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Carding 160805120542
Carding 160805120542
Unit I : Carding
Necessity & Objects of carding, Operations involved in carding, Fundamental
actions in carding, Detail study with construction and working of carding machine,
Various sections of carding machine. Types of card clothing and their significance and
effects. Theories of carding action, Analysis of flat actions and carding force.
Introduction to Stripping, Grinding and Burnishing operations. Continuous Feed vs Lap
Feed. Various settings of card, its influences on carding quality & production.
Unit-II : Carding
Transfer mechanism of fibres, Consolidation of web into sliver, Trumpet &
Calendar roller condensation. Parameters affecting Settings, Quality and Production.
Concept of draft, Types of Draft, Distribution of draft, Actual and Mechanical draft.
Card drive & calculations related to Efficiency, Production of carding machine.
Carding faults and their origin, waste collection, controlling and handling. Card
autoleveller: Principles, Types, Advantages and Disadvantages. Introduction to
developments in carding.
Unit-III : Draw frame
Introduction, objective of draw frame, operating principle; Attenuation
(draft): the draft, the drafting operation, drafting force; behavior of the fibres in the
drafting zone, friction fields, nature and role of fibre friction in drafting, distribution of
draft, additional effects of draft; perfect and real drafting; nature of drafting
irregularities; coiling- delivery, condensing, sliver coiling, can changing. Drafting force
in relation to other parameters- Draft ratio, Roller Setting, Fibre Crimp, sliver density.
Roller lapping tendency, Selection of creel and web tension draft. Monitoring and auto
leveling: structure of computerized data collection and monitoring systems, waste
collection, controlling and handling. Production calculations.
Unit-VI: Combing
Combing machines: outline, classification, description of functions- feed, feed
of lap sheet, feed device, nipper assembly, cylinder comb, top comb, take-off & the
material, piecing, withdrawal of the web and formation of sliver, sliver take-off,
drafting arrangement, coiling of sliver, waste removal (stripping), timing diagram of
comber motions, automation in comber. Detailed setting of comber machine and gauges
used for setting. Gearing, drafts and production calculation of combing machine.
Text Books
1.Spun yarn technology, volume II, carding - A.Ventasubramani.
2.Chattopadhyay R and Rengasamay R, “Spinning: Drawing, Combing and Roving”,
NCUTE-Pilot Programme, 1999.
Reference Book
3. Khare A R, “Elements of combing”, Sai book center, Mumbai, 1999.
4. Khare A R “Elements of carding”, Sai book Centre, Mumbai, 1999.
5. Klein W., “The Technology of Short-staple Spinning “, The Textile Institute.
6. Klein W., “ A Practical Guide to Opening and Carding “, The Textile Institute.
8. Technology of Carding – R . Chattopadhaya, NCUTE Publication
Objectives:
To have an introduction regarding carding process.
To study working of chute feed system.
To study advantages and disadvantages of chute feed system.
To study various developments in chute feed system.
Chute feed is a system of feeding small tufts of cotton fibres
directly from blow room to a series of cards, arranged in a circuit
through pneumatic pipe.
A condenser in the
pneumatic pipe sucks
the material from blow
room and delivers it to
the flock feeder through
pneumatic pipe by way
of the filling trunk.
Fig. Flock
Feeder or
Chute Feed
System
The automatic continuous feed directly linked to the blow room
eliminates the lap formation. This increases the working efficiency of
the blow room.
The main power requirement in doffing the lap, weighing,
transportation to card and feeding at the card is eliminated.
The processing of rejected laps in the blow room is
avoided.
The fibres are fed to the card in loose sheet form as against
compressed form so that trash particles can be easily extracted
from fibres by the carding action.
Excessive sliver irregularities due to the lap licking during high
humidity, double lap feeding, lap splitting, lap piecing etc, are
eliminated.
When compared to lap fed, there is a reduction of 1 % CV flock
feeding card sliver.
Crushing of foreign materials seed bits and other trash particles during
calendaring and difficulty of removing a subsequent processes is
reduced.
Blow room should run the same number of hours per week as the
cards do.
The card production must be kept excessive to assure continuous feed
to draw frame at the time of stoppages at blow room due to maintenance
and other unavoidable problems.
Chute feed system control short term variation but not the medium
and long term variations.
A reliable check on the nominal count can be established in lap
forming system by controlling total lap weight and C.V. value of the
weight per unit length. There is no such control in the chute
feeding system.
Change of mixing will result in more waste in chute feed.
Necessity:
It is always considered by the experts that the card is the heart of the
spinning mill.
The statement “Well-carded is half-spun” demonstrate the immense
significance of the carding for the final result of the spinning operation.
Carding is an operation where the tuft condition of the fibres is
converted into an individual fibre form.
The carding is a very important process because unless the fibres are
separated into individuals, they can not be spun into smooth and
uniform yarns neither can they be blended properly with other fibres.
Opening to individual fibres
Cleaning
Elimination of dust
Mixing & Blending
Disentanglement of Neps
Elimination of short fiber
Sliver Formation
Fiber Orientation
Fig. Passage of material through carding
- Feed region - Licker-in region - Carding region
- Coiling region - Condensing region
Be able to hold the material back against the action of the licker-in;
Present the batt to the licker-in in such a manner that opening can be
carried out gently.
Conventional system:
Fig. Conventional feed device
1 Feed plate
2 Feed roller
3 Licker-in
4 Mote knife
5 Licker-in undercasing
a. Guide surface
b. Nose of feed plate
Modern system:
The feed roller has a diameter of 80 - 100 mm
1 Feed plate
2 Feed roller
3 Licker-in
The licker-in:
-The greatest part of opening and cleaning is performed by the licker-in.
- Cast roller with a diameter usually of around 250 mm.
-Rotation speeds are in the range of 800 - 2000 rpm for cotton and about
600 rpm for synthetics
-The licker-in combs through a fairly thick fiber fringe at a rotation
speed of 1600 rpm (approximately 600000 wire points per second),
a circumferential speed of around 21 m/sec
(approximately 76 km/h) and a draft of
more than 1600.
Fig. The licker-in
Degree of deterioration can and must be precisely controlled
by adjustment of:
the thickness of the batt;
the degree of openness of the raw material in the feed-stock;
the spacing between the operating devices;
the degree of orientation of the fibers in the feedstock;
the aggressiveness of the clothing;
the rotation speed of the licker-in;
the material throughput.
Elimination of waste:
The cleaning assembly consisted of 1-2 mote knives and a grid, one
half of which was made of slotted sheet and another half of perforated sheet.
1Licker-in
2 Mote knife
3 Carding plate
3a- Special clothing
4Grid with carding segment
5- Licker-in cover
Fig. Carding segments
under the licker-in of the
Function:
Opening of tufts into individual fibers;
Elimination of remaining impurities;
Elimination of some of the short fibers;
Untangling neps (possibly their elimination);
Dust removal ;
High degree of longitudinal orientation of the
fibers.
Main cylinder :
-The cylinder is usually manufactured from cast iron, but is now
sometimes made of steel.
-Most cylinders have a diameter of 1280 - 1300 mm (Rieter C 60 card
814 mm, speed up to 900 rpm) and rotate at speeds between 250 and 500
(to 600) rpm.
-The roundness tolerance must be maintained within extremely
tight limits – the narrowest setting distance (between the cylinder
and the doffer) is only about 0.1 mm.
-The cylinder is generally supported in roller bearings.
Flats
-Altogether 100 - 120 flats
-The bars of the flats are made of cast iron (nowadays aluminum
profiles
- Longer than the operating width of the card
- Each bar is approximately 32 - 35 mm wide
1. Carding action
2. Stripping action
The separation of fibres from tuft held in b/n two wire surfaces is
called carding action.
Following conditions.
1] There should be two very closely placed (0.3mm or 20-30
times dia. of fibre) wire covered surfaces.
2] Wire points on it should face each other, i.e.
point to point arrangement.
3] Interaction surfaces should
move either in opposite direction
or in same direction.
4]It is occurred between flat
&cylinder
The process of fibre transfer from one surface to another is
called stripping.
Necessary conditions –
- Two wire covered surfaces facing each other
- The distance b/w them should be around 0.3mm or less ( 20 to
30 times the dia. of fibre)
- One surface should face back of wire from each other i.e. point
to back arrangement
- Interaction surfaces should move either in opposite direction
or
in same direction
The intensity of carding action is depends upon following points
- The arrangement and density of wire points
- The setting b/n wire points
Distinguish between carding action & stripping action with diagram.
Sl. Carding action Stripping action
no.
1. Two surfaces wire points are inclined in Two surfaces wire points are inclined in
opposite direction. same direction.
2. Their speed direction is opposite. Their speed direction is same.
3. It is occurred between flat It is occurred between T-in & cylinder.
&cylinder.
4. As in this, action, two surfaces are in As in this, action, two surfaces are in same
opposite direction, so min amount of direction, so maxmamount of fibre stay in
fibre stay in lower speedy surface. lower speedy surface.
5. Fibres are mainly individualized by Fibres are mainly transfereed by this
this action. action.
6. Points to point action. Points against point action.
Functions of the Doffing Region
(1) Transferring of fibres from the main cylinder on to the doffer.
(3) Gathering the fibre web into a twist less strand (sliver).
Fig: Condensor
- The sliver must be coiled in cans for storage and transport.
- Can diameters now lie in the 600 to 1200 mm range and can heights
are
between 1000 and 1220 mm.
Fig. Can filling device (coiler) Fig. Laying down sliver in cans
R - Rotating plate
L - Guide
passage
D - The delivery
A, main drive for the cylinder, licker-in and
flats;
B, drive for the infeed;
C, drive for the delivery, i.e. doffer,
detaching rollers and coiler;
D, drive for the cleaning roller of the
detaching roller;
E, drive for the cleaning roller of the
flats
via the strip-ping roller;
F, fan.
Several manufacturers, e.g. Rieter,
also provide a separate drive for the flats.
Individual drives have the
advantage that transmission of the forces is
better, and adjustments can be performed Fig. Drive of a
modern card
more quickly and conveniently. They are
(Trützschler)
Choice of clothing
The clothing has the greatest influence on quality and productivity.
Selection criteria are:
Type and design of card;
Rotation speed of the cylinder;
Production rate;
Material throughput;
Raw material type (natural or man-made fibers);
Fiber characteristics (mainly fineness, length, bulk, dirt content);
Overall quality requirements;
Price of the clothing;
Service offered by the clothing supplier.
Classification of card clothing:
1.Flexible clothings 2.Semi-
rigid clothings 3.Metallic
clothings
Flexible clothing:
-Here, 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 that flexes
under bending load and return to its original position when the load is
removed.
-In the flats, the point density is in the range of 240-500 points/inch.
Fig. Flexible clothing
Semi-rigid Clothing:
•Here, flat or round wires with sharp points are set in backings which
are less elastic than those of flexible clothings.
•More cloth layers and have hooks of flat wire without a knee or of
reinforced round wire with or without knee.
• These are found in flats
Fig. Semi-rigid Clothing
Metallic Clothing:
In manufacturing process, a wire with round cross section is rolled
into a long strip comprising a rib to form a base of the wire and a
thin web forming portion for the teeth.
This thin portion is stamped or punched so as to get thin serrated strip,
called as saw tooth wire.
These are found in licker-in, main cylinder and doffer.
Fig. Forming the wire profile for metallic clothing
Metallic wire on cylinder & Doffer:
•In comparison to the licker-in wire, metallic wire on cylinder & doffer
are much finer.
• The cylinder wire are much smaller in size compared to doffer wire.
• The points/inch on cylinder wire are higher than the doffer wire.
• The thickness of the rib for doffer wire is more than that for cylinder
wire.
•The angle of leading edge for cylinder wire is more than that for doffer
wire.
Comparison between flexible and Metallic wire clothing
Limitations of conventional revolving flat card clothed flexible wires
are
•The conventional carding efficiency is vary, much effected due to
frequent stoppages for stripping and grinding.
•Further, the regularity of the sliver is much affected after every
stripping condition of the wire point increases the waste% and
neps formation.
•Foundation of the flexible wire clothing is not rigid and fails to bare the
stress and strain caused by high speed, so cannot be run at high speed.
• Reduction in stripping cycles-once in 2 or 3 days
• No frequent grinding-only light grinding at an interval of 6 months on
3 shift basis.
•More production & regularity of sliver is improved & labour work is
reduced.
• NO neps formation due to better wire condition.
• Saving of good fibres. Lesser variation in card sliver owing to
reduced
stripping cycles.
• Card can run at high speed owing to rigid foundation of wires.
• Economic in long run.
•Less fibre holding power
• It shows slightly higher fibre damage.
• High fly generation.
• Requires higher power consumption.
•Greater care in maintenance and attention owing closer gauging and
setting.
• It is difficult to replace the damaged wire portion only. (Damaged
portion only can be replaced in flexible fillet clothing).
Necessity of stripping
• During the carding process, fibres and impurities become embedded in
the wires of the flats, cylinder & doffer which may reduce their
effectiveness of carding and increases the nep count in card sliver
& finally affect the quality of the yarn.
• So stripping the dust, fibres & impurities from the card clothing
is
essential to regain their efficiency
Stripping Roller: This is a wooden roller mounted on steel shaft covered
with flexible wire fillet. The roller is about 6 inch in dia and slightly
longer than the width of the cylinder.
•It has serious disadvantages of throwing a considerable amount of dust& fly
from card clothing into the card room atmosphere.
• There by creating undesirable and unhealthy working condition & spoils the
machinery and product.
Developments of stripping
Here nozzle keeps continuously sucking the fibres from beneath the
cylinder and feeds back beneath the lap that is being fed to the m/c
for being worked again.
Objects
As a card operates, the action of fibres and dirt with it, gradually wear
the points of wire causing them to become poor cleaning point.
The purpose of card grinding is to maintain the card clothing in a
sharp condition.
8 More wastes due to lap tail & damages. Processing of rejected lap is avoided.
To transfer the cotton to the main cylinder and distribute the fibres
as evenly as possible, both transversely and longitudinally, on the
cylinder surface
Major developments takes place w.r.t.
1] Improve the opening of tuft at high rate of feed in
high production cards.
2] Distribute the tuft as evenly as possible on the
cylinder. 3] Extract max. trash with minimum loss of
spinnable fibres.
To achieve first objective:
-Licker-in speed is increased in the range of 1150-1800 rpm.
-Introduced 2/3 licker-in for gradual opening of tuft. eg. M/s
Ingolstadt in their super card KU 12 has incorporated three licker-
in roller which resolve at 920, 1350 and 1800 r.p.m. respectively
Classification of autoleveller:
1] Mechanical system of control
2] Electronic control
Count of Neps:
Nep count is the no. of neps per 100 square inches of card
web forming ( a standerd hank of sliver of 12 NE on a 40 inch wide
How To Measure / Assessment the Count of Neps?
At first a web is collected from the card placed on a 10 inch ×
10 inch black board. Then the neps are counted and the no. of neps
found is corrected fro any difference in hank or card width.
Mathematically, Nep Count, n = m × 100 [ m = no. of neps
per inch square card web].