Yarn Manufacture I : Principal of Carding & Drawing

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

Lecture – 05
Sliver Formation

So today’s topic is Sliver Formation.

(Refer Slide Time: 00:23)

Now, for forming the sliver what we need is a doffer. Doffer in association with the
cylinder actually helps in forming a sliver. So, first of all let us know what doffer is? A
doffer is a cast iron cylinder, it has a diameter of around 27 inch and the surface of the
doffer is fill with lot of pins or wire points typically the speed of a doffed is around 10 to
60 rpm.

(Refer Slide Time: 01:02)

Now, the fibers which are there on the cylinder, they are already separated because of the
action between cylinder and flat. Now once this separation is over, there they need to be
transferred and transform into a sliver. So, we need to transfer the separated fibers from
the cylinder surface to the doffer now and doffer is placed very close to the cylinder the
gap between cylinder and doffer is very low and much less than a millimeter. So, as soon
as the fibers from the cylinder surface the fibers come close to the doffer, the fibers will
be transferred to the doffer surface because they will come into contract with the doffer.

Now what are the mechanism of transfer of slivers from cylinder to doffer there are two
possibilities of transferring fibers from cylinder to doffer, it could be in a carding mode
of transfer or it could be in a stripping mode of transferred.
(Refer Slide Time: 02:22)

Because we have seen that fiber transport from licker into cylinder is through stripping
mode. Now, let us see here so there should be follow carding mode of transfer for fibers
from cylinder to doffer or a stripping mode as it is practiced on for transferring fibers
from licker into cylinder. The deposited fibers on doffer should be thick enough to form a
coherent web which can be stripped off and handled easily for further processing. See the
fibers which will be deposited on the doffer must be sufficiently thick so that there is
some coherence and we can handle them without breaking.

(Refer Slide Time: 03:20)

The difficulty in stripping action is in the case of stripping action, the lap which was fed
is thin down to the extent of almost 2000 times on the cylinder surface and now if this
thin ribbon of fibers which is there or the surface of the cylinder has to be transferred to
the doffer, it is two things to be handled properly because as hardly any coherence
between the fibers.

Since the thickness of the fiber on the cylinder surface is too low almost 2000 times then,
what would be the thickness of a lap sheet? Now if we immediately transport you
through a stripping mode then this thin sheet will not have much coherence not much
strength, besides high doffer speed would have resulted in throwing off the fibers due to
very high centrifugal force; because in that case the doffer speed should have been more
than the speed of the cylinder to make the transfer of fibers from cylinder to doffer
through stripping mode and therefore, doffer speed would have been little more than the
cylinder speed and hence high centrifugal force would have acted on the doffer on the
fibers which are on the doffer and they would have thrown off by high centrifugal force.

The third problem would be that it would be very extremely difficult to transform the
web into a coherent sliver at a very high speed because there were lot of resistance of the
air as the web has to pass through the medium of air at the time of transforming them
into a sliver. So, these are the difficulties that we would face if we go for stripping mode
or transfer from cylinder to doffer.

(Refer Slide Time: 05:43)

And hence we have to think of some other mode of transfer. The other mode is carding
mode of transfer and let us first understand the disadvantages that we have when we try
to transfer the fibers from one surface to the another surface through carding mode like
fibers are also getting transferred from cylinder surface to the flats and the mechanism of
transferred is basically a carding mode of transfer.

So, true carding action is not only that we are separating out fibers we can also transfer
fibers from one surface to the other. Now in the case of transferred from cylinder to
doffer in carding mode there will be sudden deceleration as the speed will reduce from
around 26 meter per second to which is typically now a days for doffer is almost 1.3
meters per second and such a huge reduction in speed will result in disorientation of the
fibers on the doffer surface and the fibers will be completely you know disoriented from
each other and there will be lot of deformed fibers that will find on the surface of the
doffer.

So, this is what is expected when we see that we go for carding mode of fiber transferred
from cylinder to doffer because of deceleration the orientation that we had achieved on
the cylinder surface of the fibers that orientation will completely destroyed as soon as
they land on the doffer surface because of change of speed. So, this is what we have to
accept if we go for carding mode of transfer. The other problem is the transfer being not
hundred percent efficient lots of fibers are retained by the cylinder and carded again
along with newly fed fresh fibers from the licker in side. This results in building up a
thick residual fiber layer on the cylinder, this residual layer in steady state may become
too thick to deteriorate the quality of carding.

So, in the carding mode this is another problem that many fibers may not be transferred
to the doffer some of them will go back to the along with the cylinder and as a result
many fibers will circulate on the cylinder surface many times and therefore, a thick layer
of fibers will be formed on the cylinder surface this is we call fiber load and cylinder and
this residual fiber layer may cause a quality deterioration of the fibers if it is too thick it
can lead to formation of neps also.
(Refer Slide Time: 09:12)

So, these are the two different problems that we will face with carding, but even then this
is the only way we transfer the fibers from cylinder to doffer.

The advantage that we get in this mode or transfer is the fractional transport of fibers
from cylinder to doffer provides an opportunity of mixing of fibers belonging to different
returned fiber layers on cylinder. So, cylinder also acts as a mixture whatever fibers are
not transferred to doffer they will go back and they will join the fibers which are fed
from the licker in side and therefore, these fibers will get an opportunity to be mixed up
with the fibers being fed from the licker in side and hence a lot of mixing that occurs on
the surface of the cylinder that is the advantage we get by having this mode of transfer
and the other advantage is the fiber received repeated carding action between the
cylinder and flat.

Since the go back everything is not getting transferred hence they get an opportunity to
be carded again between seeing that and flat. So, if there are any fiber clusters which are
left there is a possibility that this clusters will be opened out when the cluster goes to
these interfered region. So, repeated recycling of the fibers has this great advantage of
repeated carding actions on the fibers and therefore, better opening and better
individualization of the fibers that is the advantage we get and we have actually gone for
carding mode of transfer of fibers from cylinder to doffer.
(Refer Slide Time: 11:21)

So, the action there is carding here is a diagram which is a velocity profile and of the
different organs of the carding machines and the linear density profile of the material on
the different organs of the card. What we see here is? That at the feed point the velocity
of the feed material that is the lab is only 0.013 meters per second and the typical lap
linear density could be 490 kilo text as soon as the lap is acted by the licker in text the
licker in surface rotates or moves at the speed of 13 meters per second.

So, there is a draft of almost 1000 between the feed roller and the licker in and we can
say; that means, the lap sheet is thin down 1000 times by the time they reach the licker in
surface from there as soon as the fibers are picked up by the cylinder the cylinder surface
speed typically is 26 meters per second. So, there is a draft of around two between licker
in a cylinder. So, therefore, by the time they reach the cylinder surface the sheet is further
thin down two times hence the lap is thin down to thousand times as was told earlier by
the time is reaching the surface of the cylinder.

So, he produce a very thin sheet of fibers on the cylinder and now on these thin sheet the
carding is going to carding action is going to take place. Since the seat is very thin the
gap between the flat and the cylinder surface also has to be very narrow and because of
this very narrow gap between the two surfaces there is intense opening action on the
fibres when the fibers are traveling the carding zone.
That is the zone which contains the working flats and after passing over the carding zone
as soon as they approach the doffer there is a certain draft in speed, typical speed up at
doffer could be around 1.3 meters per second. So, there is a huge change in speed from
26 meters per second to 1.3 meters per second because of these difference, the draft
could be to the order of 0.19 much less than 1.

So, draft being less than 1 would basically mean there is a condensation of fibers there is
no real stretching of the fibers. So, therefore, as the fiber lands on the doffer surface they
get packed and a large fibers from a larger surface area of the cylinder will be transferred
on a smaller surface area of the doffer and therefore, there will be accumulation of fibers
on the doffer surface hence the web of fibers which will be deposited on the doffer which
will be it will thicker than the web thickness that we get on the surface of the cylinder.

This is how the velocity of the fibers as well as the linear density of the fibers are
changing as the move from feet to the delivery point of the machine.

(Refer Slide Time: 15:25)

We will now discuss the fiber transfer mechanism that is how the fibers are getting
transferred to doffer as we are already stated that the basic mechanism of transfer is
carding action. So, the action between senior and doffer is basically a carding action the
action between cylinder and flat is also carding action, but the action between cylinder
and licker in or taker in is basically a stripping action.
Now, here what we see is the diagram a on the x axis we have distance from the cylinder
surface and on the y axis we have friction of fiber protruding from the cylinder surface.
So the fibers are gripped at the front end on the by the cylinder rod points and the
cylinder rotates at a very high speed, most of the trailing end of the fibers will be
projecting out and this length of the protruding part of the fibers from the cylinder
surface will vary depending upon the length of the fibers and the way it will vary is
shown in diagram a.

That is there are many fibers which would be protruding to a lesser extent, their numbers
are more and as we go long fibers ends protruding for cylinder surface to be much less in
number. From here as we move to figure B shows the length of the doffing arc the
doffing arc is the arc of the doffer which participates in transport of fibers from center to
doffer the entire doffer surface is not participating part of the doffer surface which is
facing the cylinder is only participating in accepting the fibers which are being thrown
towards it by the cylinder.

Now the distance e indicates the gap that exists between the doffer and the cylinder. So,
if e is the gap the from there the doffing arc is increasing as it is shown in the diagram.
So, the fibers which are long they will be having they will be actually well they are
traversing the zone between cylinder and doffer they will sweep past the long arc fibers
which are shorter in length or that projecting in short they will sweep past a smaller
length.

So, this diagram shows the length of the doffing arc which will be swept past by the
fibers which are projecting out from the surface of the cylinder the third diagram is a
doffer cylinder fiber contacts and on the x axis we have distance from cylinder surface.
Now the fiber projecting ends which are lesser than the length e these fibers will not
have any chance to be transferred because they are projecting out ends is much less than
the distance e and hence there is no possibility of such fibers to be transferred the other
fibers whose length is projecting out much more than e only they have a possibility to get
transferred.
(Refer Slide Time: 19:20)

Fiber transferred from cylinder to doffer is basically a stochastic in nature, that basically
means that we are not very sure that a fiber which is coming from cylinder side and
lessening on the doffer not necessarily would get transferred at the very fast instant it
may get transferred may not get transferred it can go back without getting transferred and
comes back again and again it meets the doffer. So, a typical fiber may repeatedly come
into contact with the doffer before it gets finally, transferred to the doffer.

So, therefore, there is no guarantee that a fiber when it is encountered into doffer for the
first time will be transferred to the doffer and hence we call it the transfer process of a
fiber from cylinder to doffer is stochastic in nature is highly random the chances of
transfer would be proportional to the fraction of fiber protruding ends at a certain
distance from the cylinder surface which has been shown in the previous diagram and the
length of the doffing arc there is number of doffer arc points with which the fibers may
come into contact.

Therefore the chances of fiber transfer occurring at different distance from the cylinder
surface can be stated as the chances of transferred is equal to the fraction of fibers at a
particular distance from the cylinder surface and the potential arc of contact of those
fibers. So, therefore, if you go back to the diagram again then we see that the diagram C
is basically a multiplication of a and B very short fibers or fibers whose ends are
projecting distance less than e are not getting transferred.
So, doffer cylinder contact points for those fibers will be basically 0. Hence, there is now
chance of that getting transferred the very long fibers which are there their numbers are
less here if you see the number this number of those long fibers are very less the
potential arc of contact is very high.

So, number being less potential arc of content being very high you multiply these two the
doffer cylinder fiber contact points for these fibers will be much less mainly because the
numbers are much low and therefore, for this fiber the potential contacts for transferred
is going to be less and in between we will find a maximum mainly because fibers
projecting out ends, number of those fibers are very large and somewhere in the middle
there for you here we get the maximum value.

When the fibers are coming to us the doffer as soon as they land on the doffer surface the
fibers are pushed to as a doffer surface and the doffers keeps on accepting the fiber as
long as a particular area of the doffer is causing the doffing arc. So, a particular area of
the doffer may take certain time to cross the doffing arc during this journey through the
doffing arc this zone of the doffer surface will keep on receiving fibers and the fibers are
pushed by the cylinder rod points to other doffer surface.

If we increase the speed of the doffer then what we can expect the even though the speed
the doffer is increased the sender speed is much larger in comparison to the doffer speed
see it is sender speed could be almost 20 times more than the surface speed of it doffer.
Therefore, even though the doffer speed is increased little bit by 10 percent or 15 percent
or 20 percent. There is hardly any change in the transport of fibers the transport of fibers
still remains more or less similar.

In fact, it may increase on the contrary because more surface area of the doffer will be
made available to the cylinder for fiber transfer one can always argue that the time to
cross the doffing arc will be less if you increase the doffer speed and therefore, one can
expect that the fiber transferred will be less.

However at the same time fresh doffer surface represented more and more for fiber
transferred, if we increase the doffer speed and therefore, the net result that we see is that
by steadily increasing doffer speed by 10, 15, 20 percent actually the transport of fibers
for cylinder to doffer increases that is the transfer efficiency will increase if we increase
the doffer speed and the reason is that clean fresh doffer arc points are presented to the
cylinder for transport of fiber from cylinder to doffer that is what actually happens.

The important thing about this process of fiber transfer is the length and size of the
doffing arc.

(Refer Slide Time: 25:22).

So, we will study the geometry of this region in order to find out how the dimension of
the doffing arc is related to the geometrical parameters of cylinder and doffer?
Now the diagram what we see there is a cylinder and there is a doffer only part
of it a sector of cylinder and doffer is are shown in this diagram and you see
from the diagram itself that this cylinder area let us say this is r the doffer area
is smaller the thickness of the fiber layer is a. If I join the centers of cylinder
and doffer we get the line o dash.

The setting between cylinder and doffer is represented by small e from here we draw a
line from o to c, where this fiber layer is touching the doffer though in the diagram it is
not. So, clear, but if we draw it here this layer let us say is touching it will thicker and is
touching at the point C is the point where the fiber layer on the cylinder surface comes
into contact with doffer. So, o C we connect similarly we connect o dash C now from this
is the doffing arc is basically this arc from here to there or from here to there this is the
doffing arc as shown in the diagram.
So, let us look at this what is x is capital r plus small r plus small e minus r cos beta and
what is ac square a C square equal to is equal to r plus a whole square. So, r plus a is
from here to there minus r plus r plus e minus r cos beta. So, from here r cos beta is this
is r cos beta and a C is this is this a is missing in this diagram this is a is somewhere here.
So, if we simplify this ac square is equal to r square minus r cos beta whole square
combining equation two and three we get r plus r a whole square equal to this and from
there we can find out what is cos beta.

(Refer Slide Time: 28:11)

And we cos beta if we write it here we get this equation what is cos beta therefore, arc a
C is r beta and it will r cos inverse this.

So, the length of the arc ac that is the doffing arc this length will increase with increase
in cylinder areas because r is coming on the numerator with the doffer radius and with
the thickness of the fiber layer I think it will be decrease in doffer areas the purpose of
understanding this doffing arc is that in the doffing arc is longer that basically means that
the cylinder wire points will get more opportunity to comb the fibers on the surface of
the doffers once they are transferred and they will be able to orient those fibers on the
surface of the doffer is once the fibrous at transferred to doffer.

Now, the fibrous had held by the doffer, but that ends our combed by the wire points of
the cylinder and hence the orientation of fibers on the doffer surface depends how long
the cylinder wire points are combing the fibers that have been transferred to the doffer
surface for a given speed of cylinder and doffer it all depends upon the length of this arc
if the arc length is more time to cylinder gets to comb the ends of the fibers which have
been transferred to the doffer surface and therefore, longer doffer arc would basically
mean that better orientation of the fibers on the surface of the doffer that is the thing that
we will get.

(Refer Slide Time: 30:31)

Now, once the fibers are transferred to doffer the next thing is stripping of the doffer
surface that is how to remove or peel off the fibers from the surface of the doffer? Doffer
is surface is full of blotter pins the fibers are embedded there. Now how do we remove
the fibers from the doffer? That is the next job to be performed and here the diagram
shows that here is this is the doffer there is one typical add point being shown here and
let say there is a single fiber also being shown in this diagram which is being pulled by
two rollers.

Let us say q is the force which counteracts tripping up way from the doffer wire. Fibers
are embedded and they are also to some extent entangled with the wire points. So, q
represents this force which counteracts the stripping of the web plain doffer wire. So, q
depends upon basically orientation of fibers on the doffer surface, thickness of the fiber
web, the coefficient of friction between the fibers and the wire points of the doffer this
all determines the value of k q.
Next f is the force of friction between doffer arc points and the fiber. Alpha as shown
here is the stripping angle at which p is directed p is the tension on the fiber as the fiber
is being pulled the fiber is these shown by this black line theta is the inclination of the
doffer wire point as shown in the diagram. So, from this we can write q plus f is equal to
p cos alpha p is here component of p is p cos alpha. So, q plus f is contradicting p cos
alpha and therefore, f is going to be p cos alpha minus q and the normal force n is going
to be p sine alpha.

(Refer Slide Time: 32:49)

That we can write f equal to mu into n and hence p cos alpha becomes minus q become
mu p sine alpha and hence q can be written as p cos alpha minus mu p sine alpha p we
can take common and we can write p within bracket cos alpha minus mu sine alpha.

Therefore p becomes a function of q divided by cos alpha minus mu sine alpha. The
stripping force is the p since the tripping force depends upon the value of q the stripping
angle alpha and the coefficient of friction mu. These three things will decide the value of
the force that we need to peel out the web from the surface of the doffer.
Now the strength of the web must be less than the stripping force p if it is not less than
this the web is going to break. So web is made of large number of fibers is very
thin fibers are entangled between each other and there is some strength of the
web, but stripping out force must be able to overcome the strength of the web
then if the web will be filled out from the surface of the doffer.

So, you have to ensure that the force p stripping force is more than the strength of the
web and that is why the it can come out easily.

(Refer Slide Time: 34:32)

Doffer speed being in the range of 25 to 60 rpm the oscillating doffing comb cannot be
used for stripping action from doffer we have to strip it. So, how do you strip the fibers
earlier we used to have oscillating comb, but when the speeds of the machines have gone
up, this oscillating comb is no more no more it cannot work now and we have replaced
this comb by draw of rollers and draw rollers are therefore, used for the purpose of
continuous stripping of the doffer surface.

Earlier when the speed of the machine used to be very low, doffers could also used to be
very low maybe 15 rpm 10 rpm or so. Those days we could use an oscillating comb to
strip the fibers from the surface of the doffer, but today’s cards are generally high
production card the speeds are much more and for at certain high speed the comb is not
going to work the comb will going to fail. So, all the machine manufactures therefore,
have given up the oscillating comb and they have gone for draw of rollers.
Now here there are three methods of web removal which can be seen in the different in
the machines made by different machine manufactures one is stripping by flexible
straight or rigid covered wire rollers, pulling by combination of fluted draw off rollers
and a blade, or lifting action by the wire covered rollers.

(Refer Slide Time: 36:24)

They are three different types feature which can be seen and in the carding machines
made by different manufacturers the first one looks like this is the doffer. There is a
flexible a roller with flexible wire points so this is wire points are basically peeling off
the web here is this is the web and moving the web in these directions and the web is
removed from the doffer by this flexible draw off roller from there it is guided forward
and it is pulled out by a pair of rollers. These are basically heavily loaded rollers which
can also cross some of the stress particles will discuss about them.

So, they are helping in pulling the web which has been removed by this flexible straight
draw off rollers this roller. This one type is another type where the flexible wire on this
roll draw off roll has been depressed by this type of roller this difference is here the
sticks are flexible here the sticks are rigid, you have rigid teeth that is the only difference
and s remains more or less similar there is no much change, the third technique is with
the help of a fluted roll this is the fluted roller and this one is a blade here is our doffer.

So, the fluted roller in combination with the blade will be able to pull the web out the
roller is pressed against the web by a spring pressure, and in the combination of these
two the web is removed from the surface of the doffer, and the third one is and the last
one is where covered roller where if you look at these wire points this these wires can
penetrate the doffer wire points.

So, this wires are on this surface this is the draw off roller draw off rollers will be having
wire points which can penetrate the doffer some extent and the wire points are also
flexible in nature. So, they do not damage the wire points of the doffer and they will be
able to remove the web from the surface of the doffer and once they are removed they
are guided forward and they are pulled out these are the redirecting rollers and this is
pulled out by these rollers and then it moves forward.

So, these are the different ways of removing the web from the doffer surface.

(Refer Slide Time: 40:00).

So, at once the web is removed the next job that is left is we have to consolidate the web
to form a sliver now web comes out in the form of a thin sheet. So, the sheet needs to be
transformed into a round sliver. So, web which is thin and two dimensional sheets has to
be converted into a round rope like assembly known as sliver. The sliver form is
necessary, since it possesses the necessary coherence for the storage and subsequent
handling that is the form you want to give to the sheet.
More important is its characteristics which is close to the yarn in terms of arrangement of
fibers within it the method of transforming a web into a sliver or with the help of a
trumpet and calendar roller combination or with by the help of traverse belt.

(Refer Slide Time: 41:06)

We will discuss these two now the trumpet and calendar roller condensation process.
Now let us see that the doffer surface is here we have placed a trumpet which is here and
a calendar roller which is here and this is the distance the web has to travel, in the case of
trumpet and calendar roll condensation process doffer surface to the trumpet this distance
is roughly 30 to 50 centimeter it is a long distance the web has to travel.

The calendar rollers moved slightly faster than the doffer which. So, that there is a little
tension on the web and the web does not sag or does not fall back. So, surface speed of
calendar roller wills little more than the surface with the doffer generally the speed
difference will be to the order of 1.0 to 1.01 or 1.05. That is what we keep as the web
passes through the trumpet sufficient lateral pressure is generated they are transform the
two dimensional sheet into a round shape sliver.

So, we are forcing the web to converge at this point through a trumpet a trumpet is
nothing, but basically a conical saves piece through which the sheet is made to pass
through. So, space is very narrow and is gradually becomes smaller and smaller and
therefore, the entire sheet is transformed into a round shape product, at the same time the
lot of transverse pressure which is generated on the sheet and therefore, will be able to
consolidate the sheet as it is passing through the trumpet.

The calendar rollers are pulling the sheet forward and because they are heavily loaded
there also applying pressure on the fibers hence the consolidation is because of the
narrow bore of the trumpet as well as the weight that we keep on the calendar rollers.
The bore size therefore, is very important and the pressure on the candidate roller these
are the two parameters which we change depending upon the consolidation that we need
in this sliver.

Normally the trumpet and the calendar rollers are placed at the middle or at the center of
the doffer and we call it symmetric condensation of the web.

(Refer Slide Time: 43:52)

The other possibility is asymmetric condensation of the web the everything is same the
only difference is that that the trumpet and calendar roller locations is not at the center of
the doffer, but little away from it.

Now, what is the reason for this it causes any unevenness present in the web to be
distributed over a larger length of the slider that is the purpose here this length of the web
is longer than this length of the web, from here to here this distance and if we see this
distance they are different. So, if there is any thick region which is coming on the web it
is some unknown reason suppose I say there is a thick region here as this moves towards
the trumpet it gets inclined because of this inclination because this end will move faster
than this end and hence a band which appeared here parallel to doffer surface in the web
that same band will be getting inclined more and more as it is approaching the trumpet.

So, by the time it will pass through the trumpet therefore, a thickness variation which
was there in the web will be distributed over a larger length of the sliver and hence the
intensity of the thickness variation will be reduced that is the very purpose of asymmetric
condensation of the web as stated here the calendar roller most slightly faster and the
speed ratio between the calendar roller and the doffer surface is 1.012, 1.05 all depends
upon the type of fibers we are going to process.

(Refer Slide Time: 45:54)

The other thing that we need to know is the differential draft on the fibers at the time of
condensation.

Here we see that this is the web which is coming out from the doffer and moving
forward. Let D is the velocity of rejection of the web from the doffer D is the mechanical
draft between the doffer and the calendar roller. So, calendar roller is here. Mechanical
draft if the draft that we get through calculations from the gating diagram of the machine.
So, the component of ejection velocity along the edges AL or B L will be V cos theta. So,
here they are called moving forward at their speed of v, but at the edges this velocity is
going to be V cos theta.
Similarly, here also it will be V cos theta, the velocity of the calendar roller which is here
this is my calendar roller the velocity is D into V because D is the drafted mechanical
draft therefore, the draft along the edges of the fiber is going to be dv by V cos theta and
hence his B and V will cancel which will be D by cos theta.

So, draft here at the edge is going to be D by cos theta for this fiber. So, as we go
towards from B towards C, if we go from B to a C what will happen? Theta is going to
be less and less. So, when we come to point C theta is going to be 0.

(Refer Slide Time: 48:03)

So, the draft at any point along B to A or A to B is going to vary, it is not going to be
constant. The draft is minimum and equal to the mechanical draft D at the center. Here, it
is exactly same to the mechanical draft that we have set on the machine, but it will be
maximum at the edges. So, these fibers at the edges will experience maximum draft or
the fibers at the center will experience the minimum draft.

So, there is a difference in the draft that the fibers are going to experience as they are
moving towards the trumpet and hence what one can see is the rugged selvedge
sometimes it can be seen in some machines. So, we get rugged selvedge or the web may
be noticed at the draft or the edges become too excessive and in some cases especially in
the older machines we could see this.
In the modern machine this zone is completely covered by lot of rollers nothing is visible
we do not see what is happening there also. If we try to find out what is tan theta is B C
by C l. So, theta is tan inverse B C by C L therefore, angle theta if we look at is as angle
theta goes down CL will increase no the other way round as CL increases angle theta will
be go down. So, if you want to deduce or play the draft you want to reduce the draft we
can either change theta. So, how do I change theta.

So, theta is a function of two parameters B C and C l. Now B C depends upon the length
of it offered a B indicating the length of the doffer. So, length of the doffer is decided by
some other factors. So, we cannot change the length B C or a b, but we can always play
with the length C L or C L is basically the distance from the doffer to the calendar roller
or to the trumpet point. So, angle theta will in decrease as C L increases.

So, if we move the calendar roller further from here to there then angle theta is going to
decrease. So, that is one way and therefore, one can say that that will reduce theta and
therefore, that will reduce the possibilities of rugged selvedge, but a long distance CL,
may cause the web to break due to its own weight for traveling too long a distance this
web is very thin. So, if it has to and it moves without any support there is no support that
is there to the web if I has to travel a long distance the web may sag and that will the web
may break also.

On the contrary if the distance is reduced too much theta will increase and if I move this
point was this then theta is going to increase causing the draft D star at the edges to cross
the critical value resulting in rugged selvages. So, the location of the calendar roller with
reference to the doffer surface is very important machine parameter too close is bad
because rugged selvedge will be generated and therefore, the web is going to be going to
be the sliver is going to be non uniform.

Similarly, if I move it too far then the web might break it may sag. So, if may another
problem and hence one has to find out optimum distance of the calendar rollers from the
sender surface. So, we have machine manufactures through travel and error has found
out what is this optimum distance.
(Refer Slide Time: 52:35).

Let us discuss traverse belt condensation now you high production cards all the modern
cards the delivery rate of the web is very fast and therefore, it is difficult to consolidate
the web when it is moving through the air at very faster rate the web is likely to
disintegrate due to air resistance since it has to travel a long distance.

Therefore we have to find out some solution now what could be the solution the web is
to be condensed immediately and close to the detaching or stripping device that is it we
should not allow the thin and very flimsy web to travel a long distance especially in high
speed cards or today’s modern cards and therefore, we need to condense as quickly as
possible and therefore, what we do if traverse belt is placed close to the cross rollers or
the stripping device and as the builds the traverse build as shown in the diagram. Moves
transversely the web moves laterally and get condensed while passing through the nip of
the belts.

Two counter rotating bands or a single circulating band carries the web to the middle or
in the case of single band, it will go to the side of the machine and it will get condensed.
This is how the way be stripped and then condensed in the modern card, but the
difficulty of such device is that the web cannot be visually seen for judging its quality in
the older version of the cards since the web was always visible to the engineer therefore,
one could easily see the quality of the web whether the web is cloudy with the a web
contains lot of crush particles or not where the selvedge is breaking. So, there was a
possibility to inspect the way to study the quality of the carding machines.

But in the modern cards since the web is no more visible such kind of inspection is not
possible with this system.

(Refer Slide Time: 55:12)

Now, we go to another important part of the machine which is known as crush roller
crush rollers are basically to precision ground hardened steel rollers positioned one
above the other as you can see in the diagram there are two crushed rollers one top one at
the bottom and these two steel rollers are pressed against each other the pressure is to the
tune of 15 Newton per centimeter a typical pressure.

Now, purpose of this crush roller is to crush out all foreign particles in the web and also
to break the bond between the particles and the fibers. So, whenever the web will pass
through this, two precision ground rollers the trash particle will get crushed and what is
the net effect of this? The particles will fall out either immediately or during subsequent
operations that is during drafting operations, or breaker draft m, or finical draft m. So,
that possibilities will be there in the slivers may not necessarily look always clean, but
the yarn will always look clean, but this device is suitable for low grade cottons since
low grade cottons contain more trash particles.
In the case of very fine great cotton this may not work properly because the fibers may
get damaged.

(Refer Slide Time: 56:55)

So, for fine long clean fibers you may not need crushing at all on the contrary the fiber
might get damaged and we may not use the crushing rollers in processing or for
possessing very fine great fibers. The other important things to remember is the cotton
with too much of seed coats should not be crushed in order to avoid roller lapping since
oil may get extracted from the crushed seed particles.

So, in case we know that a particular variety of cotton contains lot of seed coats, in that
case is better not to use the crushed rollers because as stated that the oil may get
extracted and this oil will be acting as a medium to attract the fibers, the dust particles
and it cause lapping on the drafting rollers, on the up rounds, these problems could be
there. So, with this we stop it today.

Thank you.