International Journal of Textile and Fashion Technology (IJTFT) ISSN 2250-2378 Vol.

3, Issue 2, Jun 2013, 1-14 TJPRC Pvt. Ltd.

STUDY OF LOOP FORMATION PROCESS ON 1 1 V-BED RIB KNITTING MACHINE PART1: A MATHEMATICAL MODEL FOR LOOP LENGTH
SRINIVASULU K, MONICA SIKKA & J HAYAVADANA Department of Textile Technology, National Institute of Technology, Jalandhar, India

ABSTRACT
The mathematical model was proposed in order to determine the Loop length of a V-bed rib knitting machine based on two dimensional coordinates of knitting zone. Those were obtained by stitch cam profile equations. The final configuration of loop length was divided into 17 segments and each segment is given by an equation. The rib Loop length depends up on three variables i.e yarn input tension, cam setting, and takedown were given included in the expression. In this model variables like wrap angles, depth of needles and distance between cast-off loops are considered and these variables ultimately effect the loop length calculated from the model. A computer program has also been generated in JAVA to determine the theoretical loop length of V-bed flat knitting machine from the mathematical model proposed.

KEYWORDS: Yarn Input Tension, Cam Setting, Takedown Load, Loop Length, Needle Bed Verges, Wrap Angles,
Depth of Stitch Cam, and Loop Arm Configuration

INTRODUCTION
Loop length plays an important role in knitted fabric production in order to meet buyer specifications and consumer satisfaction and the investigation of geometrical loop length or theoretical loop length which makes the production of knitted fabric easy for knitter and it consumes less time to produce the fabric of different specifications. Ultimately the rate of production will increase if we know the theoretical calculations of knitted fabric parameters. The loop formation process became a subjective matter of research from past 50 years, and some studies related to loop formation process are available in literature. The mechanism of single jersey loop formation process as explained by Knapton and Munden (1966) was based on the concept of robbing back (%). A mathematical model of the single jersey weft knitted process involving flat bottom stitch cam was formulated by Alsaka. Peat and Spicer developed a geometrical model of single jersey loop formation process. A mathematical model of single jersey loop formation process involving non-linear stitch cam and incorporating five different stages of initial geometry of knitting zone was developed by Lau and Knapton. In present work an attempt has made to study the impact knitting processing variables like yarn Input tension, Cam Setting, and Take down Load on loop length and developed a mathematical model of loop formation on 1x1 rib loop formation process on V-Bed flat knitting machine. The model is developed by considering two-dimensional coordinates of knitting elements by rotating both front bed and back bed to 450 and considering the tuck point as an origin of coordinate system. Based on 2D geometry a mathematical model has been developed for rib loop length. The model is validated experimentally and statistically.

GEOMETRY OF KNITTING ZONE

On V-Bed rib knitting machine the geometry of knitting zone (KZ) was explained by boundary elements, namely

Srinivasulu K, Monica Sikka & J Hayavadana

front bed needles (FN) and Back bed needles (BN, the yarn comes in contact with Front bed verge (FBV) and Back bed verge (BBV). The phase difference between front bed knitting point (FKP) and Back bed knitting point (BKP) on V-Bed rib knitting machine is adjustable. Hence the geometry of knitting zone will be contour of the stitch cams, cam setting, front bed gap (FG) and Back bed Gap (BG) between the beds, the phase difference between FKP and BKP, and the position of the contact points of loop arms with bed verges.

Back needle bed

Figure 1: The Knitting Zone Geometry of V-Bed Rib Knitting Zone The geometry of knitting zone of V-bed machine is three dimensional in nature (As shown in figure 1) and it can be represented in simplified form on a two-dimensional plane by rotating both the beds through 45 o.

STITCH CAM PROFILE OF 1 X 1 V-BED KNITTING MACHINE

Figure 2 Stitch Cam Profile of 1 X 1 V-Bed Knitting Machine Coordinates of the Needle Inside Knitting Zone and Geometrical Length of Loop The reference line described by the equation
.

. After crossing clearing point, the needle would follow the

profile of descending side of the stitch cam i.e. OAC After crossing knitting point(C), the needle may follow the ascending

Study of Loop Formation Process on 1 1 V-Bed Rib Knitting Machine Part1: A Mathematical Model for Loop Length

side profile of stitch cam CYZ (shown in figure 2). The position of any needle inside knitting zone can be determined from equations the stitch cam profiles. The equations of stitch cam profiles (from figure 2) derived in terms of cam angles, tuck height(Y), half needle spacing (a). So, if the X-value of any needle known, the X-value of the other needles and Y values of all the needles can be calculated using the equation of the cam profiles and other machine parameters. If , where i =1, 2, 3. is the position of along X-axis than

And distance between neighbouring FN and BN.

, where a is the half needle spacing, i.e

After initial contact with yarn, as the FN1 is shifted towards the knitting point by an amount Sx, the new positions of FNs would be given by:

= And the new positions of BNs given by:

The new coordinates Y values of FNs and BNs corresponding to new X values would then be calculated from equations of the cam profile. As the needle take up new positions after a small shift from previous positions the vertical distances of the needles with respect to the reference line also change. This would results in change in geometric length of loop arms as well as wrap angles. The new position, the inclination and configuration of loop arms may also change. Equations of Stitch Cam Profile Equations of Front Bed Stitch Cam Profile For descending side (OXOC).

Where md is magnitude of slope on the descending side of front bed stitch cam. And ma is magnitude of slope on the ascending side of front bed stitch cam. For ascending side (OCXOE)

For ascending side (OEXOG)

Where G is gap between two beds

Srinivasulu K, Monica Sikka & J Hayavadana

Equations of Back Bed Stitch Cam Profile For descending side (O<X<OD)

Where md is magnitude of slope of descending side of back bed stitch cam For ascending side (OD<X<OI)

Where ma is magnitude of slope of ascending side of back bed stitch cam

LOOP ARM CONFIGURATIONS

The configuration of loop length has been changes continuously as both needles will take a new position until needles reaches to knitting point position. There four different combinations of loop arm configurations were observed. From figures 3 to 6.

Figure 3: Loop Arm Configuration When Both Fn1 and Bn1 are Between Bed Verges After needle contact with yarn at feeding point position the front bed needle (FN1) has moved below the reference line with yarn in hook but yet to reach the level of FBV, and back bed needle has moved below the BBV line. In this case the leading and trailing arm lengths are not identical.

Figure 4: Loop Arm Configuration with Presence of Cast-Off Loops

Study of Loop Formation Process on 1 1 V-Bed Rib Knitting Machine Part1: A Mathematical Model for Loop Length

From figure 4 it is observed that both FN1 and BN1 are moved below the verge levels, and the depth of needles also same. The BN2 already takes new position and it reaches to below verge line, the depth of needle is more than that of both FN1 and BN1.

Figure 5: Loop Arm Configuration When All Three Needles are Moved Away from Bed Verges In case 5 all three needle were below verge levels but depth of needles are different. As in the last the depth of FN1 and BN1 is same but here depths of three needles are different. And the leading and trailing arms are not equal. From figure 6 the crowns of all the three needles (FN1, BN1, and BN2) are positioned below their respective bed verges. Depth of needles (FN1 and BN1) is same below the verge lines and depth of needle (BN2) is less than that of remaining two. And the loop configuration is settled in balance position, means needle were reached lower most (knitting point) positions, and this configuration taken as final loop length diagram.

Figure 6: The Final Loop Arm Configuration When Both the FN1and BN1 Reached their Knitting Point

FORMATION OF WRAP ANGLES AT DIFFERENT STAGES OF LOOP FORMATION ON V-BED RIB KNITTING MACHINE
Loop formation process was studied at different stages by moving hand lever at very minute speed. It was observed that the needle come contact with the yarn well before entering into the knitting zone. After making contact with yarn, the needle passed through different stages while moving downwards, as illustrated in figure 7 To 12.

Srinivasulu K, Monica Sikka & J Hayavadana

Figure 7: Initial Yarn Feeding Point Position

Figure 8: Front Needle (Fn1) Needle Contact Position with Yarn

Figure 9: Formation of Wrap Angle around Front Needle Position

Study of Loop Formation Process on 1 1 V-Bed Rib Knitting Machine Part1: A Mathematical Model for Loop Length

Figure 10: Position of Front Needle Below the Reference Line

Figure 11: Position of Front Bed Needle Below Reference Line with Wrap Angle a Around it

Srinivasulu K, Monica Sikka & J Hayavadana

Figure 12: Knitting Point Position of Font Bed Needle

DERIVATION FOR WRAP ANGLES (, )

Figure 13: Initial Yarn Needle Yarn Contact Point Form figure 13

ED a parallel line CA. DG, AERR

So NOW From CAF, And AD Perpendicular to CD Than From CAD

Than

From the same figure

Study of Loop Formation Process on 1 1 V-Bed Rib Knitting Machine Part1: A Mathematical Model for Loop Length

And FROM BAN

And from BAL

Than

Where K=

DESCRIPTION OF FINAL LENGTH CONFIGURATION AT KNITTING POINT

The total length of loop was divided into 17 segments (figure 14), and the expressions of length of loop arm segments are derived segment wise form the values of needles and yarn dimensions, gauge of the machine, different contact angles, coordinates of needle, angles made by yarn with bed verges, wrap angles, cam angles and depth of needles from bed verge lines. And the expressions are not similar to expressions derived on Dial and cylinder machine. The contact angle () between yarns of new loop and old loop has also been considered. The theoretical loop length represents maximum length of yarn contained in repeating unit (Loop), so the loop length has taken when the FNs reached to its lowermost position (i.e. knitting position). Assumptions and Notations In order to develop a model of the 1x1 loop formation process on v-bed machine the following assumptions were made. At their mutual contact points the yarn and needle are circular in cross-section. The line of contact between yarns in new and cast off loops follows the path of arc of circle. The line of contact between yarn and needle follows the path of an arc of a circle. Below the bed verge line the half angle of wrap around any needle is not 90 o The coordinates of a needle corresponding to that of the tip of the crown. The build up in the yarn tension obeys Amontonss capatan equation of friction as yarn passes over and under the knitting elements or across the yarn surface. The yarn tension develop inside the knitting zone is proportional to the tensile strain in the yarn. The space between two intersecting points of cast off loops is fixed between two needle separators.

The following notation is used in formulating mathematical relations (Figure 14)

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Srinivasulu K, Monica Sikka & J Hayavadana

RR Y X h1 h2 a H Ni E

= = = =
=

A horizontal line where front and back bed needles will coincide. Vertical distance between the reference line and X-axis. Horizontal distance between the feeding point and Y-axis. Depth of Front bed stitch cam below the bed verges at knitting point. Depth of back bed stitch cam below the bed verges at knitting point. half needle spacing Feeding point height with respect to reference line. The ith needle. Elastic coefficient of yarn, equalling the load per unit strain (relative rigidity). Radius of the yarn. Radius of front bed needle. Radius of the back bed needle Half wrap angle around front bed needle. Half wrap angle of trailing arm around back bed needle (Bn1). Half wrap angle of leading arm around back bed needle (Bn2). Angle made by yarn with cast- off loops. Angle of path of yarn with machine bed verges The angle made by yarn with horizontal Bed verge line at front bed knitting point. The angle made by yarn with front bed needle position at reference line Bed verge line. The angle made by yarn with horizontal Bed verge line at Back bed knitting point.

= = = = = = = = = = =

= = = =

LOOP LENGTH AT KNITTING POINT

Study of Loop Formation Process on 1 1 V-Bed Rib Knitting Machine Part1: A Mathematical Model for Loop Length

11

Figure 14 Configuration of Loop Length At Knitting Point The theoretical loop length (Lt) =AC+CD+DE+EG+GI+IJ+JK+KL+LM+AN+NO+OP+PQ+QR+RS+ST+TU+UV From figure Arc AFC = From arc CFD Draw a parallel line to DE through F and CLF is half cast off loop spacing (S/2), DE= FF2 From FF2F (I)

Loop arm makes an angle with cast- off loops From arc ECLG From figure II is parallel to BBV line and draw a perpendicular from G on II Than from GII

From arc ICLJ , From the figure JK=DE

From arc KBL

From arc LBM

AN=AC = ON=CD = OP=DE =

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Srinivasulu K, Monica Sikka & J Hayavadana

From arc PCLQ From RQQ

SR=

ST = TU =

UV = Derivation for Expression of Wrap Angle around Front Bed Needle (FN1)

Figure 15: Wrap Angle around Front Bed Needle (FN1) Consider front bed needle (FN1) is above front bed verge. The leading arm angle ( Now From BEF we have

So From BFK

Than

Study of Loop Formation Process on 1 1 V-Bed Rib Knitting Machine Part1: A Mathematical Model for Loop Length

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So

Derivation for Expression of Wrap Angle around Back Bed Needle (BN1)

Figure 16: Wrap Angle around Front Bed Needle (BN1).

The Trailing arm angle ( Now From FBK

Than From FBL we have

So

FINAL THEORETICAL LOOP LENGTH (lt) =

CONCLUSIONS
In this model three variables yarn input tension, cam setting, Takedown load has been studied and how these variables effecting the loop length. In the theoretical expression three variables included as wrap angles (L), depth needles from bed verges (h1, h2), space between two cast off loops respectively. The final loop arm configuration divided in to 17 segments each segment is given by an expression based on mathematical geometry. And a JAVA program also generated

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Srinivasulu K, Monica Sikka & J Hayavadana

in user friendly manner so that the input parameters under studied can be varied according to requirement. After execution of programme for any combination of input parameters, the required output parameters are noted or printed from result file. The output parameters were compared with experimental results.

REFERENCES
1. Banerjee, P.K., and Alaiban, T.S (1987)., Mechanism of Loop formation at Extreme cam setting on a sinker top machine: part II Analysis of limiting conditions, Textile research journal, 57, 568-574. 2. Banerjee, P. k., and Alaiban, T.S (1987)., Mechanism of Loop formation at Extreme cam setting on a sinker top machine: part I Relation between count, gauge, and tightness factor, Textile research journal, 57, 513-518. 3. Banerjee, P. K., and Ghosh, S (1999)., A model of single-jersey Loop-formation process, Journal of textile institute, 90,187-208. 4. Carmine Mazza, Paola Zonda (2001), Knitting (A reference book of textile technology), ACIMIT, The Italian association of textile machinery producers, first edition. 5. C. Prakash and C. V. Koushik (2010)., Effect of loop length on the dimensional properties of silk and model union knitted fabric, Indian Journal of Science and Technology,7,752-754. 6. 7. David H. Black (1968)., Design And Performance Of Weft-Knitting Machinery, a Ph.D thesis report. Ghosh, S., and Banerjee, P. K (1990)., Mechanics of the single jersey weft knitting process, Textile Research Journal. 60,203-211. 8. J. J. F. Knapton and T. W.-Y. Lau (1978)., The design and dynamics of non-linear cams for use in high-speed weft-knitting machines part 1: the theoretical dynamics of non-linear cams., Journal Of Textile Institute ,69,161168. 9. Knapton, J.J.F., and Munden, D.L (1966)., A study of mechanism of loop formation on weft knitting machinery ,Textile Research Journal 36, 1072-1090. 10. Knapton, J. J. F (1968)., the dynamics of weft knitting: further theoretical and mechanical analysis, Textile Research Journal, 38,914-924. 11. Knapton, J.J.F., and Munden, D.L (1966)., A study of mechanism of loop formation on weft knitting machinery, part II: the effect of yarn friction on yarn tension in knitting and loop formation ,Textile Research Journal 36, 1081-1091. 12. Noboru Aisaka (1971)., Mathematcial considerations of weft knitting process, Journal Of The Textile Machinery Society Of Japan,24,82-90. 13. Nuiting. T.S., Kinetic Yam Friction and Knitting, Journal of Textile Institute, 51, 190-202(1960). 14. Noboru aisaka, and Tatsuya kawakami (1969)., knitting tension during weft knitting process, Journal of Textile Machinery Of Japan,22,228-233. 15. Ray, S.C., and Banerjee P.K (2000)., Some preliminary investigations into mechanics of 1x1 rib loop formation on a dial and cylinder machine, Indian Journal of Fibre & Textile Research. 25, 97-107. 16. Spencer, D.J., knitting technology, third edition, 85(2001), Woodhead Publishing Limited. 17. Sadhan chandra Ray. , and Banerjee P.K (2003)., Mechanics of 1x1 rib loop formation on a dial and cylinder machine: part I- Modelling of the 1x1 rib loop formation process, Indian Journal of Fibre & Textile Research. 28,185-196. 18. Sadhan chandra Ray., and Banerjee P.K (2003). ., Mechanics of 1x1 rib loop formation on a dial and cylinder machine: part III-Validation of the Model, Indian Journal of Fibre & Textile Research. 28,246-259.