations; hence actual angle is it
compromise between these 2 and that is all.

Thank you.