Yarn Manufacturing Technology (Some Lab Reports)

Name of Experiment     :  Study on bale opener machine.

Object        :

i.                   To open the tuft of cotton.

ii.                 To mix & blend the fiber.

iii.              To remove a considerable amount of trash from fiber which is taken out by fan.

iv.               To act as a reserver box for the next machine.

Basic Function :

i.                   Regulating motion by swing paddle.

ii.                 Air suctioning.

iii.              Beating action.

iv.               Spiked lattice action.

Main Parts :

i.                   Feed lattice.

ii.                 Bottom lattice.

iii.              Spiked lattice.

iv.               Wiper roller.

v.                 Evener roller.

vi.               Breaker roller.

vii.            Grid bar.

Main setting point :

          i.        Grid bar to grid bar      =       0.75``

          ii.       Beater grid to grid bar =       2``

          iii.      Spike to spike               =       2.5``

Specification        :

i.        Motor r.p.m                                               =       1440

ii.       Motor pulley dia (A)                                  =       3.5``

iii.      M/C pulley dia (B)                                      =       15.5``

iv.      Beater shaft pulley (C)                                        =       6``

v.       Beater shaft pulley (to wiper) dia (L)        =       9``

vi.      Beater shaft pulley (to evener) dia (J)       =       8``

vii.     Beater shaft pulley (to fan) dia (N)            =       16``

viii.    Evener pulley dia (K)                                 =       10``

ix.      Wiper pulley dia (M)                                 =       6``

x.       Suction fan pulley dia (D)                          =       5.75``

xi.      Feed lattice pulley dia (I)                           =       18``

xii.     Bottom lattice pulley dia (O)                     =       18``

xiii.    Inclined lattice pulley (to beater pulley) dia   =       12``

xiv.    Inclined lattice pulley (to bottom lattice) dia  =       4``

xv.             Inclined spike lattice carrier pulley dia,    D2  =  6`5``

D3  =  8``

D4  =  9.5``

xvi.          Spiked lattice carrier pinion teeth, D1      =       24``

xvii.        Spiked lattice wheel teeth                          =       72

xviii.     Spiked lattice pulley (to feed lattice) (H)       =       8``

Calculation :

1.       Feed lattice r.p.m          =

1440*(3.5``/15.5``)*(6``/12``)*(6.5``/9.5``)*(24/72)*(4/18)*(18/8)*(8/16)*(18/10)

=  16.68

2.       Bottom lattice r.p.m =

          1440*(3.5``/15.5``)*(6``/12``)*(6.5``/9.5``)*(24/72)*(4/18)

            =  8.24

3.       Inclined spiked lattice r.p.m =

          1440*(3.5``/15.5``)*(6``/12``)*(6.5``/9.5``)*(24/72)

          =  37.07

4.       Wiper roller r.p.m =

          1440*(3.5``/15.5``)*(9``/6``)

            =  487.73

5.       Evener roller r.p.m =

          1440*(3.5``/15.5``)*(8``/10)

            =  260.12

6.       Beater r.p.m =

          1440*(3.5``/15.5``)

            =  325.15

7.       Suction fan r.p.m =

          1440*(3.5``/15.5``)*(16``/5.75``)

            =  904.78

Conclusion :

          The hopper bale opener is the first m/c in blow room section. It is important because cotton is in bale from open first to produce yarn and if not open, it is difficult to get fine yarn. The m/c that we observed was not running due to the construction of the shed, and electricity was not supplied; therefore we could not observe the working procedure of the m/c. But it helps to change our theoretical knowledge in practical basis.

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Name of Experiment     :  Study of step/ ultra/ super cleaner machine.

Object        :

i.                   To open & clear the cotton by combinations of opposite spike action & the beating action.

ii.                 To remove the impurities such as leaves, stalk, motes & sand without damage the fiber.

Main Parts :

i.                   Motor.

ii.                 Motor pulley.

iii.              Beaters.

iv.               Baffle plate.

v.       Grid.

Main setting point :

          Set to do the require amount as cleaning close grid bars, setting gives good opening & large grid bar setting gives poor opening, other setting points are, Beater to Grid bar = 1`` & beater to beater = 8``.

Specification        :

i.        Motor r.p.m                   =       695

ii.       Dia of the beater           =       18.6``

iii.      Dia of two pulley           =       21.2``

iv.      Dia of one pulley           =       16``

v.       No. of striker                 =       26

Calculation          :

          Beater r.p.m        =       695*(16``/21.2``)

                                      =       524.5

          Beater per min.   =       524.5*26

                                      =       13637

Conclusion           :

          This is the second m/c of blow room line. It works step by step & for this it is called step cleaner. It is a good instrument of opening & cleaning of cotton by the action of beater. It also removes ascertain a out of leaves, stalk & other impurities. It is suitable for process of low grade cotton.

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Name of Experiment     :  Study on high performance carding machine.

Object        :

i.                   Opening to individual fibers.

ii.                 Elimination of impurities.

iii.              Elimination of dust.

iv.               Disentangling of naps.

v.                 Elimination of short fibers.

vi.               Fiber blending.

vii.            Fiber orientation.

viii.          Sliver formation.

Machine Parts     :

i.                   Ducting pipe.

ii.                 Chute feed.

iii.              Feed roller.

iv.               Transport roller.

v.                 Brush roller.

vi.               Flat.

vii.            Fixed carding bars.

viii.          Taker in.

ix.               Grid bar.

x.                 Suction duct.

xi.               Main cylinder.

xii.            Doffer.

xiii.          Stripping device.

xiv.          Calendaring roller

xv.             Coiler.

xvi.          Can.

Action         :

                   The following actions take place in a carding machine.

                  

i.                   Combing action.

ii.                 Carding action.

iii.              Stripping action.

iv.               Doffing action.

i. Combing action          :

                             Combing action takes place feed roller & taken in. Here the pin directions of two surfaces are the same. Combing is the straightening & paralleling of fibers & the removal of short fibers & impurities by using a comb or combs which is assisted by roller & brushed.

ii. Carding action :

                             Carding action takes place between flat & cylinder.

                   In carding action,

                   i.        Directions of wire in two surfaces are opposite.

                   ii.       The moving directions of roller are also opposite.

                   iii.      One roller is slower & other is faster.

                   So carding action is known as “Point against point” action.

iii. Stripping action :

                             Stripping action takes place between,

                             a)      Taker in and Cylinder  &

                             b)      Doffer and stripper.

                   In stripping action,

                   i.        Wire direction will be the same.

                   ii.       Roller moving direction will be the same.

                   iii.      One roller will be faster than another.

So stripping action is known as “Point back point” action.

iv. Doffing action :

                             This action takes place between cylinder & doffer. In this place fiber is transferred from cylinder to differ. Low speed doffer is called fiber form of high speed cylinder & makes a condensed web for formation of sliver.

Working principle :

         

i.                   Supplying raw material by ducting pipe.

ii.                 Chute feed evenly compress a bat of 500-900 kfex.

iii.              Transport roller forwards the material to feed plate.

iv.               Feed arrangement consists of feed roller & feed plate.

v.                 Taker in opens the material to small flocks. When the material passes to main cylinder, mote knives, grid bars & carding segments eliminate a great part of impurities.

vi.               Grid equipment.

vii.            Suction dust to carry away the waste.

viii.          Main cylinder & fixed carding segments designed to assist the carding operation.

ix.               The main carding operation occurs between flats & cylinder. Flats compromise 80 to 116individual carding bars combined into a band moving on an endless path. 30 to 46 flats are always in action.

x.                 Cleaning unit cleans stripes fiber, naps & foreign matters from flats.

xi.               Grid or cover plate.

xii.            The doffer combines the fiber into a web. Because of it’s substantially lower speed relative to the cylinder.

xiii.          Stripping device & doffing master draw the web from the doffers.

xiv.          Calendar roller calendars the cotton & moves that toward.

xv.             At last by can & coiler the fabric is produced.

Conclusion :

                   Carding is the process of arranging the fiber in parallel fusion. This is necessary for all staple fiber. Otherwise it would be impossible to produce fine yarn. Before the raw stock can be made into yarn, the remaining impurities must be removed. The fiber must be in different angle & they must be straight turned. The card is the hard of the spinning mill & well carded is half spun. Demonstrated the immersed significance of carding for the final of opening operation.

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Name of Experiment     :  Study of crighton/ twine/ vertical machine.

Object        :

i.                   To strike the cotton while it is being carried by the air current.

ii.                 To open the cotton in to small fault.

iii.              To use low quality cotton (i.e. cotton of short staple & more impurities).

Main Parts :

i.                   Motor.

ii.                 Motor pulley

iii.              Discs with strikes.

iv.               Inclines Grid bar.

Adjustment of Different parts :

          1. Grid bar to grid bar  :

Wider setting:      High fiber loss, poor opening & cleaning,               high speed, high productions.

Closer setting:     Good opening, low speed gives lower fiber loss & low production.

          2. Blade to grid bar       :

Wider Setting:     No fiber damage, high production, poor opening & cleaning.

Closer setting:     Fiber damage, low production, lower removal of impurities, good opening.

Specification        :

i.        Motor r.p.m                  =       1440

ii.       Motor pulley dia            =       14``

iii.      M/C pulley dia               =       32``

iv.      No. of striker                 =       6

Calculation          :

          Beater r.p.m        =       1440*(14``/32``)

                                      =       630

          Beats per min      =       630*6

                                      =       3780

Conclusion           :

          This is the third m/c of the blow room line. It stands on a vertical shaft & hence it is called vertical opener. This m/c is a major cleaning point of blow room line. There is a by pass system. So from step cleaner cotton can be difficulty pass to the hopper feeder without vertical opener. It can be used in case of low grade cotton. For beater opening & cleaning close setting of striker is done. But there is a rise of more fiber damage. Hence moderate setting is done.

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Name of Experiment     :  Study on passage diagram of draw frame.

Object        :

i.                   To straightening the creped curled & hooked fibers.

ii.                 To make the fibers parallel to their neighbors.

iii.              To improve uniformity of fibers by drafting & doubling.

iv.               To reduce weight per unit length of sliver.

v.                 To remove dust from sliver.

vi.               To blend raw materials of same husk perfectly.

Tasks of draw frame :

i) Equalizing:

One of the main tasks of the draw frame is improving crenness over short, medium and specially long terms. Card sliver feed to the draw frame have degree of unevenness that can not be tolerated in practice and sliver from the comber contain the “in famous” piecing. It is observed by draw frame.

ii) Parallelizing:

                   To obtain an optional value for strength in the yarn characteristics the fibers must be arranged parallel in the fiber stands. The draw frame has the tasks of creating this parallel arrangement.

iii) Blending:

                   In addition to the equalizing effect doubling also provides a degree of compensation of raw materials variation by blending. The result is exploited in particular in the production of blended yarns comprising cotton/ synthetic blends.

iv)  Dust removal:

                 Dust is steadily becoming a great problem both in processing and for the personal involved. It is therefore important to remove dust to the partial extant at every possible point within the overall process.

Operating device :

→ Creel (Sliver feed)

→ The drafting arrangement

→ Suction system for the drafting arrangement

→ Cooling

→ Can changer

Working principle:

i)                   Four to eight card or draw frame slivers are feed to the drafting arrangement.

ii)                A feed roller pair is located above each can to enable the feed step to be performed in a controlled manner without false drafts.

iii)              The feed roller pair is carried in a creel frame or table and each is positively driven.

iv)              The slivers running into the drafting arrangement leave it, after a draft as a web lacking significant cohesion.

v)                 In order to avoid distinguish of the web, which would other wise be unavoidable at the high operating speeds currently in use. It is condensed into a sliver immediately after the drafting arrangement.

vi)              This sliver is then guided through a tube via a passage of the tube gear into a can. In which it must be laid in clean coils with optimal utilization of the space in the can.

vii)            To enable the can to take up as much material as possible, the sliver is compressed by passing it through it calendaring or grooved rollers.

Conclusion :

                    From a purely commercial point at view draw frame is of little significance. But it is influence on quality and evenness is greater. The carded sliver contains fibers which they are crimped, hooked for curled. They are entangled with one another and their height per unit length is high. They are irregular and constant some impurities. So they used a process for eliminating these errors.

 In cotton spinning line draw frame in the definite compensation point for eliminating errors. So the carded sliver is actually made perfect in quality and evenness of draw frame.