Principles of Spinning: Carding and Draw Frame in Spinning PDF by Ashok R. Khare

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Principles of Spinning: Carding and Draw Frame in Spinning

Ashok R. Khare

Principles of Spinning

Contents

Preface………………………………………………………………………………………………………..xi

List of Tables…………………………………………………………………………………………….. xiii

Acknowledgments………………………………………………………………………………………..xv

About the Author……………………………………………………………………………………….xvii

Chapter 1 Carding……………………………………………………………………………………..1

1.1 Objects of Carding…………………………………………………………….1

1.2 Passage of Material through Conventional Carding………………2

References…………………………………………………………………………………6

Chapter 2 Important Regions in Conventional Carding………………………………….7

2.1 Feed Plate………………………………………………………………………..7

2.2 Feed Roller………………………………………………………………………8

2.3 Licker-in……………………………………………………………………….. 10

2.3.1 Types of Licker-in Wires……………………………………… 13

2.4 Mote Knives………………………………………………………………….. 16

2.5 Licker-in Undercasing…………………………………………………….. 18

2.6 Back Plate……………………………………………………………………… 21

2.7 Cylinder…………………………………………………………………………22

2.8 Flexible Wire Points………………………………………………………..25

2.8.1 Foundation Material for Flexible Wires………………….25

2.8.2 Setting Pattern of the Crowns in Flexible Wire Clothing……………………………………………………………..26

2.8.3 Carding Action and Carding Angle……………………….27

2.8.4 Count of Card Clothing………………………………………..28

2.8.5 Metallic Wire Clothing………………………………………..29

2.8.5.1 Metallic Wires on Cylinder and Doffer…….30

2.8.5.2 Types of Wires……………………………………… 31

2.8.5.3 Wire Geometry and Material Processed….. 33

2.8.5.4 Types of Foundation Wire……………………… 35

2.8.5.5 Flexible versus Metallic Card Clothing…….36

2.8.6 Special Flexible Clothing……………………………………..38

2.9 Cylinder Bends………………………………………………………………. 39

2.9.1 Flexible Bends……………………………………………………. 39

2.9.2 Types of Flexible Bends……………………………………….40

2.10 Flats……………………………………………………………………………… 42

2.10.1 Flat Clothing………………………………………………………44

2.10.2 Metallic Wires on Flats………………………………………..44

2.10.3 Flat Tops for Higher Production……………………………. 45

2.10.4 Typical Flat Tops………………………………………………… 45vi Contents

2.10.5 Cresta Tops…………………………………………………………46

2.10.6 Eureka Tops………………………………………………………..46

2.10.7 Some Other Flat Tops…………………………………………..46

2.10.8 Split Tops……………………………………………………………47

2.11 Flat Stripping Comb………………………………………………………..47

2.12 Cylinder Undercasing………………………………………………………49

2.13 Front Plate……………………………………………………………………..51

2.14 Doffer…………………………………………………………………………….52

2.14.1 Fibre Transfer……………………………………………………..53

2.14.2 Doffer Comb……………………………………………………….54

2.15 Calender Rollers……………………………………………………………..57

2.16 Coiler…………………………………………………………………………….58

References……………………………………………………………………………….62

Chapter 3 Stripping, Burnishing and Grinding……………………………………………63

3.1 Wire Maintenance…………………………………………………………..63

3.2 Stripping………………………………………………………………………..63

3.2.1 Roller Stripping…………………………………………………..64

3.2.2 Some Other Types of Stripping Mechanisms………….65

3.3 Burnishing……………………………………………………………………..66

3.4 Grinding………………………………………………………………………..67

3.4.1 Types of Grinding Rollers…………………………………….68

3.4.2 Slow and Fast Grinding………………………………………..70

3.4.3 Flat Grinding………………………………………………………71

3.4.4 Preparation for Grinding………………………………………72

References……………………………………………………………………………….73

Chapter 4 Card Settings……………………………………………………………………………75

4.1 Why Settings?…………………………………………………………………75

4.2 Lap Guides…………………………………………………………………….75

4.3 Feed Plate to Licker-in……………………………………………………..75

4.4 Licker-in to Cylinder……………………………………………………….76

4.5 Flats to Cylinder……………………………………………………………..76

4.6 Doffer to Cylinder…………………………………………………………..76

4.7 Doffer Comb to Doffer and Flat Comb to Flats…………………..77

References……………………………………………………………………………….77

Chapter 5 Developments in Carding…………………………………………………………..79

5.1 Direction of Developments……………………………………………….79

5.2 Principles of High Production Carding………………………………79

5.2.1 Crosrol Varga……………………………………………………..81

5.2.2 Fluff Generation………………………………………………….84

5.2.3 Necessity of Stop Motions and Slow Speed Drive to Doffer…………………………………………………………….85

2.16.1 Under- and Over-Coiling …………………………………….. 61 vii Contents

5.3 India-Roll……………………………………………………………………….86

5.4 Tandem Carding……………………………………………………………..87

5.5 Dust and Fly Extraction in Tandem Carding………………………88

5.6 Doff Master……………………………………………………………………89

5.7 Modified Licker-in Region……………………………………………….90

5.7.1 Fibre Retriever…………………………………………………….90

5.7.2 Hi-Dome…………………………………………………………….91

5.7.3 Deflector Plate and Modified Licker-in Undercasing Region…………………………………………….92

5.8 Neps in Carding………………………………………………………………93

5.8.1 Effect of Carding Parameters on Neps……………………93

5.9 Fibre Hooks……………………………………………………………………95

5.9.1 Formation of Hooks…………………………………………….96

5.9.2 Tracer Fibre Technique………………………………………..97

5.10 Transfer Efficiency………………………………………………………….98

5.10.1 Method 1 …………………………………………………………..99

5.10.2 Method 2 …………………………………………………………..99

5.10.3 Factors Related to Transfer Efficiency……………………99

5.11 Processing of Man-Made Fibres and Their Blends…………….100

5.11.1 Prerequisites……………………………………………………..101

5.11.2 Carding of Man-Made and Synthetic Fibres………….101

5.11.2.1 Types of Wires for Man-Made and Synthetic Fibres…………………………………..103

5.12 Chute Feed to Card and Auto-Levelling…………………………..103

5.12.1 Automated Fibre Distribution System to Cards……..104

5.12.2 Concept of an Automated SYSTEM…………………….105

5.13 Card Maintenance…………………………………………………………107

References……………………………………………………………………………..110

Chapter 6 Features of a Modern High-Speed Card…………………………………….111

6.1 Unidirectional Feed to Licker-in……………………………………..111

6.2 Modified Licker-in Region……………………………………………..111

6.3 Carding Segments…………………………………………………………119

6.4 Flats and Their Driving………………………………………………….123

6.4.1 Reversal of Flats………………………………………………..125

6.4.2 Flat Cleaning System…………………………………………127

6.5 Web Doffing…………………………………………………………………127

6.5.1 Innovation in Web Doffing on Rieter Card……………129

6.5.2 Innovative Magnetic Web Crushing……………………..129

6.6 Sliver Regulation…………………………………………………………..131

6.7 Length Variation Curve………………………………………………….132

6.8 Nep Control in the High Production (H.P.) Card……………….133

6.9 Card Information System……………………………………………….134

6.10 Can Changing and Automatic can Transport…………………….135

6.11 Exacting Card Settings…………………………………………………..135

6.12 Individual Motor Drive…………………………………………………..136viii Contents

6.13 Rieter’s C60 and C70 Cards……………………………………………138

6.13.1 C60 Card………………………………………………………….138

6.13.1.1 Rieter’s Integrated Grinding System (IGS)………………………………………………….140

6.13.2 C70 Card………………………………………………………….141

References……………………………………………………………………………..148

Chapter 7 Faults and Their Elimination……………………………………………………149

7.1 Nep Count of the Web Unsatisfactory………………………………149

7.1.1 Condition of Wires…………………………………………….149

7.1.2 Loading on the Wire Surfaces…………………………….149

7.1.3 Settings…………………………………………………………….149

7.1.4 Immature Fibres………………………………………………..149

7.1.5 Production Rate…………………………………………………150

7.2 Holes in the Web…………………………………………………………..150

7.3 Snowball Formation………………………………………………………150

7.4 Cloudy Web………………………………………………………………….150

7.5 Ragged Selvedges (with Lap Feed)………………………………….150

7.6 Fluff Generation From the Cylinder Side………………………….151

7.7 Shifting in Web Stripping Point………………………………………151

7.8 Web Sagging…………………………………………………………………151

7.9 Poor Card Cleaning Efficiency………………………………………..151

References……………………………………………………………………………..154

Chapter 8 Draw Frame……………………………………………………………………………155

8.1 Objects…………………………………………………………………………155

8.1.1 Evenness…………………………………………………………..159

8.1.2 Regularity…………………………………………………………159

8.1.3 Short and Long Fibres………………………………………..162

8.1.4 Relative Position of Fibres…………………………………..163

8.2 Drafting by Rollers………………………………………………………..164

8.3

8.3.1 Bottom Rollers………………………………………………….171

8.3.2 Top Rollers……………………………………………………….172

8.3.3 Roller Covering…………………………………………………174

8.3.4 Cots………………………………………………………………….176

8.3.5 Cot Wear and Tear……………………………………………..177

8.3.6 Maintenance of Cots and Current Requirements……178

8.3.7 Diameter of Rollers and Roller Settings……………….178

8.3.8 Roller Setting in Relation to Drafting and Bulk…….181

8.3.9 Roller Weighting……………………………………………….183

8.3.9.1 Weight Relieving Arrangement……………..183

8.4 Functions of Different Stop Motions on Draw Frame…………184

8.5 Roller Clearers………………………………………………………………187

8.6 Trumpet and Coiling……………………………………………………..188

Passage of Cotton through Conventional Draw Frame ……… 167ix Contents

8.7 Limitations of Graduated Drafting System……………………….189

8.7.1 Drafting Wave…………………………………………………..189

8.7.2 Roller Slip…………………………………………………………190

8.7.3 Related Mechanics of Roller Slip…………………………192

8.8 Shirley Draft Distribution……………………………………………….193

8.9 Bulk Processed……………………………………………………………..195

8.10 Tension Draft………………………………………………………………..195

References……………………………………………………………………………..195

Chapter 9 Features of Modern High-Speed Draw Frame…………………………….197

9.1 Fibre Control…………………………………………………………………197

9.1.1 Specialities of Some Other Drafting Systems………..199

9.1.2 Rieters RSB 951………………………………………………..203

9.1.3 Trutzschler’s TD-7 Drawing………………………………..204

9.1.3.1 Change in the Main Draft……………………..205

9.1.3.2 Servo Draft in TD-8…………………………….206

9.1.4 Innovative Fibre Guidance………………………………….207

9.2 Modern Roller Weighting……………………………………………….210

9.3 Web Condensation…………………………………………………………212

9.4 Suction Hood………………………………………………………………..212

9.5 Stop Motions and Indicator Lamps………………………………….213

9.6 Ease in Roller Setting…………………………………………………….214

9.7 Bigger Cans and Special Coilers……………………………………..215

9.8 Roller Diameter…………………………………………………………….215

9.9 Automatic Regularity Control…………………………………………216

9.9.1 Open Loop………………………………………………………..216

9.9.2 Closed Loop……………………………………………………..217

9.9.3 Combined Loop…………………………………………………218

9.9.4 Important Considerations……………………………………218

9.9.5 Open Loop Control in RSB 951…………………………..219

References……………………………………………………………………………..220

Chapter 10 Faults in Draw Frame………………………………………………………………221

10.1 Roller Gearing Faults…………………………………………………….221

10.2 Top Rollers……………………………………………………………………221

10.3 Eccentric Bottom Rollers……………………………………………….222

10.4 Roller Vibrations…………………………………………………………..222

10.5 Bouncing of the Weights………………………………………………..222

10.6 Singles and Doubles………………………………………………………223

10.7 Uneven Draw Frame Sliver…………………………………………….223

References……………………………………………………………………………..225

Chapter 11 Card Gearing Calculations……………………………………………………….227

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11.1 General Gearing Plan…………………………………………………….227

11.1.1 Speeds of Various Parts……………………………………..227x Contents

11.1.2 Draft Calculations……………………………………………..229

11.1.3 Production Calculation……………………………………….229

11.1.4 Length of One Coil and Twist in the Coiled Sliver……230

11.1.5 Doffer Comb Oscillations…………………………………..230

11.1.5.1 Doffer Comb (Worked Examples)………….230

11.1.5.2 Exercises…………………………………………….231

11.1.6 Card-Draft Calculations (Worked Examples)………..231

11.1.7 Exercises…………………………………………………………..232

11.1.8 Card Production Calculations (Examples)…………….232

11.1.9 Exercises…………………………………………………………..234

11.1.10 Calculations of Length and Count of Fillet……………235

11.1.10.1 Worked Examples………………………………..236

11.1.10.2 Exercise………………………………………………237

11.1.11 Waste Percentage Calculations…………………………….237

11.1.11.1 Worked Examples………………………………..237

11.1.11.2 Exercises…………………………………………….238

11.2 Draw Frame Calculations from Gearing…………………………..238

11.2.1 Speed Calculations…………………………………………….238

11.2.2 Draft Calculations……………………………………………..239

11.2.3 Production Calculations (from Calender Roller)…….239

11.2.4 Worked Examples………………………………………………240

11.2.5 Calculations for High-Speed Draw Frames…………..242

11.2.6 Exercises…………………………………………………………..243

References……………………………………………………………………………..244

Index …………………………………………………………………………………………….. 245

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