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Critical analysis of speed parameters of carding machine – a review

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Critical analysis of speed parameters of
carding machine – a review
The study mainly deals with analyzing the effect of licker-in, cylinder, flat and
doffer (delivery) speed on yarn quality. The different speed trials have to be
conducted to identify the yarn quality by changing the carding machine
speed parameters and the changes in result of card sliver and yarn were
checked by testing the samples on an AFIS and a UT-3 tester to compare
their properties.
Vijay D. Chaudhari, Pankaj S. Patil,
Prafull P. Kolte
SVKMs NMIMS MPSTME,
Centre for Textile Functions, Shirpur/India
Carding is the very important process in yarn
spinning. The setting of speed parameters
need to be optimized to achieve better qual-
ity and productivity. In the spinning process,
basically in the carding trials are generally
taken due to continuous variation in the raw
material. Any revolving organ or parts of the
carding machines affected the quality of
delivered material. The speed parameter of
carding machine changes the fiber behavior
in the next process. Today, to achieve better
production and quality of delivered material,
the speed parameters of carding machine
such as licker-in speed, cylinder speed, flat
speed, and doffer (delivery) speed need to be
optimized. The variation in carding sliver
leads to faults in subsequent process. The op-
timization means setting standards for the
material with particular count and speed. The
speed of licker-in has an effect on the trash
removal and also may cause damage to the
fibers; cylinder speed has an effect on fiber
individualization; flat speed is a responsible
for cleaning and removal of short fiber and
the delivery affects the evenness of the ma-
terial and generation of hook. The study of all
these parameters plays important role in
achieving better quality output of the card.
Carding is the final stage of the spinning for
cleaning of the cotton and therefore it plays
very important role for improving the quality
of the yarn. The basic objective of the card-
ing machine is to individualize the cotton
fibers which directly affect the yarn quality.
Improvement in the individualization of the
fibers during the carding process significant-
ly improved the resultant yarn characteristics.
Carding speed parameters significantly affect
fiber to fiber separation. A high production
rate of the carding machine reduces the qual-
ity of sliver and its resultant yarn. To satisfy
the demand of high production, the produc-
tion rate of carding has to be increased with-
out reducing the quality of sliver.
Necessity to optimize carding speed
parameters
The carding is the heart of spinning depart-
ment and well carded means half spun. The
licker-in speed affects the various yarn prop-
erties. The maximum speed provides high
production but reduces the quality of final
product that is yarn; but by achieving opti-
mum speed we get better quality of final
product with increased production. To
achieve this optimum speed the speed of
licker-in was changed. The licker-in is respon-
sible for waste extraction in carding. The
fiber damage and rupture were higher due to
excessive licker-in action; for this reason
optimum speed has to be achieved for im-
proved production with better quality.
The main carding action is done in between
the flat and the cylinder. The 18-20 revolu-
tions of cylinder clean the material with im-
provement in orientation of the fiber. The
best cylinder action removed the entangle-
ment of fiber and reduced the neps. This
neps create the main problem in final yarn
this will affect the increment in IPI value. To
reduce neps and IPI in the final yarn, the
speed parameter of cylinder had to be opti-
mized. The production rate of carding de-
pends on the cylinder and cylinder loading,
the optimum speed and quality with respect
to production beneficial for final yarn.
The short fiber removal and fiber individual-
ization happen in between the cylinder and
the flat. The flat and the cylinder wire points
are responsible for the removal of the neps
and the short fiber. The maximum of short
fibers and neps is removed by the flat. The
flat speed affects waste generation and has
to be optimized with a minimum amount of
spinnable fiber loss in the waste. Thus, the
optimum speed of flat is kept which is neces-
sary for improved carding action.
Spinning
The higher the delivery speed the higher the
production, but with reduced sliver quality.
This occurs due to the reduced time for card-
ing action. The higher speed of delivery is
responsible for generating more neps and
more fiber entanglement. To satisfy the de-
mand of high production with good quality
of yarn, spinners always want to optimize de-
livery rate.
Analysis of carding speed parameters
Effect of licker-in speed
The U% gradually increases as speed of
licker-in increases due to fiber rupture or
damage. This occurs due to the peripheral
speed difference between the licker-in and
the cylinder as the licker-in speed changes
[1]. The hairiness increases as licker-in speed
increases due the high rupture of fiber and
generation of short fiber in yarn [2]. The
speed of licker-in was increase to achieve
better cleaning of the material, waste and
short fiber removal. Reduction in short fiber
content RKM in yarn increases [7]. With an
increase the speed of licker-in the material
gets cleaner, waste and short fiber removal is
higher, because less short fiber content in
yarn CSP occurs [4]. Due to the increase in
the speed of licker-in, the fiber gets damaged
and this is leads to the higher short fiber con-
tent in yarn. Due to the fiber rupture and
fiber damage, this leads to variation in yarn,
which is why the imperfections increase as
the speed of licker-in increases [5].
Effect of cylinder speed
The U% gradually increases as the speed of
the cylinder is increased due to the fiber
rupture or damage which is more when the
speed of the cylinder is increased [8]. As far
as hairiness is concerned there is no signifi-
cant change found in hairiness. The hairi-
ness increases as cylinder speed increases
due the high rupture of fiber and genera-
tion of short fiber in yarn. The fiber state-to-
state separation is more when the cylinder
speed is lower [3].
The yarn tenacity initially found increases and
then decreases. It is found that due to the in-
creasing, maximum orientation of fiber this
leads to improved RKM value in yarn. The
fiber to fiber separation and individualization
is more when minimum speed of cylinder is
kept, as the short fiber removal is more in the
melliand International 3/2019 177
2019-3-MI_MI-2007-3.qxd 04.09.2019 10:52 Seite 178
Spinning
cylinder zone [3]. The less short fiber content
in yarn, the more CSP increases. When the
speed of cylinder is increased, the yarn CSP
gradually decreases. The optimum speed
cylinder opens the fiber intensively and ori-
ents the fiber.
The yarn imperfections are improved with
the increase in openness by increasing cylin-
der speed and improved cleaning efficiency,
adherence of trash particles were removed
[3] which leads to an improvement of the to-
tal imperfections.
It was observed that there was significant
change in hairiness and elongation, but IPI
value was improved on optimum cylinder
speed (500 rpm) which gives the better qual-
ity of yarn. This may be due to the fact that,
at optimum speed of cylinder, i.e. 500 rpm,
nep removal efficiency was found to be im-
proved which therefore leads to an improve-
ment of total IPI value [3].
Effect of flat speed
When the speed of flat is increased, the yarn
U% improves compared to the slow speed.
The opening and short fiber removal is more
in carding action due the yarn U% getting bet-
ter [4].
A higher the speed of flats reported better
NEP removal efficiency. Due to better NEP re-
moval and short fiber removal efficiency the
hairiness of the yarn is reduced [4]. The yarn
tenacity initially increases and then decreases
with the increase in openness of card web
and at a lower level of openness. The yarn
RKM is increases with increasing in flat
speed. As the flat speed increases, the clean-
ing efficiency of carding is also increases, due
to an increase in RKM [4]. The yarn CSP in-
creases with increasing in flat speed, and as
the flat speed increases, the cleaning effi-
ciency of carding also increases due to CSP
increase. The lower amount of short fiber
content in the yarn leads to better CSP or an
increase in the tenacity of the yarn [4].
As the flat speed increases, the cleaning effi-
ciency of carding also increases due to the IPI
value also decreasing, and this results in the
good yarn quality obtained. More than stan-
dard flat speed improves or increases the
yarn quality because as flat speed is in-
creased trash removal also increases. Clean-
ing efficiency in carding increases almost lin-
early with the increase in fiber openness at
card. The higher waste extraction results in
reduction of IPI of final yarn. The trash is re-
sponsible for neps and thick places in yarn.
The lower the trash content, the better the
quality of the final yarn [4].
Effect of delivery speed
The optimum speed gives the best U% be-
cause the fiber collection from cylinder is
optimum. The fiber damage or rupture is re-
178 melliand International 3/2019
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duced [2]. The hairiness is optimum at the
optimum delivery speed because the higher
delivery speed breaks the fiber due to the
fact that short fiber is increased and there-
fore the hairiness also increases. The opti-
mum delivery speed reduced the fiber rup-
ture and reduced short fiber generation [2].
The speed of doffer increased and the RKM
of yarn increased due to poor collection of
fibers from cylinder and generation of neps
[6]. The speed of doffer is optimum when the
CSP of yarn decreased due to poor collection
of fibers from cylinder and generation of
neps.
The slower delivery speed does not generate
neps and gets material from the cylinder
without damaging the fiber because the CSP
of yarn is increased. The reason is less short
fiber content in yarn [2]. The speed of the
doffer increased, the IPI of yarn increased
due to poor collection of fibers from cylinder
and generation of neps [6-12].
Conclusion
Licker-in
In the case of the licker-in speed, when the
speed was increased, there was a direct im-
provement in the final yarn. In another case,
the licker-in less speed ratio was responsible
for the improvement in the final yarn quality.
A lower speed of licker-in helps to improve
the yarn strength and reduced IPI and hairi-
ness in the yarn. When intensive opening and
cleaning is carried out, this improves the neps
removal efficiency of carding at the sliver
stage. However at the same time there is an
increase in fiber rupture. Fiber damage de-
creases short fiber percentage in the card
sliver which increases the card sliver uneven-
ness [1].
Flat
The higher the speed of flats reported, the
better the nep removal efficiency. Due to bet-
ter nep removal efficiency, variation in the
yarn was reduced. As the flat speed increas-
es, the cleaning efficiency of carding also in-
creases and due to this IPI value also de-
creases. This resulted the good yarn quality
obtained [4]. Cleaning efficiency in carding
increases almost linearly with the increase in
fiber openness at card. Card sliver irregulari-
ty improves with the increase in openness
but at very high level of openness the irregu-
larity increases. Nep count decreases to a
minimum value, and increases for higher
fiber opening. The yarn tenacity initially in-
creases, and then decreases with the in-
crease in openness of card web [5].
Cylinder
The yarn imperfections improved with the in-
crease in openness by increasing cylinder
speed and improved cleaning efficiency, ad-
herence of trash particles were removed. This
leads to an improvement of the total imper-
fections. The yarn tenacity initially found in-
creases and then decreases; the increasing
orientation of the fiber leads to an improved
RKM value in yarn. With the increase in open-
ness of card web at a higher level of open-
ness, the hairiness increases with the in-
crease in openness, and at a lower level of
openness does not affect the hairiness. Large
speed ratio is not beneficial to the improve-
ment of the yarn quality, while smaller speed
ratio is helpful for the improvement of the
yarn quality [3].
Delivery speed
The higher delivery speed affect the yarn
quality, the result is yarn strength and yarn IPI
increases as the delivery speed is increased.
Single yarn strength also goes down because
of the higher delivery speed of card. If a spin-
ner wants to achieve expected production
then the speed is optimized with respect to
quality of final yarn [2]. ■
References
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