Short Staple Spinning: Major Processes Bale Preparation (Blow Room) Lap or Flock Carding (Card) Carded Sliver
(Can)
Open/ Mix/Clean Open/ Mix/Clean
Carding
Flock Feed (Direct from Blowroom)
Sliver
Can
Flats
Carding
Functions:
Cylinder Lap Feed
Opening/disentanglement Cleaning Mixing Sliver forming
Cotton Card: Revolving-flat Card
Card Clothing
Main Types
Flexible: wired teeth protruding from foundation of laminated structure
Metallic (rigid): toothed steel strip
Depth (C)
Overall height (h)
=Carding (working) angle
Metallic clothing Pitch (t) Base width (a)
Card Clothing
Important parameters Working angle Depth Point density Sharpness
Flexible Clothing
Card Clothing: Arrangement
Point-to-Point
Setting
Possible Actions between Two Surfaces with Card Clothing
Point-to-Back
Carding (Point-to-Point) Action
Brushing (Back-to-Back) Action
Fibre clusters divided by two surfaces
Fibres brought to the gap between two surfaces (not used in cotton card)
Stripping (Point-to-Back) Action
Point to Point: Carding Point to Back: Stripping Back to Back: Brushing
Fibres transfer to faster surface
Carding Operations
Feeding Carding Doffing / sliver forming
Feeding Area
Fibres fed by feed roller/feed plate in lap form Pressure =2V2 Lap opened to small tufts by taker-in Trash extracted by mote knifes/grids Fibres transferred to cylinder =1000V1
Key parameters
S1= 0.25-0.5 S3 S2 L1 L2 (1) Lap density Speeds Settings Taker-in clothing
Carding Area
Intensive opening Carding action between flats and cylinder separates fibre tufts to single fibres Trash extracted by flats/removed by fly comb Slow Setting
Flats Cylinder
Fast
Mixing Key parameters Speeds Settings Card clothing Cylinder loading
Fast
Slow
Doffing Area
Fibre transfer (cylinder to doffer) Point to point action Transfer factor: 20-30% If too low: over carding of fibres over loading of cylinder To increase transfer factor: Increase doffer wire working angle and depth Increase doffer speed Decrease cylinder-doffer setting Doffer web removed by stripping roller Web condensed into sliver and deposited in sliver can by coiler
DRAFT
Input Linear Density L1 Machine Input (Feed) Speed V1 Technical draft (actual draft) TD Mechanical draft MD Without Wastage: L1xV1=L2xV2 V2 V1 or L1 L2 = V2 V1 With Wastage: Output (Delivery) Speed V2 L1 L2 Input (Feed) Speed V1 Output Linear Density L2 Input Linear Density L1
DRAFT
Output Linear Density L2 Machine Output (Delivery) Speed V2
Waste (W% of Feed) L1xV1=L2xV2+L1xV1xW% MD=TD (1-W%)
Production Rate
Vd x 60 x Ls (Kg/h) 1000 Vd: Sliver delivery speed (m/min) Ls: Sliver linear density (Ktex) Production rate is affected by: Fibre type Fibre length/thickness Trash content Machine design, settings, maintenance Type Micronaire Staple Length Max. Kg/h Indian 5.0 16-24 41 Low American 4.5 24-26 39 Good American 4.2 26-28 32 Sudan/Egyptian 3.8 29-35 20 Long Egyptian/Pima 3.4 >35 16
Recommended Production Rates (Platt Type 600)
Draft & Production Calculation Example
Given:
Fibre Configuration in Card Sliver
Fibres largely aligned along sliver length
Feed lap linear density: Sliver linear density: Waste: Feed roller diameter: Feed roller speed: Calculate: Total Technical Draft Total Mechanical Draft Production rate (Kg/h)
700 Ktex 5 Ktex 5% 100 mm 3 rpm
Most fibres have hooked ends: 50% (majority) trailing hooks 25% leading hooks 15% double hooks 10% straight
Leading hook in
Trailing hook out
Each process reverses hook direction
Fibre hooks adversely affect:
Yarn strength Yarn appearance Performance of subsequent machines
Sliver quality needs further improvement
