CHAPTER 1

INTRODUCTION
Carding is known to have a critical influence on yarn quality and

performance in ring frame. The two proverbs of the experts holds true today. "The

Carding is the heart of spinning mill" and "Well carded is half Spun."

Technologically the card has the task of CLg and seperation of immature

fibres and neps along with removal of other impurities and of producing a uniform sliver

with minimum uH deviation yard.

The carding quality could be judged by

1) Transfer Efficiency %

2) Nep Removal Efficiency.

3) Fibre Arrangement In Sliver.

So here we have studied some of the aspects of carding mainly associated

with the transfer of fibre between Cylinder and Doffer.

"Transfer Efficiency is defined as the percentage of fibre transferred to

doffer from cylinder per revolution of cylinder."

The Transfer Efficiency of card is important from the point of view of

determining the level of loading of the cylinder. A poor Transfer Efficiency results in

excessive loading of fibres on cylinder, which restricts the further scope of card for

improving the quality and increasing the production level. But the higher Transfer

Efficiency need not be taken as a measure of good carding.

 The cylinder load consists of two parts viz-basic load and working load.

The basic load represents the fibres, which get absorbed into the cylinder foundation over

a period of time. And the working load represents fibre load on surface from which fibre

get transferred to the doffer. In the metallic cards fibres on the surface constitute the

cylinder load.

A high cylinder load is naturally determined to good carding. Since it enter

fares with fibre separation and individualisation in cylinder flat region.

Transfer Efficiency of card is very sensitive to some of the settings in card.

Transfer Efficiency or Transfer Ratio is going to change not only from machine to

machine but also due to some machine parameters, like speed, settings, card clothing etc.

when ordinary card clothing is used the Transfer Efficiency is about 5%. Now a day with

metallic wires being introduced, the Transfer Efficiency is enhanced upto 25%. This is

because the loading and unloading characteristics of the card varies with the flexible wire

and metallic wire.

 CHAPTER 2

LITERATURE REVIEW

1. CYLINDER LOAD AND TRANSFER EFFICIENCY

Chattoppadhyay (l) shows that during the course of carding, a layer of

fibre accumulates on cylinder. Part of it continuously passes on to the doffer whilst it is

replenished by fresh fibres from feed. The quantity of fibre that remains on cylinder at the

steady state operation level is termed as cylinder load. This has a considerable influence

on carding efficiency and productivity.

1.1 Transfer Efficiency:

The nature and direction of cylinder and doffer wire points and their

relative surface speeds are such that only a fraction of the fibres on the cylinder are get

transferred to the doffer during each rev of cylinder. This fraction when expressed as

percentage of cylinder load is termed as transfer efficiency. It can be calculated as per cut

and weight method.

1.2 Cylinder Load Built Up :

As only some fibres get transferred from cylinder to doffer during each

revolution of cylinder the cylinder load will built up initially when an empty card is first

started and attains a steady state after a few minutes of working, at this stage, the rates at

which fibres are fed to the cylinder and transferred to the doffer are equal. The steady

state of cylinder load will depends upon other things like cylinder speed, card production

rate and transfer efficiency.

1.3 Carding Quality:

 A high cylinder load is naturally determined to good carding since it

interferes with fibre separation and individualisation in cylinder flat region. Low transfer

efficiency is also undesirable, as it not only leads to building up of higher cylinder load

but also over working of fibres since poor transfer efficiency results in the fibres being

taken round the cyl more no. of times than necessary and it causes nep generation.

1.4 Behaviour Of A Card During Transient State :

When a carding machine is started with feed engaged, one can notice that

the sliver that comes out initially is very thin. The linear density of the sliver gradually

builds up and reaches the steady state value. Similarly when the feed to the card is

stopped suddenly the linear density of the sliver gradually reduces till it becomes zero.

The behaviour of the card during these two transient stages is very important and gives an

interesting insight about the carding process.

1.5 Simpson's Analysis :

Simpson(2) shows that it has been pointed out that the doffer collecting

fraction i.e. the proportion of fibre transferred to doffer depends upon the following ratio

of wire angles

i.e.

R = ( Sin β2 + Cos β2)/( Sin β1 + Cos β1)

β1 = inclination angle of cylinder wire point.

β2 = inclination angle of doffer wire point.

This ratio reaches its maximum value 1.414 when β1 =90° and β2=45°.
 However, since a cylinder wire point angle of 90° would not given a good

carding action. Hence angle of 88° for cylinder and 45° for doffer are suggested.

1.6 Parameters Affecting Cylinder Load And Transfer Efficiency :

1.6.1 Doffer Speed:

Krylov's [3] shows keeping production rate constant, if doffer speed is

enhanced with a proportionate reduction in sliver hank the load on cylinder decreases and

Transfer Efficiency increases.

It means at the same production rate a combination of faster doffer and

lighter sliver improves carding.

1.6.2 Cylinder Speed:

Krylov's [3] experimental data shows an increase in cylinder speed

reduces load on cylinder. Baturin plotted values of transfer coefficient (K) as a function

of ratio of production rate to cylinder surface speed (P/Vc). it may be observed from data

that transfer efficiency (K) gets affected to a substantial extent bd reduction in ratio P/Vc.

By enhancing cylinder speed, the load cylinder reduces.

Bhaduri [4] has shown that with an increase in cylinder speed the load on

cylinder reduces with a concomitant increase in transfer coefficient.

1.6.3 Sliver Linear Density:

 Simpson and Fiori [5] the influence of liver linear density can be studied

by following two different methods.

1. Change in linear density at a constant cylinder speed and production rate (i.e. varying

constant cylinder doffer surface speed ratio).

2. Change in linear density at a constant production rate and varying cylinder speed (i.e.

constant cylinder doffer surface speed ratio).

In the first case, in order to keep the production rate constant, the doffer

speed needs to be adjusted according to sliver linear density. This however changes

cylinder doffer surface speed ratio since cylinder speed remains unaltered.

In the Second Case, to keep the cylinder doffer surface speed ratio

constant, the cylinder speed is also changed in proportion to change in doffer speed.

From above discussion it can be concluded that heavier sliver increases

loading and decreases transfer efficiency.

Simpson and Fiori [5] had also observed the load to be more for heavier

sliver (80 gr/yd) than the lighter (50 gr/yd) one irrespective of production rate. Transfer

efficiency was always higher for lighter sliver

1.6.4 Cylinder Doffer Surface Speed Ratio:

Bhaduri [4] shows that this ratio can be changed by tow ways i.e. by

changing

1. Doffer speed keeping cylinder speed constant

2. Cylinder speed keeping doffer speed constant.

 However, method (1) will also need to change the sliver linear density, in

order to keep the production rate constant. A study conducted by Bhaduri [4] shows that

the influence of this ratio depends upon methodology adopted for its change. When the

ratio is increased by decreasing doffer speed, cylinder load increases and transfer

efficiency decreases. However if it increased by increasing cylinder speed, loading

decreases and transfer efficiency increases.

1.6.5 Production Rate:

Through increase in doffer speed

Bhaduri [4] shows that an increase in production rate through doffer speed

results in increase in loading and as well as transfer efficiency. It means even though

transfer efficiency increases, it does not increase proportionate to increase in production

rate, resulting cylinder load to increase. Simpson and Fiori [5] have also reported cylinder

load to increase with production rate which was varied in the range of 15-50 lb/h.

Transfer efficiency increased with production rate only in the case of higher

micronaire (5.5) cotton. For others it shows a tendency to decrease.

Through increase in sliver linear density

Change in production rate (from 6.1 lb/hr to 18.1 lb/hr) through (gr/yd)

increases loading and decreases Transfer Efficiency [5] as shown.

1.6.6 Cylinder Doffer Setting:

 Chattopadhyay [1] have shown using fluorescent tracer fibres that Transfer

Efficiency increases with closer setting Nerukar and Murthy [6] also had made a similar

observation. Bhaduri [4] also has reported loading to decrease and transfer coefficient to

increase with closer setting since it increases the zone of interaction between cylinder and

doffer.

1.6.7 Effect Of Cylinder And Doffer Diameters:

Chattopadhyay [1] shows that the diameter of Cylinder and Doffer affect

two important parameters namely

1. Entrapment Power

2. Length of interacting zone.

The coefficient determining the ration of entrapment powers of the card

clothing of cylinder and doffer in relation to the angle of inclination of front flank (K2)

gets affected by the diameters of cylinder and doffer. The higher is the coefficient the less

will be the fibre load.

If the diameter of doffer is reduced by half, the zone of interaction is

reduced by 0.7 and the coefficient of entrapment by 1.18. Hence reduction in size may

increase cylinder load.

1.6.8 Wire Parameters:

Wire Point Density

Simpson [2] analysis reveals that a higher wire point density on doffer will

reduce cylinder load. A comparison of data indicate that though cylinder load reduces

with enhancement of wire point density on doffer but the effect is less critical than wire

angle.

The influence of all the variable discussed so far has been given in a

tabulated form.

2. MECHANISM OF TRANSFER OF FIBRES IN CARD

The production rate of the card is considered to have a critical influence of

processing at subsequent machines a well as on yarn quality and it is only recently that

attempts to increase the production rate of the machine without deterioration of quality

have met with some success. Developments in carding have been considerable

hampered for want of an adequate measure of carding quality, that would give

appropriate weightage to the different actions of carding and bear a significant

relationship with yam quality and processing performance. The operation of carding can

be broadly classified into the following aspects:

1. Cleaning capacity of the card

2. Degree of fibre to fibre separation

3. Level of nep generation in card

4. Time required to get the fibres carded

5. Time during which fibre remains on the card after carding action is over
 6. Means by which only the carded fibres are taken cut while the uncarded portion of

fibre is allowed to remain in the card till the carding is complete for that portion.

Insufficient fibre-to-fibre separation, blunt card wire which causes rolling

of fibre and improper machine settings. A low level of neps may not always assure

satisfactory degree of fibre to fibre to fibre separation. Hence, degree of fibre-to-fibre

separation has to be considered as another aspect of carding.

Poor level of fibre-to-fibre separation produces cloudy web and further

affects the even drafting of card sliver at the subsequent processes even upto ring frame.

But a present there is no tool to measure the degree of fibre separation achieved in

carding.

The time required to get the fibres carded, and the time for which fibres

remains on the card after carding action is over decide the potentiality of the card for high

production rates without deterioration of the quality. With increase of this time element,

loading of cotton fibres on cylinder increases, resulting either in deterioration of carding

quality or limiting any increase in the card production rate further. Put, here also, actual

time required for carding and the time for which the fibres remain in the card after

carding cannot be measured separately.

When the production rate of carding has to be increased, three factors

should be considered:

1. Card should be able to clean the cotton at the highest speed;

2. It should separate fibres from other in the time available; and

 3. Fibres should get transferred from cylinder to doffer immediately after carding

(fibre-to-fibre separation) is complete and there is no undue build up of load on

the cylinder.

The studies revealed that a fibre rarely gets transferred from cylinder to

doffer at the first revolution, but, in fact, goes around the cylinder a number of times

before getting transferred to the doffer. This technique of tracing the path of an individual

fibre has given valuable information about the transfer efficiency of a card but it has the

limitation that it involves measurements to be made on a large number of fibres to get

adequately reliable information.

Trials were conducted at BTRA pilot plant both on metallic card and

flexible clothed card at different production rates, with the objects mentioned above, and

information obtained is presented here in this note.

The transfer efficiency of card is important from the point of view of

determining of level of reading of the cylinder. Poor transfer efficiency results in

excessive loading of fibres on cylinder, which restricts the scope of the card for

improving quality and increasing the production level.

A greater proportion of the fibres fed goes into the foundation of the

clothing and this action continues, though more gradually, until the foundation gets

fully saturated with fibres. This quantity of fibres is termed as termed as 'basic load'.

There is build-up of layers of fibres on the surface of the cylinder, which arises from the

very low rate of transfer of fibres between cylinder and doffer. This is termed as 'working

load'. There is no dear line of demarcation between working load and the basic load in the
flexible clothed card and the figures for transfer efficiency obtained should be used for

comparing experiments made under similar conditions.

 CHAPTER 3

METHOD TO CALCULATE TRANSFER

EFFICIENCY
To calculate Transfer Efficiency we have to find cylinder load of the

carding machine, which we have to find Transfer Efficiency. There are two methods to

find out cylinder load and Transfer Efficiency

i) Krylov's Method

ii) Cut Weight Method

I) Krylov's Method

a) Determination Of Cylinder Load

A card should be started and allowed to run till it attains steady state

operation condition i.e. the sliver of nominal linear density starts coming out. The

movement of flat should be stopped followed by simultaneous stopping of feed roller and

doffer by disengaging appropriate gears. The cylinder is allowed to run continuously. The

doffer is restarted keeping drive to feed and flat inoperative. The doffer will at first

deliver a web (in the form of a sliver), which was already on its lower half. It is then

followed by fibres stored on cylinder.

A clear cut dividing line exists between the fibres, which were already on

the lower half of doffer when it was stopped and the fibres transferred from cylinder later

on, in the form of a thick deposition.

The sliver is detached across the thick portion and the weight of the sliver

portion delivered later is taken. The quantity of these fibres is the cylinder load.
b) Transfer Efficiency

It is defined as the percentage of fibre transferred to doffer from cylinder

per revolution of cylinder. Mathematically

K = (q/Q0) × 100 (1)

Where, K = Transfer Efficiency

q = Amount of Fibre transferred to doffer per revolution of cylinder.

Q0 = Load on cylinder i.e. quantity of fibre on cylinder at steady state.

During one revolution of cylinder the length of sliver (L) delivered by

doffer is,

L = 2 π Rd nd / nc (2)

where Rd = doffer diameter (inch)

nd = speed of doffer (r.p.m.)

nc = speed of cylinder (r.p.m.)

If Ne is the sliver count (English), then the weight of sliver (q) delivered

per revolution of cylinder becomes.

q = 453.6 2 π Rdnd / 840 × 36 Ne nc (g) (3)

Hence K = (453.6 2π Rdnd /840 × 36 NencQo)100 (4)

or Qo = (453.6 2π Rdnd / 840 × 36 Ne nc K) 100 (5)

If P is production rate, (g/min), then

P = 453.6 2π Rdnd / 840 × 36 Ne (g) (6)

Hence K can also be expressed as

 K= (P / ncQo)100 (7)

Or K= (2π Rc P / VcQo)100 (8)

The transfer efficiency can be easily calculated from either equation (4) or

(8), after experimentally determining the magnitude of cylinder load Qo.

II) Cut Weight Method:

Allow the card to run for 15-20 min. so that cylinder load could be built up

to maximum level. The flats are to be disengaged by removing the belt from the pulley, in

the running condition of machine stop the feed of the machine.

As the feed is stopped, but the card is running the sliver from the delivery

end continuously goes on decreasing in the weight per unit length and at last all the

cylinder load is removed from cylinder surface collect this sliver cut into small pieces of

10cm length and sequentially go on weighing it and record it.

Plot the graph of weight of cut sliver against the number of readings. After

plotting the graph you will get a point on the graph from whore the weight per unit length

of the sliver decreased suddenly the point from where the weight drop suddenly is

nothing but the cylinder load in gms (Q).

Precaution

While taking reading card should run minimum 20 minutes other wise you

will get improper cylinder load.

Next thing is that the sliver should not mishandle. It is observed that any

variation could lead to false reading.

 CHAPTER 4

EXPERIMENTAL DETAILS
Material:

For calculating Transfer Efficiency we select few models of modern

generation cards from Navmaharashtra Co-Op Spinning Mills and Indira Mahila Co-Op

Spinning Mills of different companies as follows:

i) Marzoli

ii) Trumac DK740

For calculating Transfer Efficiency we have followed Cut Weight Method

as discussed earlier.

As we have discussed in literature review there are number of parameters

affecting Transfer Efficiency. So to study machine wise and effect of wire point density

we have to keep other parameter constant These parameters are,

i) Production Rate

ii) Cylinder Speed

iii) Doffer speed

iv) Sliver Linear Density (Hank)

Machine Parameter:

i) Marzoli C40:

Working Width - 1016mm (40")

 Flats - Total Present - 104

Working - 40

Feed roller - 84mm

Cylinder - 50 inch

Cans - 24"-40"

Total draft with chute feeding - 90-25

Carding Cylinder Speed - 300-600

Taker in Speed - 655 - 1500

Doffer Speed - 16-65

Flat Speed - 64-179 mm/min.

ii) LC300:

Flats - Total Present - 112+stn

Working - 43

Cans - 24"-45"

Total draft with chute feeding - 80-190

Carding Cylinder Speed - 300-600

Carding Cylinder Dia - 1280mm

Taker in Speed - 655-1500

Doffer Speed - Maximum 53

Doffer Dia - 680 mm

Flat Speed - 82 - 430 mm/min

iii) Trumac -DK-740:

Inner Frame Width - 1055mm

Feed Roller Dia - 100mm

Licher in Dia - 250mm

Rotational Speed with Cotton - 350,400,450

Man Made Fibres - 280,350

Doffer Dia. - 27.56"

Flats Total - 80

Working - 30

Speed - mm/min - 88-360

Travel Direction - is apposite to the sense of

cylinder rotation

Application Of Method:

Allow the card to run for 15 - 20 min so that cylinder load could be built

up to maximum level. The flats are to be disengaged by removing the belt from the

pulley, in the running condition of the machine, stop the feed of the machine.

The feed is stopped, but they are running, the sliver density of from the

delivery end goes on decreasing and then the flow stops. Then the total cylinder load is

removed from the cylinder surface. Collect this sliver cut into small pieces of 10 cm

length and sequentially it is weighed and readings are noted.

The graph is plotted of weight of cut sliver against the no of readings.

After plotting the graph, we get a point on the graph from where the weight/unit length of
the sliver decreased suddenly the point from where the weight drops suddenly is nothing

but the cylinder load in ml gms (Q)

For understanding purpose we have discussed one example.

e. g. LC300

1. 0.013 2. 0.020 3. 0.031 4. 0.050 5. 0.062 6. 0.073 7. 0.074 8. 0.088

9. 0.089 10. 0.089 11. 0.093 12. 0.102 13. 0.096 14. 0.102 15. 0.108 16. 0.118

17. 0.136 18. 0.140 19. 0.137 20. 0.146 21. 0.151 22. 0.162 23. 0.146 24.

0.152

25. 0.146 26. 0.160 27. 0.177 28. 0.184 29. 0.191

By putting this value on graph Semilog paper we get value of cylinder

=176. (Graph No. 3)

Calculation of Transfer Efficiency

Machine Parameter

Cylinder Speed = 450 rpm

Doffer Speed = 39 rpm

Doffer Dia. = 70 rpm

S. S. of Doffer = 8576.55 cm/min

Lengths deliver per

Revolution of cylinder = S.S. of Doffer in cm/min/cylinder Speed in rpm

= 8576.55 / 450

= 19.05 cm
 Length calculated from graph (Cylinder Load)
n =
Lengths deliver per revolution of cylinder

176
n = = 9.23
19.05

−1
log q = = −0.108
n

∴ q = log-1 - 0.108

= 0.7793

Now Transfer efficiency.

P = (1 - q) x 100

= ( 1- 0.77) x 100

= 22 - 01

Like this we take three readings on each card for transfer efficiency.

Testing

Quality of silver produced on card is very important in regard of the yarn

quality. A too higher Transfer efficiency can cause deterioration in quality of silver. So

we are going to decide which card can give the optimum Transfer Efficiency with best

quality of silver. So for this reason we have carried out testing of silver for following.

Parameters

1. Evenness (U%)

2. Neps / gm

1. Evenness (U°/o):
 If Transfer Efficiency is higher, then the fibres are transferred from

cylinder to doffer a little earlier than required, so it may have an effect on opening of

fibres. This causes variation in sliver density. So we have to test the U% of sliver.

2. Neps:

If the Transfer Efficiency is lower, then the fibres remain on the cylinder

surface for a long time therefore rolling and rubbing action of fibres occur. This may

cause increase in generation of neps. So we have to check neps content in c/d sliver.

CHAPTER 5

RESULT AND DISCUSSION

Table No. 1 gives us results about the Transfer Efficiency And Cylinder

Load, which are obtained from different machines.

As we sun that the Transfer Efficiency is mainly affected by the

entrapment power of clothing. Which will be the function of

1. Wire point density and its inclination and height and life of wire point.

2. Dia Meter of roller and

3. Rotational Speed of wire covering surface (i.e. Doffer arch)

Table No. 2 gives us 'the wire point specification, which is used on that

machine on which we calculate the Transfer Efficiency. Here we have found that the

difference between density, angle, which leads to variation in Transfer Efficiency. The

ratio of entrapment power of cylinder and doffer and the ratio of their loadings becomes

equal to the ratio of tooth count of the respective card clothing. Density varies from 865
to 860 of cylinder and 395 to 416 of doffer. Angle also varies from 30° to 55° of cylinder

and 25° to 40° of doffer. The cylinder, load is reduced with large Cylinder and small

doffer tooth angles.

Depth of tooth has a strong influence on carding intensity and Transfer

Efficiency in case of cylinder clothing, lesser the height facilitates transfer of Fibres to

doffer since fibre mainly. Stays on the surface of the wire point. Initially the height of

wire point is same. But the wire point are being used for long time and for No. of Kg. of

production. Since from that time to uptill now how many times grinding has done that

will lead in reducing the wire height. The life of wire point that is how much production

(Kg.) they passed out that will be shown in Table No. 5.4

Table No. 5.5 shows us about quality of sliver. Quality of sliver is differ

from machine to machine so we have carry out the Uster evenness (U%) and nep level in

the sliver and find out the quality of sliver. Here we find out that the LC-300 produce

good quality of sliver as compare to U% and Nep

level in sliver.

Table 5.1

Important Parameters and Transfer Efficiency

Sr. Name Diameter (mm) Speed Production Surface Cylinder Transfer Hank
No. of (Kg/hr) speed Load efficien
Card Ratio of cy (%)
Cylinde Doffer Cylinde Doffer cylinder to
r r Doffer
1 LC 1290 680 450 39 27 21.88 3.000 21.16 0.11
-300
2 M 1290 706 450 39 27 21.08 5.365 15.16 0.11
 ARZ
OLI
3 DK- 1290 700 450 39 27 21.26 5.650 19.61 0.11
740

Table 5.2

Wire Specifications On Cards

Machine Cylinder Wire Point Doffer Wire Point

MARZOLI 865 30 395 25
LC- 300 865 30 395 25
DK-740 860 55 416 40

Tables 5.3

Sliver Produced On Wire

Sr. No. Machine Production (Kg)

1 LC - 300 169600
2 DK-740 158522
3 MARZOLI

Tables 5.4

Testing Parameter Of Cards Sliver

Machine Uster (%) Nep Content/gm C.V. (M)

MARZOLI 5.02 120 3.90
LC-300 3.84 40 3.03
TRUMAK DK-740 4.39 98.6 3.02

Tables 5.5

Calculated Reading of Transfer Efficiency And Cylinder Load

 Machine Transfer Efficiency Average Transfer Efficiency
MARZOLI 15
18.32
13.56 15.63
LC 300 22.05
21.21
20.23 21.16
TRUMAK DK-740 19.87
19.36
19.60 19.61

CHAPTER 6

SUMMARY AND CONCLUSION

From the result it is dear that Transfer Efficiency of LC 300 is high than

DK 740 and MARZOLII with respect to sliver quality that is U% and nep level at 27

kg/hr production.

The Transfer Efficiency on modern cards is improved because of use high

density wire point, angle of inclination, height of wire point, increase in life of wire point,

diameter, of roller and rotational speed of wire covered surface i.e. doffer arc are

consider to be increase entrapment power of both cylinder and doffer. Because Transfer

Efficiency depend upon entrapment power of clothing:

Calculations

Transfer efficiency - LC - 300

Observed reading
Machine Parameters

Cyl. Speed = 450 rpm

Doffer speed = 39 rpm

Doffer φ = 70 cm

S.S. of doffer = 8576.55 cm/mm

S.S. of doffer in cm/min

Length delivered /rev. of cyl. =
cyl. speed in rpm

8576.55
=
450

= 19.05

length calculated from graph 176

η= = = 9.23
length delivers / rev. of cyl. 19.05

−1
log q = = −0.108
n

∴Now T.E. = p = (1-q) × 100

= (1-0.77) × 100

= 22.01