Guideline for writing a Lab Report

Title page:

A title page needs to contain the name of the experiment, course code and title, and the date. Titles
should be straightforward and informative.

Introduction:

A good introduction provides the reader with background to the experiment. State the topic of your
report clearly and concisely.

Objectives:

Purpose of the experiment.

Experimental setup/ Figure:

Figures must be labeled with a descriptive title.

Experimental procedure / Working procedure :

Describes the process in chronological order. Using clear paragraph structure, explain all steps in
the order they actually happened, not as they were supposed to happen.

Conclusion:

Conclusion can be very short in most cases. Simply state what you know now for sure, as a result
of the lab.

References:

References include your lab manual and any outside reading you have done.
Experiment No: 01
Experiment Name: Study on Layout Plan of spinning Lab with machine
specification.

Introduction:

Layout planning is deciding on the best physical arrangement of all resources that consume space
within a facility. This arrangement includes the space needed for arrangement of machines,
processing equipment of machines, processing equipment, material movement storage, labors and
all supporting activities. It helps to promote the efficient use of equipment, material, people and
energy. A good plant layout for spinning laboratory is directly associated with good work flow.
According to James Lundy, “layout identically involves the allocation of space and the
arrangement of equipment in such a manner that overall operating cost is minimized. In the
spinning laboratory, we can define this layout plan by which we categorize different
spinning machines into a specific area is called a spinning layout plan.

Objective:
1. To know about the overall arrangement of spinning lab.
2. To know the machine and their technical specification.
3. To know about their function.
4. To know about the special purpose of different machine.
5. To know about the process sequence of spinning.
Layout Plan of Spinning Lab:

W E

S
Machine Specification:

Machine-01
Machine Name: Conventional Bale Opening
Manufacturer: Qingdo Ji Mart Machinery Manufacturing Co. Ltd.
Model: JM850K
Country of Origin: China
Output: Chute/Mat

Function: Opening and cleaning, mixing and blending of fiber.

Machine-02
Machine Name: Digital Carding Machine
Manufacturer: Qingdao Ji Mart Machinery Manufacturing Co. Ltd.
Model: JM950M
Country of origin: China
Input: Chute/Mat
Output: Carded Sliver

Function: Fiber individualization, neps removal and sliver making.

Machine-03
Machine Name: Drawing Frame Machine
Manufacturer: Qingdao Ji Mart Machinery Manufacturing Co. Ltd.
Model: JM301-B
Country of origin: China
Input: Carded Sliver
Output: Drawn Sliver

Function: Fiber parallelization, drafting and doubling the sliver.

Machine-04:
Machine Name: Roving Frame/ Simplex Machine
No. of spindle: 04
Manufacturer: Qingdao Ji Mart Machinery Manufacturing Co. Ltd.
Model: JM401
Country of origin: China
Input: Drawn Sliver
Output: Roving
Function: Drafting and Roving Package making

Machine-05
Machine Name: Ring Spinning Machine
No. of spindle: 06
Manufacturer: Qingdao Ji Mart Machinery Manufacturing Co. Ltd.
Model: JM501
Country of origin: China
Input: Roving
Output: Yarn
Function: Drafting, twisting and yarn making.

Machine-06
Machine Name: Precision Package Winding
No. of Drum: 06
Manufacturer: SSM (ScharerschweiterMettler AG)
Model: XENO-BW/BD
Country of origin: Switzerland
Input: Yarn Package
Output: Re-cone yarn package (Hard/soft)
Function: Soft and hard re-cone/ cone package making.

Machine-07
Machine Name: Carding Machine
Manufacturer: Trytex Machinery Company Limited
Country of origin: India
Input: Chute
Output: Carded Sliver
Function: Fiber individualization, neps removal and sliver making.
Experiment No: 02
Experiment Name: Study on material passage diagram of conventional
bale opener machine.

Introduction:

Bale Opener Machine is the first major machine in blowroom line for short staple spinning.
Bale opener consists of several opening and cleaning device which is suitable for
processing various kind of cotton fiber where fiber opening, slightly cleaning, blending
and mixing and then cotton is transported to next machine for additional process.
Bales of natural or synthetic staple fibres are opened manually & then feed to it. The
opening line normally includes bale opener, fibre flock cleaners, mixers and fine openers.
Depending on the fibre material type and quantity of production, machines can be added
or removed from the processing sequence for the short staple spinning. The aim of this is
to provide an appropriate fibre opening line for the opening of fibres that can then be further
used for the manufacture of mechanical and aerodynamic formed nonwovens.

Objective:

i. To open the tuft of cotton.

ii. To mix & blend the fiber.
iii. To remove a considerable amount of trash from fiber that is taken out by
suction duct.
iv. To act as a reserve box for the next machine.

Action of Bale Opener Machine:

1. Regulating motion
2. Air suctioning
3. Beating action
4. Spiked lattice action

Main Parts:
 Feed lattice
 Bottom lattice
 Spiked lattice
 Wiper roller
 Evener roller
 Breaker roller
 Grid bar
 Material Passage Diagram:

Output ( Lap/Chute )
Input (Fiber in bale form)

7
2
3 8
4
6 9
1 3
5 9

For Fig-01

1--> Feed Lattice 6--> Spike Lattice

2--> Feed Roller
7--> Evener Roller
3--> Opening Roller
8 --> Take-up Roller
4--> Beater
5--> Bottom Lattice 9--> Delivery Roller

Working Principles of Bale Opener Machine:

• Bale opening is done in blowroom section which is 1st and essential
process of yarn production.
• In this step compressed bales are opened manually. Cotton fibers are
opened and partly cleaned by several actions of bale opener machine.
• In blowroom bale or opened fiber are arranged according to qualities of
cotton fiber to meet up the customer’s requirement or required quality of
yarn it’s called bale management.
 • In opening section 1st compressed fiber or bale fiber get into feed lattice to
feed roller where fiber start to opening.
• After feed roller it goes to opening roller then beater beat the fiber for
opening and cleaning dust and trash.
• Bottom lattice receive the open fiber then it send to spike lattice.
• After then evener roller receive clean fiber and make even chute or lap for
next machine.
• Take-up roller receive chute or lap and send it to delivery roller where chute
or lap are delivered as a output of a blowroom.

Remarks of Bale opener Machine:

1. It’s essential process for produce yarn from textile fiber.
2. It dose lots of process in one section.
3. It can remove a considerable amount of trash from fiber. So that good amount of yarn
can be produce.
Experiment No: 03
Experiment Name: Study on different types of actions and settings
parameter involved in Blow room.
Introduction:

In spinning, blowroom is the first machine where fiber in bale form is to be fed, blowroom
is not a single machine. Several types of opening and cleaning machine are involved. In
blowroom some settings point are to be maintained depending on fiber quality. Too
excessive beater speed or roller speed will cause fiber damage or produce excessive neps
in fiber. This will lead to sliver, roving or yarn breakage in subsequent process, so, quality
personnel have to be cautious about settings of different machineries of blowroom.
Objects:

 To optimize settings parameter considering fiber quality and machine

condition;

 To know the controlling points of different machineries in blowroom.

 To implement the work practice for quality and production personnel in
spinning.

Action Involved in Blow-Room:

i) Action of Opposing Spikes-

i) Action of Air
Current-
ii) Action of Beater
And Lattice-

iii) Regulating
Action :
Functions of Blowroom

1. Opening the compressed bales of fiber and making the cotton tuft a small size as
far as possible.
2. Detecting the metal objects and fire in fiber
3. Cleaning the fiber by removing the dust, dirt, broken seeds and other foreign
materials from the fibers.
4. Mixing and blending of different classes or grades of fibers 5. Removing foreign
fibers and plastic contaminations
6. Uniform feeding to the next stage.
1

Experiment No.:04
Experiment Name: Study on Material Passage Diagram of Pre-cleaner
(Uniclean).
 Uniclean
2
 Working Principle
3

 The material is fed to the uniclean B11 and passed mechanically seven times over
the cleaning grid on special pins.
 In the process the raw material is guided over the integrated dedusting filter, where
dust , fibre fragments and pepper trash are stripped off mechanically.
 The cleaning process takes place undisturbed by air currents and thus in a controlled
and effective manner.
The trash removed drops into the waste chamber and is fed to the waste removed
system by an airlock cylinder.
4

Experiment No.:05
Experiment Name: Study on Material Passage Diagram of Mixing Machine
(Integrated multimixer MX-I)
 Integrated multimixer MX-I
5
 Working Principle
6

1. The fan is located directly on the mixer

2. The feed funnel distributes the material over the width of the feed duct
3. The rotating flaps release one trunk at a time for filling
4. The large-size mixing chambers
5. The feed duct distributes the material into the chambers
6. Light barriers monitor the filling status of the various chambers
7. The exhaust air is fed to the filter installation via the exhaust air funnel
8. The perforated plates separate the chambers and ensure a turbulence-free deposit of the tufts
in the chambers
9. The delivery rolls empty the chambers
10.The opening rolls produce small tufts
11.A sandwich-type web is formed on the mixing conveyor belt
12.The mixing duct receives tufts from all chambers at the same time
13.The material transport belt supplies the tuft web to the feed rolls of the cleaner
14.The material suction funnel collects all tufts over the working width of the machine
15.The CLEANOMAT Cleaner CL-C 4 is directly coupled to the mixer
7

Experiment No.:06
Experiment Name: Study on Material Passage Diagram of Fine cleaner (uniflex)
 Uniflex
8
 Working principle
9

 A fan draws the tufts by suction from the preceding machine and a distribution
element ejects them into a filling chute(1).
 The rear wall of the chute consists of individual aluminum lamellae with slot
openings through which the air can escape (first dedusting step) .
 Thus a very homogeneous batting laydown is formed both lengthwise and crosswise.
The adjustable chute depth determines the lap weight required depending on
production and type of fibre .
 The material is carried further by perforated drum (2) ( second dedusting step) and a
plain drum. The machine is equipped with automatic lap intake. Thus no manual
intervention is needed when starting up the fine cleaner. This distance between feed
trough (3) and opening cylinder is adapted by the programming to the material being
processed.
 Working principle
10

 The feed roll supplies the material to the opening cylinder, which is available in
different versions depending on the requirements of the material, takes over the
material.
 Using varioset, the spinner can set the rotation speed of the opening cylinder
according to his objectives and raw material.
 A grid (4) made of carding segments and knives forms the cleaning surface and
extracts impurities.
11

Experiment No.:07
Experiment Name: Study on Material Passage Diagram of Multi Function
separator SP-MF.
 Multifunction separator
12

The Multi Function Separator SP MF, positioned directly after the Automatic Bale
Opener BLENDOMAT BO-A, all relevant protective functions are realised, including
the first dedusting.
In the multifunction separator the followings functions are accomplished. .
• Suction of the BLENDOMAT BO-A
• Heavy part separation
• Dedusting
• Fire protection
• Metal separation
• Waste re-feeding
The Multi Function machine is designed for production rates up to 2,000 kg/hr. An
integrated micro-computer control system controls all functions.
 Multifunction separator
13
 Principle of the Multi Function Separator Sp-MF
14

 The material is sucked off from an Automatic Bale Opener BLENDOMAT BO-A(I)
The automatic control of the fan (2) ensures that the air volume is uniform .
 A guiding profile(3) has been developed for the aerodynamic heavy part separator
The spark sensor (4) detects burning material The dusty air (5) is separated out in the
air separator.
 The metal detector (6) detects all types of metals. The extraction flap (7) does not
work with pre-tensioned springs, but is actively opened and closed.
 The next machine, generally a fan(8) in front of the mixer, sucks the material off.
 A flap (9) conveys the separated heavy parts into the wheeled waste container.
 The two wheeled waste containers (10) are large in size' Burning material (11)
in the wheeled waste containers is extinguished by the fire extinguishing unit.
 Principle of the Multi Function Separator Sp MF
15

 A heat sensor (12) monitors the passed waste container for fire.
 The dusty exhaust air is feed to a filter installation.
 Opened waste (14) from the Waste Opener BO-R can be fed back in without an
additional fan.
1

Experiment No.:08
Experiment Name: Study on Material Passage Diagram of Foreign Part
Separator (SECUROPROP SP-FP).
 SECUROPROP SP-FP(Trutzschler)
2
 SECUROPROP SP-FP(Trutzschler)
3

It is possible to clearly detect and reliably separate out white and transparent particles
such as PP or foil as well. Precisely this advantage is by Foreign Part Separator
SECUROPROP SP-FP.

Operation :
1. The dedusting unit is housed in the upper part
2. The large 1,600 mm wide sieve provides a large dedusting surface
3. The disribution flaps distribute the material over the working width
4. The released dust is permanently sucked off
5. The opening roll with fine needles is coated in cotton color
 SECUROPROP SP-FP(Trutzschler)
4

6. Four neon lamps provide uniform lighting over the whole width
7. special cameras permanently scan the roll surface
8 & 9.The 32 nozzles specifically separate the foreign parts out and
divert them into the suction system
10. Illumination unit with polarised light
11.Special cameras for detecting light and transparent parts
12.64 x 3 nozzles selective separate detected foreign parts out.
13.Bucket wheel lock for diverting foreign parts to the suction air flow
14.The dusty exhaust air is used to transport the separated parts away
Experiment No: 09
Experiment Name: Study on material passage of a carding machine.

Introduction:

The Word carding had been taken from Latin word “Cardious” which mean thistle or teasel. In
history people use these kinds of items in wool yarn making. Carding is the 2nd process of cotton
spinning that comes after blow room. This is the method of disentangling. Cleaning and
intermixing is done in carding to make a continuous web/strand name as ‘Sliver’. The carding
machine is located in the spinning process between the blow room and the drawing frame. It cleans
and individualizes the fibers. The resulting card web is then formed into a sliver and placed into a
can.

Objectives of Carding M/C:

I) To know about different parts of carding machine.

II) To know about mechanism of carding machine.

III) Drawing a simple material passage diagram of carding machine.

IV) Make a short report about carding machine.

Material Passages diagram:

Main Parts Of Carding M/C:

 Feed table
 Feed roller
 Taker in
 Taker in under casing
 Cylinder
 Flat Bar
 Flat Cleaner
 Doffer
 Doffer comb
 Trumpet
 Calender Roller
 Sliver Guide
  Coiler trumpet
 Coiler Roller
 Sliver Tube
 Sliver can
 Sliver can Plate

Working Principle of carding machine:

1. Supplying raw material.(Chute)

2. Transport roller forward the material to feed plate.
3. Taker in opens the material to small flocks. When the material passes to main
cylinder grid bars and carding segment eliminate a great parts of impurities.
4. Grids Equipment & Suction duct carry away the waste and dust.
5. Main cylinder and fixed carding segments designed to assists the carding
operation.
6. The main carding operation occurs between flats and cylinder.
7. Cleaning unit cleans stripes fibres, naps and foreign matters from flats.
8. The doffer combines the fibres into a web/Sliver.
9. Calendar roller calendars the cotton and moves that toward.
10. At last by can and coiler the sliver is produced
Experiment No: 10
Experiment Name: Study on different types of actions involved in a carding
machine.

Introduction:
If two close surfaces have opposite wire direction & their speed direction or relative motion also
is opposite, then the action between two surfaces is known as carding action. Carding action is
occurred between flat & cylinder. Here pin direction & rotational direction both are opposite.

Objectives:
1. Maximum individualization of fibres is achieved in this region by opposite spikes.
2. Neps, short fibres, dirt & dust are removed.
3. The difference of surface speed cylinder & flat is more. So in carding actions maximum
fiber get individualized.

Different Actions:
Stripping action: When two close surfaces have same wire direction but their speed direction
is opposite to each other, then the action between two surfaces is called stripping action.
Opening and cleaning of fibers is done by this action.
1. Action between taker in and cylinder
2. Wire direction same
3. Speed direction opposite
Carding action: If two closed surfaces have opposite wire direction and their speed direction
is also opposite to each other, then the action between two surfaces is known as carding action.
Opening to individual fibers and neps removal is done by this action.
1. Action between cylinder and flat
2. Wire direction opposite
3. Speed direction opposite

Doffing action: when two close surfaces have opposite wire direction and their speed
direction is also opposite to each other, then the action between two surfaces is known as
doffing action. Web formation of fibers is done by this action.

4. Action between Cylinder and doffer

5. Wire direction opposite
6. Speed direction opposite
7. Face to face arrangement
Advantage of Carding Action:

1. improved dirt and dust elimination;

2. improved untangling of neps;
3. the possibility of a speed increase and hence a production increase;
4. preservation of the clothing; and hence
5. longer life of the clothing, especially on the flats;
6. the possibility of using finer clothing;
7. better yarn quality;
8. Less damage to the clothing;
9. Cleaner clothing.
Experiment No: 11
Experiment Name: Study on different types of card clothing used in carding
machine & specification of a card clothing.

Introduction:
The pin or the inclined wire which is used to cover the surface of carding roller such as taker
in, cylinder, doffer and are of fine in diameter, spaced closely and bended in shape is defined
as card clothing.

Objective:
o To open the tuft of fibers
o To make the fiber parallel & straight
o To remove remaining trash particles
o To remove short fibers
o To remove naps
o To produce a rove like fiber called
silver, which is uniform in per unit
length

Classification:
o Flexible card clothing
o Semi-rigid card clothing
o Metallic card clothing

I . Flexible card clothing:

Flexible clothing have hooks of round or oval wire set into elastic, multi-ply cloth
backing. Each hook is bent into a U-shape and is formed with a knee that flexes under
bending load and returns to its original position when the load is removed.

Advantages of flexible card clothing:

o Higher point density so better carding action.

o Fiber damage is less due to flexible wire point.
o Only the damaged part of the clothing is needed to be
repaired.
o Exerts desirable force on cotton causing good carding.
o Less expensive.

Disadvantages of flexible clothing:

o Requires textile fabric or rubber as foundation

material.
 o The wires can be loosened.
o Production less due to stripping.
o Need regular grinding.
o Wire and foundation maybe damaged as both wire and
foundation are flexible.

II. Metallic clothing:

These are continuous, self-supporting, square wire structures in which teeth are cut at the
smallest possible spacing’s by a process resembling a punching operation.

Advantages of metallic card clothing

o Does not require separate foundation material. The metal surface of the machine works as foundation
material.
o The teeth do not get loose as teeth and foundation both are metallic rigid.
o Can choose any carding angle
o Does not require regular grinding
o Production increases as regular grinding and stripping is not performed.
Disadvantages of metallic card clothing
o Fiber damage is more as the wire points are metallic

o Difficult to repair in the mill when a portion of it is worn out

o If any part of the wire is damaged, then the total clothing is rewind. O

o Expensive

III. Semi-rigid clothing:

Semi-rigid clothing have wires with square or round cross-sections and sharp points are
set in backing which is less elastic than that of flexible clothing. This backing is a multi-
ply structure with more plies than the backing of flexible clothing, comprising layers of
both cloth and plastics.

A dvantages of semi-rigid clothing:

o Does not choke with fiber
o Eliminate less flat stripping
o Does not need sharpening
Specification:

S L. NO N AME S YMBOL C OMMENTS

i. Base width. a1 in mm

ii. Tooth thickness at the a2 in mm

root.

iii. Tooth thickness at the a3 in mm

tip.

iv. Overall height h1 in mm

v. Height of the base h2 in mm

vi. Depth of the tooth h3 in mm

vii. Tooth pitch T Spacing between

successive tooth
points measured with
the wire stretched out

viii. Carding angle α Angle between a line

normal to the base of
the tooth and the
leading edge of the
tooth, measured with
the wire stretched out

ix. Tooth apex angle β Angle between the

leading and trailing
edges of the tooth

x. Points Per Square ɸ Pin / tooth density

Inch (PPSI)
Experiment No.: 12
Experiment name: Study on different settings involved in carding and
measuring those settings by using leaf gauge.

Introduction:
Carding is the most important process in spinning. It contributes a lot to the
yarn quality. The following process parameters and specifications are to be selected
properly to produce a good quality yarn with a lower manufacturing cost cylinder
wire (wire angle, height, thickness and population) flat tops specification licker-in
wire specification doffer wire specification feed weight draft between feed roller and
doffer cylinder grinding doffer grinding flat tops grinding cylinder, flat tops, doffer
wire life Licker-in wire life Cylinder speed flat speed licker-in speed setting between
cylinder and flat tops setting between licker-in and feed plate setting between licker-
in and under casing elements like, mote knife, combing segment etc. setting between
cylinder and doffer setting between cylinder and back stationary flats setting between
cylinder and front stationary flats setting between cylinder and cylinder under casing.

Figure: Carding machine

Objectives:
1. To know about different settings of a carding machine.
2. To know about how to measure the settings of a carding machine.
3. To know about application of leaf gauge.
4. To know about carding actions.

Settings:

o The setting between cylinder and doffer is the closest setting in the card. This
setting mainly depends upon the cylinder speed, hank of the delivered sliver and
the type of wire. Cylinder speed up to 360, the setting should be 0.1mm. For
cylinder speeds more than 450, the setting ranges from 0.125 to 0.15.

o Closer the setting between cylinder and flats, better the yarn quality. Neps are
directly affected by this setting. Of course, very close setting increases the flat
waste. For processing cotton the setting can be 0.25, 0.2, 0.2, 0.2, 0.2mm. For
synthetic fibers it can be 0.3, 0.25, 0.25, 0.25, 0.25mm

o The setting between feed plate and Licker-in depends upon the type of feed
plate. Conventional feed plate setting is decided mainly by the feed weight
and to some extent by the fiber length and type. With the latest feed plate and
feed roller arrangements, the setting is decided mainly by the fiber length and
to some extent by the feed weight.

o Normally the setting between the feed plate and Licker-in is around 0.45 to
0.7mm, depending upon the feed weight and fiber type.

o The setting between Licker-in and the first mote knife is around 0.35 to 0.5
mm. This helps to remove the heavier trash particles and dust. Closer the
setting, higher the wastage. The setting between Licker-in and combing
segments is around 0.45 to 0.6.

This helps to open the material.

o The setting between the cylinder and stationary flats at Doffer side helps to
transfer the fibers to doffer by stripping the fibers to the top of the cylinder
wire. This setting can be as close as 0.15mm. The number of wire points on
 stationary flats also plays a major role. It is normally around 300 to 400. For
a high production application, it can be as high as 600.

o For cotton processing, the stationary flats are fixed with a knife attachment.
The setting should be as close as possible, i.e. around 0.15mm. This helps to
remove the trash particles of very small size.

o The setting between cylinder and cylinder under casing should be as per the
manufacturer's recommendation. The design of under casing is different for
different manufacturers. This setting is very important, as wrong settings will
affect the fiber transfer and can also create air turbulence.

Major setting points in carding machine:

S/L Setting Points Distance (mm) Distance (Thou)

01 Feed plat to feed roller 0.10mm 4 thou

02 Feed roller to liker-in 0.25mm 10 thou
03 Liker-in under casing to liker-in 0.91mm 36 thou
04 Liker-in to cylinder 0.18mm 7 thou
05 Cylinder to cylinder under 10mm to 12mm 394 thou to 472 thou
casing at the starting point
06 Cylinder to cylinder under 12mm 472 thou
casing at the end point
07 Cylinder to flat 0.25mm 10 thou
08 Cylinder to doffer 0.18mm 7 thou
09 Doffer to striping roller 0.56mm 22 thou
Diagram: Leaf Gauge (7 leaf)
Experiment No.: 13
Experiment name: Study on Material Passages diagram of a modern
drawing frame machine.

Introduction:

Draw frame is a machine for combining and drawing slivers of a textile fiber (as of hemp for
rope manufacture or cotton for spinning). Drawing is the operation by which slivers are
blended, doubled and leveled. In short staple spinning the term is only applied to the process
after fiber opening, cleaning and individualizing.
It is a process of yarn manufacturing in which the sliver is elongated when passes through
pairs of rollers, each pair moving faster than the previous one .This permits combination of
several slivers. These slivers are drawn and elongated to straighten and create greater
uniformity. There are two types of draw frame
1. Draw frame -1/Pre-comb drawing/Breaker draw frame
2. Draw frame -2/Post-comb drawing/Finisher draw frame

Objectives of Draw Frame:

1. To straighten the fibres in the slivers.
2. To make them lie in a manner parallel to their neighbors and to the sliver axis.
3. To improve the uniformity or evenness of the slivers by drafting and doubling.
4. To remove dust from the sliver.
5. To make perfect blending of the component.
6. To reduce weight per unit length of sliver.
7. To blend raw materials of same husk perfectly.

Material Passages of Drawing Frame Machine:

Importance of Draw Frame:
To parallelization of fiber and blending the carded sliver, draw frame is needed. In carded sliver, fibers
are present in hook form i.e. trailing hooks and leading hooks. To parallel these hooks raw frame is
used.
Majority of the fiber hooks in a carded sliver are trailing hooks while leading hooks are comparatively
less. Trailing hooks are also known as major hooks, while leading hooks are known as minor hooks.

Function of draw-frame:
Several Carded Slivers are fed into the Draw-Frame and are stretched/straightened and made in to a
single sliver. Also fiber blending can be done at this stage. The cans that contain the sliver are placed
along the draw-frame feeder rack, usually including eight pairs of cylinders (each pair is above the space
occupied by a can), the lower cylinder is commanded positively, while the upper one rests on the lower
one in order to ensure movement of the relative sliver that runs between the two.

Working principle of draw-frame:

Four to eight card or draw frame slivers are fed to the drafting arrangement. A feed roller pair above
each can feeds the material without false drafts. The slivers runs into the drafting arrangement
subjected to a draft of 4 to 8 and leave it as a web and condensed into a sliver immediately. This sliver
is then guided through a tube via a passage of the tube gear into a can, in which it must be laid in clean
coils with optimal utilization of the space in the can by sliver compressing with passing it through
calendaring rollers.

Conclusion:
To parallelization of fiber and blending the carded sliver, draw frame is needed. So, we should learn
about this experiment very carefully and sincerely. By this Experiment we learn a lot about this draw
frame and get practical experience about Operation of this and in front of my view this Practical
Experience will help us in our Future job life.
Experiment No.: 14
Experiment Name: Study on determination of shore hardness of rubber coated
top roller.

Introduction:
The Shore hardness is measured with an apparatus known as a Durometer and consequently is
also known as 'Durometer hardness'. The hardness value is determined by the penetration of
the Durometer indenter foot into the sample. Because of the resilience of rubbers and plastics,
the indentation reading change over time so the indentation time is sometimes reported along
with the hardness number.
Shore Hardness is a measure of the resistance a material has to indentation. There are different
Shore Hardness scales for measuring the hardness of different materials (soft rubbers, rigid
plastics, and super soft gels, for example). These scales were invented so that people can
discuss these materials and have a common point of reference.
Objective:
 To know about shore hardness test and convenient way to measure hardness of
elastomers.
 To investigate the effect of thickness on the measured hardness.
 To know about top cot roller

Specification of top cot roller:

Normally synthetic top roller costs are available in cylindrical form. The technical
specifications of a top roller cot are-
 Bare roller diameter (BRD)
 Finished outer diameter (FRD)
 Width or length
 Construction like Alufit or PVC core and
 Shore hardness, shore hardness is one of the main properties of top roller and varies
for different types of fiber, application etc.

Figure: Top roller cot

Durometer:

The Shore durometer is a device for measuring the hardness of a material, typically of
polymers, elastomers, and rubbers. Higher numbers on the scale indicate a greater resistance
to indentation and thus harder materials. Lower numbers indicate less resistance and softer
materials.

Figure: Durometer analog and digital models

The term is also used to describe a material's rating on the scale, as in an object having a “‘Shore
durometer’ of 90.” The scale was defined by Albert Ferdinand Shore, who developed a suitable
device to measure hardness in the 1920s. It was neither the first hardness tester nor the first to
be called a durometer (ISV duro- and -meter; attested since the 19th century), but today that
name usually refers to Shore hardness; other devices use other measures, which return
corresponding results, such as for Rockwell hardness.
Working Principles of Durometer:

1. The specimen should be at least 6 mm in thickness.

2. The surface on which the measurement made should be flat.
3. The lateral dimension of the specimen should be sufficient to permit measurements at least
12 mm from the edges

Durometer scales:
There are several scales of durometer, used for materials with different properties. The two
most common scales, using slightly different measurement systems, are the ASTM D2240 type
A and type D scales. The A scale is for softer ones, while the D scale is for harder ones.
However, the ASTM D2240-00 testing standard calls for a total of 12 scales, depending on the
intended use: types A, B, C, D, DO, E, M, O, OO, OOO, OOO-S, and R. Each scale results in
a value between 0 and 100, with higher values indicating a harder material.
Process of measurement:

The principle used to measure hardness is based on measuring the resistance force of the
penetration of a pin into the test material under a known spring load. The amount of penetration
(max. 2.5 mm) is converted to hardness reading on a scale with 100 units.
1. Whenever possible, a Durometer measurement should be taken at least 12 mm (approx.
0.500") in from the edge of a sample, as the hardness characteristic of any sample tends
to change at the edges.
2. Whenever possible, the thickness of a sample should exceed 6 mm (approx. 0.250"). If
the sample is thinner than this, then the sample can be backed with a sample of the same
material to increase the thickness.
3. Test Coupons or test blocks (rubber or plastic) should not be used for calibration
verification. As all samples are subject to characteristic changes over time along with
temperature and lighting conditions, the rated Shore value when supplied as new can
and will vary with age. Proper calibration verification requires independent
confirmation of the internal spring forces along with the verification of the pin
displacement vs. the indicated value on the scale.
4. Per the ASTM Standard D 2240, readings below 10 and above 90 are not to be
considered reliable and should be discarded. Therefore, it is important to select the
appropriate Scale that will provide results between 10-90 units.

Conclusion:
From this experiment, we have learned about the shore hardness of rubber coated top roller.
The knowledge which we gained from this experiment will be very helpful for us in future as
well as in our job life.
Experiment No: 15
Experiment Name: Study on determination of roller setting of draw frame.

Introduction:

Draw frame is a very critical machine in the spinning process. Drawing is the operation by
which slivers are blended, doubled and leveled. In short staple spinning the term is only
applied to the process at a draw frame. It’s influences on quality, especially on evenness is
very big. If draw frame is not set properly, it will also result in drop in yarn strength and yarn
elongation at break. The faults in the sliver that come out of draw frame cannot be corrected.
It will pass into the yarn.

Objectives:

a) To know about the roller settings of draw frame.

b) To understand the impact of rollers on draw frame.

Description:

The effective length is the upper quartile of the fiber length distribution obtained by ignoring
short fibers whose length is below half the effective length. A total of five settings were studied
for the two mixings. Based on initial trials and normal spinning experience, for each of the
settings, the back-zone setting was maintained 4mm in excess of the front roller setting. The
various setting experimented for the different materials are given. Slivers were obtained, they
were processed up to ring frames and the quality was assessed at the sliver and yarn stages.
Experimenting on different settings parameter and select the settings in which optimum quality
can be achieved and productivity also increased.

Settings of a modern drawing machine:

Front roller Diameter: 36mm

Middle Roller Diameter: 28mm
Back Roller Diameter: 28mm
Front roller to middle roller distance:11mm
Middle roller to back roller distance: 15mm
• Front Roller to Middle Roller settings: 43mm
• Middle Roller to Back Roller Settings: 39mm
 Roller Settings (mm) = Fiber Effective Length (mm) + Allowance
(mm) #38(BZ) X 36(FZ) # 38 (BZ) X 34 (FZ)

Effective Length:
The effective length is the upper quartile of the fiber length distribution obtained by ignoring
short fibers whose length is below half the effective length.
Significance of Effective Length:
1. The term ‘effective’ is used because it is to this length value that many machinery
settings are related, in particular, the distances between the nips of successive pairs of
drafting rollers.
2. The effective length correlates well with the classer’s staple length and hence
provide the measurement of the staple of cotton.
3. Effective length can be determined from the analysis of fiber diagram by the
following

Figure: Fiber length diagram

Procedures of measuring Draw Frame Roller Settings

• The variability in fibre length leads to several problems in the spinning process while
the raw cotton mass is converted into the yarn through several processing stages.
 • Drafting is an important process affected due to the length variability. At the draw
frames, the drafting or stretching of the slivers takes place through pairs of rollers set
apart at a pre-defined distance and rotating at different speeds. The distance between
the nips of the pairs of rollers is commonly referred as the ‘roller setting’. The roller
setting should neither be too close nor wide.

𝑅𝑜𝑙𝑙𝑒𝑟 𝑆𝑒𝑡𝑡𝑖𝑛𝑔𝑠 (𝑚𝑚) = 𝐹𝑖𝑏𝑟𝑒 𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝐿𝑒𝑛𝑔𝑡ℎ (𝑚𝑚) + 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 (𝑚𝑚)

 An allowance of 8 mm in the front zone and an allowance of 12mm in the back zone
of draw frame are maintained while producing yarn using effective length concept.

Quality test that are carried out after roller settings:

 Sliver and Yarn count test and count variation (CV% of Count)
 Evenness (Irregularities of material) testing
 Lea strength testing of yarn
 Classmate fault analysis

Conclusion:
From this experiment, we have learned about the roller setting of draw frame. By taking
necessary steps we can optimize the roller settings of draw frame. The knowledge which we
gained from this experiment will be very helpful for us in future.
Experiment No.: 16
Experiment Name: Study on auto leveler used in modern draw frame.

Introduction:

Auto leveler is an online monitoring device in spinning process. It has become an integral
part of the spinning process for production of high-quality yarn. It helps in achieving
consistent count CV%.

There are two types of Auto leveling systems.

1. Open loop system.

2. Closed loop system.

In closed loop system, sensing is at the delivery side and correction is done by changing
either a break draft or main draft of the drafting system. Most of the earlier card auto levelers
are closed loop auto levelers. But the latest cards have sensing at the feed rollers and as well
as at the delivery calendar rollers.

Open loop system is very effective, because the correction length in open loop system is
many folds lower than closed loop system. But in case of closed loop system, it is confirmed
that the delivered sliver is of required linear density. In case of open loop system, since the
delivered material is not checked to know whether the correction has been done or not, Sliver
monitor is fixed to confirm that the delivered sliver has the required linear density.

Objective:

1. To maintain consistent hank of sliver.

2. To adjust the draft continuously, which will depend on thickness of material fed.

Various parts of auto leveler:

 Scanning roller (Groove & Tongue)

 Signal convertor
 Levelling processor
 Servo drive
 Quality monitor sensor
The drive system operates via servomotor which ensure absolute precision-

 The mass of the fed sliver is controlled through the tongue and groove system.
 This system achieves extremely fast and result in a very regular sliver in short,
medium and long term.
 The digital d-T&G system is based on the well-proven principle of tongue and groove
and performance constant measurement independent of feeding speed at very short
distances. Tongue and groove rollers also called as scanning rollers.
 The tongue and groove principle ensures low friction between fibers and metal,
decreases the deposits in the pneumafil and allows the application of higher
compression force on the incoming sliver, being able to measure with greater
accuracy in the sliver feeding mass.
 This constant compression force is exerted by a high precision spring on measurement
disc in the T&G system.
 The signal is transmitted by a total digital “dual laser sensor” with no need to Analog-
to-Digital conversion in the other T&G system.
 After detection of feed sliver mass variation by the d-T&G, the measured signal is
transmitted to the TMS-25 CPU, and then send commands to the highly dynamic
servomotor, correcting the mass variation inside of the main draft.
 Quality measurement sensor is located in the measuring funnel at delivery side and
measure continuously mass deviation and irregularities, sending visible alerts to
controlling panel.
Advantages of Auto levelling:
1. All variations are corrected.
2. Count c.v.% will be consistent & good, hence the yarn will be suitable for knitting.
3. Ring frame breaks will come down, hence pneumfil waste will be low.
4. Fabric quality will be good because of lower number of fluffs in the yarn.
5. Labor productivity will be more.
6. Machine productivity will be more.
7. Work ability in warping & weaving will be good, because of less no. of thin places &
lower end breaks in spinning & winding.
8. Production will be more accurate in auto leveler draw frame compared to non-auto
leveler in draw frame.
9. Fabric appearance after dyeing will be excellent.

Conclusion:
For obtaining good yarn quality, installation of auto leveler is must. As long as the auto
leveling system is set properly, advantages mentioned above can be achieved. Otherwise the
negative impact will be very big compared to working without auto-leveler.
Experiment NO: 17
Experiment Name: Study on different types of drives used in textile machine.

Introduction:

In a machine, drives are required to transmit power from electric motor (usually) to various
elements and from one element to others so that the various elements could perform their desired
operations. Between any two elements of a machine, the one which drives the other is called
‘Driver’; and the other one is termed ‘Driven’. The power/motion is transmitted by means of
various drives such as belts, chains and gears. The machine designer has the options of selecting
the nature/type of drives. Different drives have certain advantages and limitations.

Objective:

 Observe different types of drives.

 Make a short report about drives.

Theory of drives:

The parts of machine used to transmit motion from one component to another component then it’s
called drives.

List of different types of drives:

 Pulley & Belt

 Gear
 Sprocket and chain
 Tappet
 Variable drives

Pulley & Belt:

A belt is a loop of flexible material used to mechanically link two rotating shafts most often
parallel. Belt may be used as a source of motion to transmit power efficiently. Belts are looped
over pulleys. In a two pulley system the belt can either drive the pulleys normally in one
direction, or the belt may be crossed, so that the direction of driven shaft is reversed.

Types of pulleys and belt:

 Flat pulley and belt.

 V- belt
 Timing belt.
 Round belt Etc.

Flat belts and pulleys:

The flat belt is a simple system of motion transmission. It can deliver high power at high speed.
But this wide belt and large pulleys required lots of space and high tension for operation.
V belts:

V belts are mostly used for transmission motion. They provide the best combination of traction,
high speed of movement and long service life. It solved the alignment problem but it still there is
a problem called slippage.

Timing belt:

When the slippage of belt is a big matter to production there we used timing belt.

Round belt:

Round belts are circular cross section belt designed to run a pulley with v-groove. Round groove
are only suitable pulley that guide the belts.

Gear:
A gear is rotating machine parts having cut teeth which mesh with another toothed part to
transmit power or motion.

Different types of gear:

 Straight cut gears

 Hailed gears
 Bevel gears
 Warm gear
Straight cut gears:

These are simplest types of gear. They consist of a cylinder or disks with projecting radically. The
each tooth is straight and align parallel to the axis of rotation

Hailed gear:

Hailed gear offer a refinement over straight cut gear. The leading edges of the teeth are not
parallel to the axis of rotation, but are set of an angle.

Bevel gear:

A bevel gear is shaped like right circular cone with most of its of. It stands and make 45 0 angle to
transmit motion.

Tappet:

A tappet is a projection that imparts a linear motion of some other component with is
amechanism.

Variable drive:

Its slow the drives motion in time constantly.

Conclusion:

Drives are important for transmit motion. Noted and draw diagram carefully.
Experiment No: 18
Experiment Name: Gearing diagram of drawing frame machine.

Introduction:

Draw frame is a very critical machine in the spinning process. Drawing is the operation by which
slivers are blended, doubled and leveled. Gearing of draw frame has a vital role in performing all
the necessary operations properly. Without a proper gearing setting it will be impossible to get
proper drawing during spinning. For this reason it is necessary to maintain the gearing parameters
for smooth operation.

Objectives:

 To know about the gearing diagram of drawing frame

 Gearing Diagram of Draw Frame Machine:

Fig:-Gearing diagram of draw frame (Brand: Rieter; Model: SB-D45)

Calculation of draft:

Third roller and back roller

Second roller and third roller

Front Roller and Second Roller

Result:

So the Total Draft without Tension draft from the Calender rollers
Total Draft = 4.011*1.015*1.485 = 6.046

Conclusion:

Gearing of drawing frame is very important. So, we should learn about this experiment very
carefully and sincerely. By this Experiment we learn a lot about this Draw frame and it’s gearing
mechanism which will help us in our practical experience and will help us in our Future job life.
Experiment No: 19
Experiment Name: Study on usable and unusable cotton waste produced
in cotton spinning mill.
Introduction:
The action or process of losing or destroying something by using it carelessly or
extravagantly, waste includes all items that people no longer have any use for, which they
either intend to get rid of or have already discarded.

In practical, 𝐼𝑛𝑝𝑢𝑡 − 𝑂𝑢𝑡𝑝𝑢𝑡 = 𝑊𝑎𝑠𝑡𝑎𝑔𝑒

Objective:
1. To know about the usable and unusable cotton wastes produced in cotton spinning
mill.
2. To know the factors that can reduce wastes in cotton spinning mill.

List of waste in cotton spinning mill with percentage:

 Blow-room of waste = [3%]
 Carding of waste = [3-5%]
 Draw frame of waste = [0.5%]
 Lap former of waste = [0.5%]
 Comber of waste = [12-18%]
 Simplex of waste = [0.5%]
 Ring frame of waste = [2-3%]
 Winding section of waste = [1%]

Usable and unusable cotton wastages:

 Flat Strip-
It is produced in carding machine. In export mill it is not used. But in rotor spinning it is usable.

 Dropping 1 & 2-
Produced in blow room, in export mill it is not used. I is unusable. But in rotor spinning for some
cases it is usable (Terry towel yarn making)

 Hard waste-
Produced in ring frame and winding section. It is non usable waste.

 Micro dust-
We collect these dusts from A/C plant. It is non usable waste.

 Filter waste-
Produced at different sections of spinning mill and collect from A/C plant.

 Dirty cotton-
It is produced because of wrong worker handle.

 Fine dust- It is collected from A/C plant. It is non usable waste.

  Sweeping-
Produced at different section of spinning mill and collect from A/C

 Pneumafil-
Produced in ring frame, when end breaks form then increase pneumafil. It is usable waste.
Mainly it is used in rotor spinning mill. In Export spinning mill it is not used.

 Roving Cut-
Produced in Simplex and Ring frame. These wastes are not usable. It increases because of
wrong worker handling and also bad practices of mill.

 Bonda-
Produced in Ring frame. If cotton bale contains shorter fibre then Bonda waste will be
increased. It also depends on high end breaks and also Temperature and RH%. Bonda is
usable waste. But it is not used in export spinning mill. Mainly it is used in rotor spinning mill.

Major Factors for waste generation in spinning mill:

 Errors and mistakes during weighing
 Loose cotton falling from bales while transportation
 Rejection from faulty work
 Poor sliver can topping and replenishing procedure

 Poor housekeeping
 Quality standards not met
 Poor work practices
 Improper material handling
 Poor condition and performance of machines
 Higher end breakage rate and lapping tendency
The waste is affected by changes on blow room such as:
1. Distance between the grid bars and the angle of inclination of bars.
2. Speed of beater.
3. Fan speed in relation to the beater speed.
4. Setting between feed rollers and beaters.
5. Setting between beater and brid bars.

Controlling the waste at carding:

1. Use of only one mote knife, placed slightly below the normal position of the top
mote knife to give less waste and better cleaning in cotton mixing.
2. Higher licker-in speed or greater wire point density on licker-in gives higher cleaning
efficiency accompanied by some increase in the lint lost under the licker-in.
3. Use of perforated under casing helps in reducing waste.

4. With other speeds and setting held constant, the flat strip waste varies almost
proportionately with the flat speed.

5. Wider front plate and back plate setting increases flat strip waste.

The waste at comber needs to check and controlling:

1. More waste other than the nominal means financial loss.
2. Less waste other than the nominal could lead to unacceptable yarn quality and
performance.
3. Comber waste variation could contribute to lea count variation.

Waste control in ring frame:

This is done in the following steps:
1. Analysis and segregation of the waste of different types.
2. Weigh that waste and recording that section wise, person wise, shift wise.
3. Comparison with the standards.
4. Feed backs and action to improve waste generation.

Factors for Wastage Reductions:

 Raw materials selection
 Spindle speed
 Setting (Rollers, R/T)
 Traveler cleaner etc.
 Twist of yarn
 Machinery condition
 RH% and Temperature
 Proper material handling
 Adequate supervision
Conclusion:
From this experiment, we have learned about the usable and unusable cotton wastage in
cotton spinning mill. By taking necessary steps we can reduce the wastage production of
cotton spinning mill and can also use those wastes in other purposes.