CARDING: Opening and individualization of fibses Elimination of remaining impurities that are not removed in blow room. Reducing neps of fibre. Fibye blending Elimination of short fibwes To produce a thick untwisted rope of fib¢e called sliver which is uniform in Weight per unit length and suitable for subsequent process. fo ayeene < yallef Types of Card: 4 1. Roller card 2. Stationary flat card 3. Revolving flat card 4.Tandem cad SPF lat : Flak @ Ci) e@ Wc Dope Carding is called the heart of the spinning: why? 1. The fibezg are open more or less single fibve state. 2, Neps, seed coat neps, dirt & dust, trashes, short fibers are removed here. 3. Fibéeblendingiis alse: done here, 4, Sliver is formed here in order to facilitate the next process. For this above reasons carding is called heart of the spinning. Five important setting points in carding 1. Teinto cylinder... 7thou 2... Cylinder to doffer . 4-5 thou t 3. Flat to cylinder i 888.8, Ao 9,9.9.10: Low : Back to ww back to front |. Feed roller to T-in 40 thou e . Motes knife to T-in teh) Cib- peta) a) Upper if P10 th b) Lower knife ~ 12-15 thou eK so ws ‘Thou mean one part of the thousand parts of the one inch. Action in Carding: 1. Carding actions: - This action takes place in between flats to cylinder wire direction are opposite, motions directions are also opposite. Flat2; Stripping action: - This action takes place between taker-in and cylinder wire direction are same, motions are opposite. w 3. Doffing action: - This action takes place between cylinder and a ost Direction of wire is opposite and movement of moving parts are also opposite. < = py — a - Foundation mate: #2 ply foundation — a) Warp cotton & weft woolen, b) Cotton cloth back. #3 ply foundation — a) Cotton cloth face, b) linen warp & woolen weft ©) Cotton cloth back. #4 ply foundation — a+b+c+Yubber (vulcanized) #5 ply foundation — a+b+e+vuleanized rubber + cotton Specification of carding machine: (Conventional carding machine) * Taker-in speed 00-350 r.p.m, * Feed roller surface speed f/min * Feed roller r-p.m. 1.16-2 * Cylinder r.p.m. = 160-170 * Flat surface speed -T inch /min, = Comb vibration 200-1600/min °® Doffer surface speed 0 min * Doffer rpm, * No of flats * Draft Effect of increasing the 1. Waste increase 2. Web quality improves 3. Fibve damage mrejerenr.. 4. Nep percentage reduces Effect of increasing cylinder speed- Cylinder strip reduces, Fibre damage more if setting is closer Good web Leading hook reduces tailing hook increases Better carding action yaere6. Flat and doffer strip high 7. Nep percentage reduces Effect of increasing (changing) doffer speed 1. Production increases, 2. Bad web quality 3. Less fiber damage 4, Cylinder strip increases, doffer strip decreases 5. Leading hook increases, tailing hook decreases Effect of increasing flat speed 1. Flat strip increases 2. Good web quality due to higher strip extraction 3, Neps reduces 4, Fiber damage increases 5. No efffect on hook formation Typical example of card surface speeds and ratios: Part of card Speed (m/min) Feed roller 0.49 Taker-in 340 Cylinder 695 Flats 0.089 Doffer 36.6 Calenders 378 Surface speed ratio: Parts of card exact ratio T-in to feed roller 694:1 Cylinder to taker-in 2.05:1 Cylinder to doffer 19:1 Cylinder to flats Calenders to doffer Card Waste “s Motes and flyes. (33% of total card waste) © Cylinder stripe -16% © Dofferstrip -2.5% | © Flatstripe 45% Clearer waste Sweeping waste | Rest % Re-usableWaste Control: Motes and fly ' 1. Byusing plain sheet under taker-in 2, By increasing length of taker-in under casing 3. By ag the setting between taker-in & feed plate . 4, Bysitetss the setting between taker-in and taker-in under casing Cylinder & dof strip 1. By better opening in taker-in 2. By closer setting between cylinder to doffer 3. By closer setting between doffer and doffer comb 4. By increasing the cylinder speed, higher will be fibyetransfer, less cylinder strip Flat strip: 1. By closer Setting between flat to cylinder 2. By reducing the flat speed , less flat strip Clearer waste: 1. By opening between taker-in cover & feed plate 2. By widening back plate in taker-in region-less air pressure, less clearer waste Features of high production card: 1. Production 4-5 times greater than conventional card 2. Speed — Cylinder -310 r-p.m/450 r.p.m. Doffer ~7-35 rp.m. / 50-70 rpm. T-in = 900-1200 r.p.m. (Medium staple) +700 p.m. (Long staple) ~ 450-500 r.p.m. (Synthetic staple) 3. Card clothing - Metallic card clothing of cylinder, doffer dP pL $ Fredend - Adjustable lap end can accommodate lap 24 ine da 5. Taker-in ~ Extra cleaning arrangement is fitted, extra opening arrangement is fitted. 6. Cylinder under Casing — - Strong & distance betwee two pairs keep less, ° | 7. Flat _ RPeed same but slight mechanical modification ( albamiutaats fled: oa 8. Doffing ~ Roller doffing instead of doffer comb natend » 9. Stop motion -a) Feed end * ee ) Delivery end Hat ae) ¢) ull can stop mation 10. Canchange | ~Can change aftr fll sliver can se «goon 11. Suction hood - More suction hood for better hearing12. Advantages - . * Production high * Low capital cost * Lower labor cost, * Less wastage due to presénge of stop motion * Doffing frequenty less due to large can size * Less stripping & grinding * Less maintenance Web: The filmy like materials is called web3. The comb removes the fibres from the doffer surface as thin sheet. This sheet is called web. This passes through the trumpet the form of sliver where it is deposited into a sliver can. Draft: Ratio of surface speed ofthe elivery roller to the surface speed of feed roller is known as draft. Surface speed of delivery roller Draft = Surface speed of feed roller Drafting: The process of attenuating or increasing the length per unit wt of slivers is called drafting. Regions of carding machine: 1. Taker in (L-in) region 2, Cylinder region and flat region 3. Dofifer and coiler region ; Grinding: The process of sharpening of tooth points in order to give better shape to.the edge is called grinding. Or the process of sharpening and making the wires as equal height from time to time inorder to give better shape to the edge is called grinding. ‘Two types of grinding apparatus are used: 1, Full width long grinding roller/dead roller 2. The traversing wheel grinding Carding angle: ~ Taker-in +5° to -10° Cylinder ++12° to +27° 2 Doffer —++20°to 4.40" Points to &E considered by the spinner when ordering for clothing :( Selection criteriay” Type and design of card Rotational speed of the cylinder Production rate Material through put Type of raw material Overall quality requirement of end product f.- aveene7. Price of the clothing : Factogwhich influenced the optimum setting distances: Staple length 5 Amount of trittrto be removed Weight of lap fed Waste percentage desired Mechanical condition of the machine Hank of the desired sliver au ben ‘What happens 1. Back plate to cylinder setting is wide 2) If setting is too wide, i wll cause the cloudy web, loss of fibre. It wills also intense air current giving production of ly. 2. Setting between cylinder and dofier is increased a) The cotton will be Bapped on cylinder itself or fall down and the doffer will ‘unable to get sufficient cotton anda cloudy web will result. 3. Setting between flat and cylinder is increased: 4) Insufficient amount of neps can be removed b) Poor appearance-af web ©) Less flat stripes 4. Setting between percentage plate or front top plate and cylinder i 8) Loss of good fibre will increase b) Too much flat strips will be expected 5. Setting between feed plate and T-in : a) Fibre rupture Ways of increasing the production of card: 1. By increasing the speed of the machines 2. By putting larger barrow wheel or production wheel 3. By thielenigthe lap <" or increasing its wliyd Fibres arrangement in card sliver: In carded sliver sliver the fibres are ories orientation of fibre is about $5 with fibres are as follows: 15% fibres = leading hook 50% fibres = Tailing hook 15% fibres = Double hook 20% fibres = No hook nted in different directions. Angle of the sliver axis. In the sliver the condition of hookifference between Metallic and Flexible card Metallic Card 1. In metallic wire clothing the teeth are f¢ fl formed integrally with the metallic foundation and rib teeth are rigid. Foundation is also rigid. 2. The teeth have no knees. 3. The teeth angle can not alter under the strain of carding and the fibres can not become embedded behind anything resembling knee: 4. No regular grinding is necessary. 5. The production can be increased to 18-20%. ie: 6. Higher cost of installation due to higher cost of metallic wire. 7. Difficult to repair. 8. No significant deterioration of web quality with time. Flexible Card 1 The wires are inserted in separate foundation material. Both teeth and , foundation is flexible. ‘2. The teeth have knees. 3. The teeth angle can alter under the strain of carding. Fibres become embedded behind knees 4, Regular grinding is necessary. 5, Low production due to loss of time and lower running speed. 6.Less costly. 7. Only the damage part can be replaced instead of reclothing completely. 8.Deterioration of web quality with time. Factor of card clothing that influences the carding action:- Kind and gauge of wire The angle formed at the knee. ‘The grinding of the points The dendéty of the wires ‘Nature of the foundation used ‘The manrier of the insertion of wire The angle at which the wire teeth’s are inserted The relative height of knee and wire pointProblem = ight = 40 Ibs, 1. No of cards feeding to one draw frame =6, Lap weight ye Production of one lap end = 400 Ibs/hr, no of lap ends per blow room =2 Here, N=6, W=40 Ibs, P=4C0lbs/tir, no of lap ends per blow room, I=2 Blending delaystime in minD- Nx Wx 60 PxL 6x 40x60 1. What will be the required mechanical draft ina card making 6% waste to produce a sliver of 0.17 hanks from a scutcher lap weighin; 2 13 ozs/yd? Weight ofsliver = 2000 , a 49 G00 ake a £ ot Mechanical draft ae Actual draft = 99 Fee alle 100 — Wastage % “ a. Ne), = BRED | 4, 100-6” HD ib, G4 160 H:D.= 1092, Calculate the production in Ibs per shift of 8 hrs of a card machine product stiver of 0.20 hanks with 6% waste from the following particulars 9 Diameter of doffer =27 inch R.P.Mofdoffer =8 Running efficiency= 90% 214327 ea60s8s90 36x840x0.20 Production = = 48.45 Ibs per shift. 3. Find out the no of carding machine required for 30000 Ibs per day blow room production from the following data- Card sliver hank=0.12 Card delivery speed =150 m/min Efficiency = 90% 150 x 1.0936 x 60 x 24 x 0.90 Production of carding machine /day = —————_ 840 x 0.12 =2109 Ibs 30000 No of carding machine required = 2109 14.12 14 wu 4, What will be the required D.C.P., when present hk=0.128, required hank = 0.16, and present D.C.P. =31 teeth Present hank Requized D.C.P. = Present D.C.P, x» ——_______ a e Required hank 0.128 =31Kx 0.16 =25 teeth ete 5 fed fle prodeabn 4 6 coal noclian! from ta fellaning parbionles orema cabnkic tole = 80,@ dia ] hake lhe = toch DO eal oliewehtes ous Opeany 9 akrprfe 8G Qaim tenth 4 acd mfes eS prcackion/fhiyl = Clinics, poses aprots STS, peo eS = Bb x GoxXbor Bx CROEL = . a. ERB GORO IF arenes les .A: Production lap wt = 13 oz/yds, production sliver hank =0.14, Actual draft =? 16 Hank of lap = —7-—— 13x 840 = 0.00146 0.14 Actual draft = 0.00146 = 95.89 =96 933 7 } Weight of lap = 14 ibé/yds, Weight of card sliver = 70 grains/yds Actual draft =? 1 1b = 7000 grains, Wt of lap ee = 6125 grian/yd ‘Actual draft = £125 70 = 87.5 = 88, 8. The surface speed of feed tye‘roller is 35 em/min and the coiler calendar rollers have a surface speed of 41.3 m/min. What is the calculated draft? Find out also the production/br. Linear density of card sliver is 4 K-Tex. Out put speed 41.3 x100 Calculated draft= ——____= ______=118 Input speed 35 41.3 x 604 Production per hour=———— =10 kg/hour. 1000 WRE= Xe