Textile Engineering

1. Workingprincipleofcardingmachine:
1.Feedroller-takerinzone:From thefeedarrangement,thechutematispushed
intotheworkingzoneofthefeedroller-takerin.Thechutematisopenedtotuftsby
thetakerinwirethroughcombingaction.
2.Takerin-cylinderzone:From thefeedroller-takerinzone,theopenedtuftsare
transferredtothetakerin-cylinderworkingzoneforopeningtosmalltuftsize.For
cleaning,thematerialispassedovergridequipmentandmoteknifeattachedthe
undersideoftakerin.Herepointsareinfacetobackarrangement.Suctionducts
carryawaythewastefromtrashbox.
3.Cylinder-Flatzone:Thesmalltuftsarethentransferredtocylinder-flatzoneand
openedupintoindividualfiberwhichisdefinedastheactualcardingprocess.Here
pointsareinfacetofacearrangement.Nepsareremovedinthiszone.Theflats
comprise80-116individualcardingbarscombinedintoabeltmovingonanendless
pathandapprox.30-50flatsareactivetothemaincylinder.Therestareonthe
returnrun.Duringthisreturn,acleaningunitstripsfibers,nepsandforeignmatter
fromtheflatbars.

2. 4.Cylinder-dofferzone:Afterthecardingoperation,thecylindercarriesalongthe
fibersthatareopenedtosingleandlooseconditionaswellaslieparallelwithout
continuousstructure.Forthepurposeofformingacontinuousstructureofthe
cardedsinglefibersthedofferisrequired.Thedoffercombinesthefibersintoaweb.
Herepointsareinfacetofacearrangement.
Actionsincardingmachine:
1.Strippingaction:whentwoclosesurfaceshavesamewiredirectionbuttheir
speeddirectionisoppositetoeachother,thentheactionbetweentwosurfaces
iscalledstrippingaction.Openingandcleaningoffibersisdonebythisaction.
- Actionbetweentakerinandcylinder
- Wiredirectionsame
- Speeddirectionopposite
- Facetobackarrangementofwires
2.Cardingaction:Iftwoclosedsurfaceshaveoppositewiredirectionandtheir
speeddirectionisalsooppositetoeachother,thentheactionbetweentwo
surfacesisknownascardingaction.Openingto individualfiberandneps
removalisdonebythisaction.
- Actionbetweencylinderandflat
- Wiredirectionopposite
- Speeddirectionopposite
- Facetofacearrangementofwires
3.Doffingaction:whentwoclosesurfaceshaveoppositewiredirectionandtheir
speeddirectionisalsooppositetoeachother,thentheactionbetweentwo
surfacesisknownasdoffingaction.Webformationoffibersisdonebythis
action.
- ActionbetweenCylinderanddoffer
- Wiredirectionopposite
- Speeddirectionopposite

3. - Facetofacearrangement
Functionsofcardingmachine:
1.Openingtoindividualfibers:whereastheblowroom onlyopenstherawmaterial
toflocks,thecardingmustopentothestageofindividualfibers.Thisisessential
toenableeliminationofimpuritiesandperformanceoftheotheroperations.
2.Eliminationofimpurities:eliminationofforeignmatteroccursmainlyinthezone
oftakerinandcylinder.Thedegreeofcleaningachievedbythemoderncardis
veryhigh.Cardsliverstillcontains0.05–0.3%foreignmatter.
3.Nepsremoval:whilethenumberofnepsincreasesfrom machinetomachinein
theblowroom,thecardingreducesthenepsbycardingaction.Actuallynepsare
noteliminatedatthecarding,theyaremostlyopenedout.
4.Eliminationofshortfibers:eliminationofshortfibersinthecardingmustbe
viewedinproportion,actuallyverysmall,thelessthan1%shortfibers.
5.Sliverformation:Todepositfibermaterial,totransportitandprocessitfurther
anappropriateproductmustbeformed.Thisisthesliver.
Characteristicsofcardsliver:
1.Notproperuniform
2.Wt.perunitlength=65-80gr/yd
3.Draft=90-120
4.Moreshortfiberspresent
5.Morefibersareprojectedoutoftheslivers
6.Production/hr=(50-100)kg-
7.Hookispresent
8.Cardedsliverareorientedindifferentdirection
Carding:Cardingmaybedefinedasthereductionofanentangledmassoffibers
toafilmywebbyworkingbetweentwocloselyspaced,relativelymovingsurfaces
clothedwithsharpwirepoints.
Neps:Nepscanbedefinedasasmallknotofentangledfibers.Thestructureof
entangledfiberstypicallyrangesfrom0.3to3mmindiameter.
Neps removal efficiency (NRE):

4. = ×100%
nepspergmatmat-nepspergmatsliver
nepspergmatmat
Cardclothing:Thepinwhichisusedtocoverthesurfaceofcardingrollersuch
astakerin,cylinder,dofferandareoffineindiameter,spacedcloselyandbendedin
shapeisdefinedascardclothing.
Typesofcardclothing:
1.Flexiblecardclothing
2.Semi-rigidcardclothing
3.Metalliccardclothing
Cardclothingmanufacturers:
1.Graf
2.Trutzschler
3.Lakshmi
4.ICC(Indiancardclothing)
5.ECC(Englishcardclothing)
Wirespecification:
P-2040S×0.4-B8R
Where,20=heightofwireinmm
40=angleofwireindegree
0.4=thicknessofwireinmm
Selectionofcardclothing:
1.Typeanddesignofcard(jutecard,cottoncard,woolencard)
2.Rotationalspeedofthecylinder(forhighercylinderrpm bettercard
clothingisrequired)
3.Productionrate(togivehigherproductionbetterqualitycardclothingis
needed)
4.Materialthroughput(throughputcapacity800,900or1000ton)
5.Rawmaterialtype(naturalorman-made)

5. 6.Fibercharacteristics(suchasimmaturity)
7.Overallqualityrequirements
8.Priceofthecardclothing
9.Serviceofferedbytheclothingsupplier
Effectivenessofclothinginfluencedbyfollowingfactors:
1.Thequalityofwire
2.Thegaugeofwire(distancebetweentwowire)
3.Theinsertionangleofwireinthefoundation
4.Thegrindingofthewirepoints
5.Thedensityofthewires
6.Theheightofthewires
Grinding:Grindingistheoperationbywhichtheeffectivenessofthewire
pointsofallorgansinthecardingmachineismaintained.Wirepointsof
differentorgans such as takerin,cylinder,dofferand flats loss their
effectivenessinregularfiberprocessingandvariablewt.ofwirepointsand
getirregularcardingaction.So,grindingisnecessarytomakethepoints
sharp.Aftergrinding,theheightofwirereduced.
Objectsofgrinding:
1.Toincreasesharpnessofthewirepoints
2.Tokeepequalheightofwires
3.Togetregularcardingactionanduniformsliver
Typesofgrinding:
1.Traversewheelgrinding:Traversingwheelgrindingdevicecontains
anemerywheelof3.5inchwidthwhichperformsgrindingprocessby
traversingmotion,movingfrom oneendtoanotheracrossthewirepoints
ofdifferentparts.
2.Rollergrinding:Thisdeviceprovidesalongrollerwhichmovesoverfull
widthofcylindersurfaceandperformsgrindingprocess.
Generalfaultsincardingmachine:

6. 1.LowerNRE%:Ifnepsarenotremovedasstandardleveltherefore,card
slivercontainhigherneps/gm.Thisfaultiscreateddueto:
- Impropersettingbetweendifferentcardsurfaces
- Incorrectpointdensityofcardingwire
- Damagedcardingwire
- Impropergeometryofcardcloth
- Incorrectspeedsettingofdifferentcardingsurfaces
2.HighersliverCVm%:Ifslivermassvariationishighincardsliver,then
CVm%ishigh.Thistypeoffaultisproducedduetomalfunctioningofcard
autoleveler.
3.Sliverbreakage:sliverbreaksduetodisruptioninmaterialinflowand
incorrectcalendarrollerpressure.
4.Poorwebstructure:damageddofferwireorimproperstrippingroller
function.
5.Outoflevellinglimit:Ifcontrollimitoflevellingisexceededthen
machinestops.Thistypeoffaultisproducedduetodisruptioninmaterial
inflowfromblowroomorjamminginchutedevice.
6.Rollerlapping:calendarroller,coilercalendarrollerlappingtakeplace
duetoimproperworkingambientcondition.(RH%,temp.)
Developmentincardingmachine:
1.Firedetector
2.Continuoussuction
3.Chutefeedsystem
4.Electroniccontrolsystem
5.Eachsectionisdrivenbyseparatemotion
6.Autolevelling
Autolevelling:Forregulardeliveryorregularoutputofmaterialchanging
draftaccordingtothechangeofinputamountiscalledautolevelling.
Draft:Draftisdefinedastheratioofwt.perunitlengthoftheinputmaterial
tothewt.perunitlengthofoutputmaterial.Draftreducesthewt.perunit
lengthorincreasesthelengthperunitwt.ofthematerial.

7. Draft=
inputmaterialwt.perunitlength
outputmaterialwt.perunitlength
Question:How autolevellingisperformedincardingmachine??
(let,cardmatwt.is550gm/m andrequiredcardsliverwt.is70
gr/yd)
Blowroomandcardingwastagecalculation:
Let,
Cardingmachineproduction=70kg/hr
AmountofDropping2in1hr=3kg
AmountofDropping1in1hr=2kg
AmountofFlatstripin1hr=1kg
So,totalinputinblowroom=(70+3+2+1)
=76kg
Dropping2%= ×100%
3
76
=3.94%
Dropping1%= ×100%
2
76
=2.63%
Flatstrip= ×100%
1
76
=1.31%
Totalwastage=(3.94+2.63+1.31)
=7.88%
1.ToincreaseD2%wehavetoincreasethebeaterspeedandwidenthegridbar.
2.ToincreaseD1%wehavetoincreasethetakerinangle(theanglebetweenfeed
rollerandtakerin)
3.ToincreaseF/S%wehavetoincreasetheflatspeed.
Practice:

8. 1.Aspinningmillhas20cardingmachines.Eachmachinedeliver60kgsliverperhour.
Everyonehour60kgD2,40kgD1&20kgF/Sarecollectedfromdustchamber.Find
outblowroom&cardingwastagepercentageforthisspinningmill.Let,efficiencyof
eachcardingmachineis98%.
Mathematicalproblem:
1.Ifmotorrpmis950,motorpulleydia6inch,beaterpulleydia8inch,thencalculate
beaterrpmandbeats/min.let,no.ofspikesofthisbeateris30.whatcanyoudoto
increasethebeaterrpm?
2.Findoutthedraftofacardingmachineifcardmatwt.is550gm/m,cardsliverwt.
is70gr/yd.
3.Ifdofferrpmis100,dofferdiameteris27inch,thenwhatwillbethesurfacespeed
ofdoffer?
4.Ifdofferspeedis215m/min,cardsliverwt.is70gr/yd,thencalculatethe
production/hr(inkg)ofthiscardingmachine.Let,efficiencyofthiscardingmachine
is96%.
5.Aspinningmillhas10cardingmachine.Cardmatwt.is500gm/m.100drafthas
beengiventoallmachine.Dofferdiameteris68cm,dofferrpmis120,efficiency
95%.Thencalculatethetotalcardingmachineproduction/day(inkg)ofthis
spinningmill.
6.Ifdeliveryspeedofacardingmachineis220m/min,sliverlength/canis9000m.
Findoutthetimerequiredforadoff.Let,efficiency97%.
7.Findoutthesliverwt.(inkg)ofadoffwheredofflengthis9000m.cardsliverwt.is
70gr/yd.
8.Howmuchtimeneededfor10cardingmachinetodeliver1tonsliver.Let,sliverwt.
70gr/yd,surfacespeedofdoffer230m/min,efficiency97%.