‘Md. Shahjalal Lecturer.CTEC Carding Carding may be defined as the reduction of an entangled mass of fibers to a filmy web working between two closely spaced, relatively moving surfaces clothed with sharp wire points. Carding is a mechanical process that disentangles, cleans and inters mixes fibers to produce a continuous web or sliver suitable for subsequent processing. This is achieved by passing the fibers between differentially moving surfaces covered with card clothing. It breaks up locks and unorganized clumps of fiber and then aligns the individual fibers to be parallel with each other. Carding is the heart of the spinning mill. The importance of carding is still greater where new spinning system is concerned. Carding Objectives of carding 1. Opening the tufts into individual fiber: Card opens the tufts into the stage of individual fibers, whereas the blow room only opens the raw materials into flocks. his is essential to enable the elimination of impurities, and performance of the other operation to be achieved 2. Elimination of impurities: Elimination of the impurities of the fiber is mainly done in taker in zone, The degree of cleaning achieved by the modern card is very high, in the range of 80-95%. The overall deg cleaning efficiency by the blow room & carding together is 95-99%., but carded sliver still contain 0,00 foreign matters. 3. Elimination of Dust: ‘The card also removes a large quantity of micro particles that are bound to the fibers produced in the blow room. Card is considered as the best dust removing zone. 4, Removal of short fiber: Very small or fewer than 10% short fibers are removed from the card. Those short fibers can only be removed if those are pressed into the clothing. 5. Blending of fibers: Intimate fibers with fibers mixing is achieved here for the formation of web and repeated rotation of the fibers in the main cylinder. It should be noticed here that; carding is the only machine for processing the individual fibers. 6. Fiber’s orientation: It is often attributing the effect of parallelizing, The card can be given the task of creating partial longitudinal orientation of the fibers. 7. Formation of sliver: The main output of carding is sliver. Here sliver is formed to deposit the fibers material for further operation. It also done to transport from blow room to draw frame process, Carding is called heart of Spinning carding is one of the most crucial steps in the production of cotton-spun yarn. This is the method used to prepare fibers for the production of yarn. In this process, fibers are opened individually, more dust & impurities are removed here. Parallelizing & stretching of fibers are also done here. Fiber orientation & transformation of fiber into sliver are also done here. Since, all the major qualities of yarn are gained here, that’s why carding is called the mother or heart of spinning.‘Md. Shahjalal Lecturer.CTEC Material passes diagram/Cross section of a high-performance carding machine steno —_, seater Moving Nats — ‘wears "wedi Fig: Cross section diagram (Material Passes) of a high-performance carding machine (Revolving flat card) Operating principle of modern high performance carding machine 1 Raw materials are supplied from the pipe ducti to feed arrangement, to the card chute, The transport roller forwards the materials The feed rollers push the sheet of fibers to the taker in, These flocks are the gird equipment and transfer to the main cylinder, Passed over During passing the materials between feed tray & licker in zone greater parts of impurities looses and suction duct carries the waste. The flocks are carried along the cylinder, penetrate to the flats and open up to individual fibers. These two devices in the actual carding process. ‘The flats are consisting of about 80-116 carding bars. Some of 30-40 flats carry with the cylinder and the rest are on the return run. During the return, a cleaning unit separates the short fibers, neps and foreign materials from the flats ‘Two fixed carding bars are designed to assist the carding operation. After carding, the cylinder carries loose fibers which lie parallel without hook & they are not transportable, So a doffer is used to combines the fibers, into web, A stripping device draws the web from the doffer. Afier that calendar roller compressed the sliver to some extent. The coiler deposits it in cans. ‘The working roller, cylinder and flats are provided with clothing which becomes worn during fiber processing and must be grounded at regular intervals,Md. Shabjatal Lecturer.CTEC Advantages of Modern high-performance card © High production. © Lower labor cost. * Less doffing frequency. © Less wastage. © Less stripping, © Less grinding. Card clothing The inclined wires set in base material, which are covered around the surface of taker-in, cylinder, doffer and flat in the carding machine is called card clothing. The wire points are placed by base material of all the individual components of the card. The clothing has the greatest influence on quality and productivity. ‘Types of card clothing 1. Flexible clothing 2. Semi rigid clothing 3. Metallic clothing hese have hooks of round or oval wire set into elastic, multiple-ply cloth backings. Each hook is bent to a U-shape and is formed with a knee. Those fibers under bending load and returns to its original position when the load is removed. Uses: It is used in cylinder, flats and doffer. — EAMd. Shabjatal Lecturer.CTEC Advantages of Flexible clothing: 1. Point density is high, so carding action is good. 2. Wire point is flexible, so fiber damage is less 3. Finer yarn count can be prepared 4, Low cast Disadvantages of Flexible clothing: 1, Wires may be loose. 2. Low production for stripping action. 3. Fiber becomes loose due to grinding action, 4, Any carding angle cannot be choosing, 5. Need of regular grinding, 6. Foundation material. ie textile fabri, rubber required. 2, Semi rigid clothing Semi rigid is the modified version of flexible card clothing. In flexible card clothing we use 3 to 4 layers, but in semi-rigid we use more layers. These are less elastic than those of the flexible clothing. The wires cannot bend and are so deeply set in layers of cloth, Uses of Semi- igid clothing: It is used in Flat wool and long staple fiber. Se Advantages of Semi-rigid clothing: 1. No need of frequent sharpening, 2. No need of stripping.‘Md. Shahjalal Lecturer.CTEC 3. Metallic clothing: These are continues, self -supporting flat wire structures in which teeth’s are cut at smallest possible spacing by a process resembling a punching operation. They do not need any base material. Medium staple length fibers are produced. Uses of Metallic clothing: It is used in taker-in, cylinder and dofter. ell Advantages of Metallie clothing 1. No need of foundation material 2. No need of stripping 3. No need of regular grinding. 4, Any carding angle can be chosen, Disadvantages of Metallic clothing 1. Carding action is not better 2. More fiber damage. 3. High cost 4. Difficult to repair. Difference between flexible card clothing and metallic card clothing Flexible Card Clothing Metallic Card Clothin; 1. Teeth have knees. 1. Teeth have no knees. 2. There is possibility of damage foundation, 2. There is no possibility of damage of foundation the teeth become loose. ‘material, the teeth become loose on foundation. 3.__Any carding angle can’t be chosen. 3._Any carding angle can be chosen. 4, Regular grinding is necessary. 4. Regular grinding is not necessary. 5._ Stripping is necessary. '5._ Striping is not necessary. 6. Carding action is good due to high point ‘6. Carding action is not better due to Tess density. den: 7._ Only damaged portion ean be replaced. 7._ Difficult to repair, complete reclothing necessary. 8.__ Low cos 8. High cost.‘Md. Shahjalal Lecturer.CTEC Grinding: Grinding is the operation by which the effectiveness of the wire points of all organs in the cylinder machine is maintained. The purpose of card grinding is to maintain the card clothing in a sharp condition, Objects of Grinding: * To increase the sharpness of the wire points. To keep equal height of wires * To get regular carding action and uniform sliver. ‘Types of Grinding 1. Top Grinding (Grinding away the top of the wire) 2. Side grinder or Needle grinding (grinding away a litle the side of each point to make it somewhat narrower) 3. Plow Grinding (grinding away sides of each wires so as to leave more space for cotton fibers) Grinding Rollers 1, Long Roll Grinder or Dead Roll Grinder 2. Traverse grinder or Horse fall grinder 1, Long roller grinding: This device provides long roller, which moves over hole width of cylinder surface and performs grinding process. Advantages: ~ Its suitable for high-speed grinding. + This used for low and medium count yarn, 2, ‘Traverse grinder or horse fall grinder: Traversing wheel grinding device contains an emery wheel of 3.5” width which performs grinding process by traversing motion from one end to another across the wire points of different parts. Advantages: ~ Better grinding action. = _Norisk of hooking or fusing of wires.‘Md. Shahjalal Selection of card clothing Type and design of card. Rotational speed of cylinder, Production rate, Material through put. Raw material type (natural/synthetic). Fiber characteristics (Fineness, length, bulk etc.) Overall quality requirements. Price of clothing. Service offered by the clothing supplier. How can reduce neps in eard sliver 1. Closer spacing between the clothing. 2. Sharper clothing. 3. Optional speed of the taker in, 4. Low doffer speed 5. Lower through put. nt Actions in carding machine 1, Carding action (This action takes place between Cylinder and Flat) 2. Stripping action (This action takes place between taker in and cylinder, doffer and stripper) 3. Doffing action (Cylinder and dofter) 4, Combing action (Feed roller and taker in) 1. Carding Action: If two closed surfaces have opposite wire direction and there speed direction or relative motion is also opposite, then the action between two surfaces is known as carding action. Features: It is occurred between flat and cylinder. Direction of wire in two surfaces are opposite. ‘The moving direction of roller are also opposite. One roller is slower and other is fast. ‘There is always should be point against point direction,‘Md. Shahjalal Results by the action of carding: ‘© Maximum individualization of fibers is achieved in this region by action of opposite spikes. © Neps, short fibers, dirt and dust are removed, © Ifthe difference of surface speed between cylinder and flat is more carding action is maximum occurred. 2. Stripping Action: When two close surfaces have same wire direction and their speed direction or relative ‘motion is also same than the action between two surface is called stripping action. In each case the faster moving surface will stripe the other one. Striping action is occurred between: Taker in and cylinder. + Doffer and stripper. Results by the action of Stripping: ‘Trash, neps are transferred from cylinder taker in by stripping action. 3. Doffing Action: When two close surfaces wire points are inclined in opposite direction and their speed direction is same then the action between two surface is called doffing action + Itis occurred between cylinder and doffer. ‘+ Wire direction is opposite but speed direction same, + Itis special type carding. Sliver formation is done by this action. 4. Combing Action: + This action takes place between feed roller and taker. + Here pin direction is same.‘Md. Shahjalal Difference between Carding action and Stripping action Carding Action Stripping Action 1. Two surfaces wire point are inclined in opposite 1. Two surfaces wire point are inclined in same direction, direction, 2._ Their speed direction is opposite. 2._ Their speed direction is same. 3. It is occurred between flat and cylinder. 3. It id occurred in i. Taker in & Cylinder, Doffr and stripper. 4, Asin this action, two surface are in opposite direction, | 4, As in this action, two surface are in same so minimum amount of fiber stays in lower speedy direction, so minimum amount of fiber stays, surface. in higher speedy surface. Fibers are mainly individualized by this action. Sliver formation is performed by this action 6. Difference between Carding action and Doffing action Carding Action Doffing Action point are inclined inclined opposite direction. | Two surface wire point are inclined in same direction, T. Tow surface 2. Their speed direction is opposite. 2. Their speed direction is same 3. Tis occurred between flat and cylinder. 3. Tis occurred between taker-in and eylinder, doffer and “Minimum amount of fiber Stay in Tower speedy surface 4, Maximum amount of fiber stay in lower speedy surface. '. Fibers are mainly individualized by this action 5. Fibers are mainly the faster moving surface with stripe the other one. Flats: Together with cylinder, the flats form main carding zone, 40-60 flats are in operative relationship to cylinder, further flats are need to return the movement on the endless path so that altogether 100-200 flats are fitted to the chains, Function of flat: The chain of flats revolves on the surface of cylinder and it have the following functions: + Opening the flocks of fibers into individual fiber. + Orientate the individual fiber in longitudinal direction. * Elimination of impurities, short fibers and dust. © Untangle neps. Function of Doffer: ‘The doffer is designed to take the individual fibers from the cylinder and condense them toa web. The doffer is mostly formed as cast-iron drum with a diameter of 600-750 mm. It is fitted with metallic clothing and runs upto about 300 m/min, * Collection of individual fibers from cylinder and condensed them into web. Straight fibers are converted into hook at the end of fiber. © Supply the fiber web at condenser and delivery roller.‘Md. Shahjalal Lecturer.CTEC Product of carding machine: The product of carding machine is called sliver. Sliver is « thick untwisted continuous rope of fibers, which is uniform in weight per unit length and suitable for subsequent process. the English count of sliver is 0.1-.14. Characteristics of card Sliver ‘Fibers in card sliver are oriented in different direction, + Hooks and also projected fibers present in card slivt The uniformity of sliver is not so very good. Various fiber hooks and their effect on yarn quality. Card sliver contains Tailing hook-5O% Leading hook-15% Straight- 20% Both end hook-15% For eliminating tailing hook from the fiber strands there must be an even number of passages between the card and the comber. Effect on yam quality: © Drafting disturbance. © Yam hairiness increase, © Yam strength decrease Card Setting: The distance between two adjacent parts/rollers working simultaneously i.e cylinder-flat, eylinder-doffer, feed roller-taker in, doffer-stripper is termed as setting, The optimum settings are influ ed by the following factors The staple length of the material ‘The amount of trash to be removed. ‘The hank of the lap. ‘The expected waste percentage. Type of clothing, ‘Mechanical condition of the machine. oyrene Importance of set ng between cylinder and flat - Maximum individualization of fiber. - Remove of neps, short fiber, dust ete. = Parallelization of fiber. - Straightening of fiber Heal and Toe Arrangement ‘The top half of the cylinder is surrounded by a series of flats. The flats are also covered with wire teeth, the points of which oppose and are set close to wire on the cylinder. The setting between flats and cylinder is arranged that there is a‘Md. Shahjalal Lecturer.CTEC wider setting at the back or trailing edge on which cotton first reaches for being carded and closer setting at the leading edge where the cotton leaves the flat. This arrangement is generally termed as “Heal and Toe arrangement.” Auto Leveling For regular delivery or regular out put of material changing draft according to the change of input amount is called auto levelling. Auto levelling is usually performed by adjusting the feed roller speed. Control System of Auto levelling: i. Open Loop control System fi, Close loop control system ‘Open Loop control System (Principle) A measuring sensor is provided in the region of the infeed for continuous detection of the actual value~ mechanically, optically, pneumatically or otherwise. ‘* A regulator compares the result with the set reference value, amplifies the difference signal and feed it to an adjusting device (actuator) , which then finally converts the impulse into mechanical adjustments Control by this chain of steps requires an additional element, namely the store. * Since the material has to travel certain distance between a measuring and adjusting points and arrives at the adjusting points with a time delay, the signal must be held back in the store Disadvantages: _ Lack of self monitoring. _ Very exact values of the adjustment are required all times, _ If measuring sensor improper, not possible to control regularity. _Accurate regularity maintaining is possible, _ Suitable for compensating the variation of short to medium wave length. Close Loop control System (Principle) + The measuring sensor is usually arranged in the delivery region that is downstream from the adjustment device + Incontrast to open-loop control, the measuring point is after the adjustment point. The same measuring, regulating and adjusting devices can be used, but no store is reduced. # Moreover, the actual value does not have to be established as an abyolute value but can be detived as positive or neutral pulses‘Md. Shahjalal Lecturer.CTEC + If too much material passes through the sensor, the regulating transmission receives a negative signal (ie reduce speed) until the set values coincide again. * Neither a positive nor a negative signal is produced when there is coincidence the instantaneous speed ‘maintained. + The measured portion has long passed adjusting point when the adjusting signals arrives. Advantages: * Suitable for compensating errors of long wave length, ‘The principle is substantially simpler than open loop control. + A past of faults can be eliminated by it in first passage, Disadvantages: * Can not eliminate picing as finely as open loop control. * Very costly. + Unsuited to compensation of imegularity over short lengths. Carding Faults 1. Sliver variation © Inegular and uneven feed. * Damaged feed roller/doffer/calendar roller. * Wide setting of feed plate to feed roller and taker in to cylinder. + To much tension between doffer and calendar roller and calendar roller to coiler head. Remedies: © Regular and even feeding. ‘© Grinding dotfer, making effective feed roller, and calendar roller. © Proper setting of feed roller and taker in to cylinder. Controlling tension in delivery region.‘Md. Shahjalal Lecturer.CTEC 2. Cloudy web Causes: * Wider setting between doffer and cylinder. ‘+ Improper setting of back sheet. © Damages wires on cylinder, doffer, flats and taker in. * Wider setting between cylinder and bottom sheet. * Broken of fly comb, Remedies: # Closer setting between doffer and cylinder. Proper setting of back sheet * Grinding of wires on cylinder, doffer, flats and taker in + Closer setting between cylinder and bottom sheet © Correct of fly comb. 3. Hole in web ‘* Damaged wire on organs of card specially on doffer. + Various heights of wire points. + Roughly surface of under casing in eylinder. Remedies: * Location the damaged wire portions on doffer and replacing the damaged portion skillfully and then leveling the new wires with the rest of doffer wire points. + Smoothy surface of under casing in cylinder. 4, High nep count * Wider setting between cylinder and flat or doffer and cylinder. * Dull or damaged cylinder, doffer or taker in wires. © Too high immature fiber. © Too high fibers in process in cylinder. © Too high RH% Remedies: * Correction the incorrect setting. + Grinding wire points © Mature fibers used, * Maintaining correct R.H% (for cotton 45-55% temp. 70-80°F, for synthetic 55-56% temp. 80-90°F)5. Web Sagging Causes: * Lower tension draft between doffer and cylinder. + High doffer speed. © Low humidity. Remedies: # Increasing tension draft between doffer and cylinder. * Reducing doffer speed. # Maintaining humidity at 50-60%. 6. Bad selvedges Causes: ‘Wider setting of selvedge guide and lap stand. + Excessive defective of lab selvedge. © Damaged wire in doffer. Remedies: * Closer setting of selvedge guide. * Good lap selvedge. * Grinding of wire in doffer. 7. Uneven flat strip Causes: # Incorrect setting of top feather speed. © Incorrect setting of flat strip comb. * Wider setting of back plate and cylinder Remedies: * Correct setting of top feather sheet. * Correct setting of flat stripping comb. * Closer setting of back plate and eylinder. 8, Excessive flat strip Causes: © Wider setting of back plate to cylinder. * Closer setting of flat and cylinder. + Excessive speed of fat Remedies: © Closer setting of back plate to cylinder. ‘Md. Shahjalal Lecturer.CTEC+ Wider setting of flat to cylinder. * Reduce speed of fat 9. Impurities in sliver Causes: © Damaged wire in taker in. + Wider setting of top and bottom mote knife to taker in * Closer setting of taker in under casing and cylinder to cylinder casing, Remedies: * Grinding or replace wire in taker in. * Closer setting of top and bottom mote knife to taker in. ‘© Wider setting of taker-in to taker-in under cashing and cylinder to cylinder under cashing. 10. Loss of good fiber Causes © Closer setting of mote knife to taker-in. © Closer setting of taker-in under cashing and taker-in, © Wider setting in cylinder under cashing to taker-in, Remedies: © Correct setting of different parts of machine. 11. Too much fly under cylinder and take Causes: © Excessive movement of taker- + Wider setting of taker-in to cylinder under cashing, Remedies: * Closer setting of taker-in to cylinder under cashing. * Reduce movement of taker in, 12, Snow ball formation Causes + Excessive waste in cylinder under cashing. Remedies © Clean cylinder timely. ‘Md. Shahjalal Lecturer.CTEC‘Md. Shahjalal ‘What is Card Clothing? ‘Carding is the heart of spinning, justify the statement. Discuss on various fiber hooks and their effect on yarn quality. Explain carding and stripping action, Sketch material passes diagram with right direction and specification of main parts of modem carding machine. Differentiate between flexible and semi rigid card clothing. ‘Write the objects of carding. Discuss different actions in carding machine with figure. Define grinding and write about Horse fall grinding m/c. What is draft? State the amount of draft in carding machine. ‘What is card setting? write the considering factors for optimum card settings. Write the faults of carding machine with their cause. Calculate the production/hour of a carding machine from the following data: Doffer Speed 15, Doffer Surface 85”, Sliver weight 65 griyd, efficiency 85%. m Find out lap hank of a carding machine from the following data: sliver hank 0.112Ne, Mechanical draft 87, wastage 5%. 15 ‘A lap of 14 oz/yd is processed in carding machine having total draft of 100 and waste removed 4% find out delivery sliver count.