Carding Research Articles

Analisis tentang Setting Roller Gauge dan Break Draft Tidak Merubah Total Draft pada Mesin Roving Rieter type F10 / 55011- 00425 Tahun Pembuatan 1998

At PT Indiratex Spindo, there are 2 units that produce 100% cotton yarn. For unit 1 produces open end yarn, and for unit 2 produces ring spinning yarn. The production process in unit 2 starts from the raw material, namely cotton in the blowroom process, opening and mixing of the cotton so that the shape of the feathers will be processed in the carding machine to further open cotton fibers, clean dirt and short fibers with long fibers. The result of the card is that the card sliver will then be duplicated and drafted on the draw frame breaker, after which it will be processed and duplicated again in the finisher draw frame. Then the sliver drawing finisher will be drafted, given a twist and rolled in a bobbin on the roving machine. The output of the roving machine will then be processed in the ring spinning machine, the roving will be drafted, twisted so that the yarn will then be rolled into the cop, then put in the winding machine to remove thread imperfections or yarn defects and change the cop roll to cones rolls. After the process is complete, the thread will be packed in the packing section. To produce good quality yarn, it is necessary to plan production, repair and maintenance as well as repair machines properly. Drafting is one one process that is very important and to be hard to the quality of the yarn that will be produced. If the drafting process is not perfect it will affect the unevenness of the material or yarn. One of the problem topics related to drafting on the Rieter type F10 / 55011-00425 roving machine in 1998 is that if the break draft is changed, the total draft will change. This assumption is really true because if the draft is damaged, what will change is the main draft, and the total draft will remain the same. Meanwhile, for the correct setting of the roller gauge so that the roving does not experience a high level of unevenness, if the setting is wide, the draft break must be small. And if the arrangement is eternal then the break draft used must be large. The second arrangement is so that the fiber can be properly drafted and does not experience floating fibers or fiber cracks.

Effect of Secondary Raw Material on the Change of Single Extensive Elongation of Non Woven Fabrics

The article describes research studies in the laboratories of the departments of "Spinning Technology" and "Silk Technology". For this purpose were taken samples of cotton fiber and silk waste from the carding machine in the spinning process, 100% cotton fiber waste, 50% cotton fiber, 30% silk, 20% mulberry bark fiber, 70% cotton fiber, 15% silk, 15% mulberry bark fiber, non-woven fabrics were produced from 75% cotton fiber 10% silk 15% mulberry bark fiber blends. The single-period elongation deformation of the obtained non-woven fabrics was determined using the device "Stoyka".

Development and characterization of thermoset nanocomposites reinforced with cotton fibres recovered from textile waste

The present research reports thermoset nanocomposites reinforced with cotton fibres extracted from textile waste called as ‘shoddy’ and graphite oxide nanoparticles as filler. The oriented fibre web of shoddy was produced by using the carding machine and it was used as reinforcement. The thermoset epoxy composites with four different fibre volume fraction values namely 0.1, 0.2, 0.3 and 0.4 were developed. These composites were characterized by mechanical properties to optimize the fibre volume fraction. Further, thermoset epoxy nanocomposites were developed by incorporating graphite oxide nanoparticles as filler in four different weight percentages, namely 0.1, 0.3, 0.5 and 1%. All the composites were characterized for mechanical properties, dynamic mechanical properties, thermal degradation behaviour and water absorption behaviour. It has been found that the developed composites can be used in items of furniture materials and to develop some visible and non-visible automotive components.

Studies of the carding of Arselon fibers for fireresistant yarn

Studies of the carding of Arselon fibers for fireresistant yarn

Mechanical properties and water absorption characteristics of composites reinforced with cotton fibres recovered from textile waste

The primary aim of this research is to develop thermoset composites reinforced with cotton fibres extracted from textile waste. These composites are mainly targeted to replace timber in its application for furniture items and in some visible and non-visible automotive components. The pre-consumer cotton textile wastes such as cutting waste, in garment manufacturing, and defective fabrics were converted into the fibrous form called ‘shoddy’, using rag-tearing technique. The fibrous web of shoddy was produced using the carding machine. This web was used for developing thermoset composites as a reinforcement material. The thermoset composites with four different fibre volume fraction values, namely 0.1, 0.2, 0.3 and 0.4 were developed using compression moulding technique. The developed composites were characterised by mechanical properties, dynamic mechanical properties, thermal degradation behaviour and water absorption behaviour. The mechanical properties of the composites were found comparable with that of commercial wood. These composites can be used to develop a dashboard panel. The composites developed in this research have shown low water diffusion coefficient values as compared with pine, oak and linden wood.

Evaluation of Kenaf/Polyester Fiber Blended Sliver Produced from Carding Machine

Controlling sliver evenness is very important since this parameter can affect the quality of the yarn produced. In kenaf sliver production, kenaf fibres alone could not form a good sliver. Thus, fibres such as polyester are needed to blend with kenaf to improve fibre cohesiveness and form a better sliver. The aim of this study is to identify the optimum ratio of kenaf that can be used for sliver production. The heart of the process for the production of kenaf/polyester slivers is carding. The weight percentage of kenaf used for the kenaf/polyester sliver production was 50%, 60% and 70%. After sliver formation, the waste percentage, diameter and size were determined. The sliver images were analysed under video analyser and captured by digital SLR camera to observe the fibre blending. The research showed that lower percentage of kenaf offered better waste percentage and sliver diameter. Whereas, sliver size showed some decrement with an increment of kenaf fibre percentage. The presence of polyester in the production of kenaf/polyester sliver seems to play an important role to bind the kenaf fibres together.

Processing of waste carbon and polyamide fibres for high-performance thermoplastic composites: influence of carding parameters on fibre orientation, fibre length and sliver cohesion force

The processing of waste carbon fibre on carding machine for the developments of nonwovens, tapes and hybrid yarn structures is an emerging trend. These structures are widely used to enhance the performance efficiency of recycled carbon fibre reinforced thermoplastic composites. The aim of the research presented in this study is to process waste carbon fibre on a carding machine and to investigate the influence of different carding parameters on waste carbon fibre. For this purpose, card slivers composed of waste carbon and polyamide fibres were developed on a double cylinder card machine by varying technical parameters. Then, effect of these parameters on card sliver quality was assessed in terms of fibre orientation, fibre length and sliver cohesion force. Results revealed that fibre orientation and fibre length is significantly affected by technological parameters carding zones, whereas the sliver cohesion force is significantly affected by the speed of feed roller and doffer.

Effect of Variation in Different Mechanical Setting of Draft Change Pinion in Trutzschler Carding Machine for Cotton and Polyester Carded Slivers

Effect of Variation in Different Mechanical Setting of Draft Change Pinion in Trutzschler Carding Machine for Cotton and Polyester Carded Slivers

Mathematical Logic Establishment for Automated Trash Controlling in Carding Machine

In this paper, it is intended to establish a mathematical logic for the purpose of removal of trash in an automatic way and removal of trash will refer to the cleaning process of carding machine. But the selection of degree of cleaning has to be optimum considering other process factors like fiber loss, fiber rupturing, neps generation etc. Higher degree of cleaning causes higher degree of fiber loss. And in spinning mill, fiber loss means money loss as raw cotton purchasing cost consumes 50% to 60% of total manufacturing cost of yarn in terms of Bangladesh. Alongside, fiber loss is affected the cleaning system because the system is designed for fiber cleaning, not for fiber loss. So, it is necessary to measure the performance of the system. For this purpose, we have chosen two terms, ‘Cleaning Efficiency (C.E.)’ to measure the degree of cleaning & ‘Effective Cleaning (E.C.)’ to measure the performance of the system. In this paper, it is intended to describe a relationship between these two terms, graphical expression of the individuals, a way to calculate the force applied by mechanical means and the force required to clean. The ultimate result of this project is to find the relationship between the surface speed of taker-in and the trash weight of output material.

Effect of flat speed of carding machine on the carded sliver and yarn quality

Processing parameters play an important role in influencing the quality of the final product in any kinds of production. The aim of this project is to observe the quality of the carded sliver and yarn by applying different flat speeds on the carding machine while the other machine parameters were fixed. Five flat speeds (200, 240, 280, 320, and 360 mm/min) have been used to produce slivers and yarns. Sliver fineness of Ne0.11 and yarn of two different counts (Ne24 and Ne30) were produced for assessing the quality. It is found that the neps, short fibers, and unevenness of sliver and yarn are reduced proportionally with the increase of flat speed, whereas the tensile properties of yarn are increased. The unevenness and tensile properties are found to be best for flat speed 360 mm/min with significant increasing of waste percentage. The Ne24 and Ne30 cotton yarns have comparable unevenness and tensile properties. The quality of yarn improved continuously as the yarn becomes finer.

Electromagnetic shielding effectiveness of high loft activated carbon web prepared by using acrylic waste

This work represents a novel method for the formation of activated carbon web using charcoal through physical activation in high temperature muffle furnace. The acrylic fibrous waste was separated from bath mats and transferred to carding machine which was transferred to needle punching machine for obtaining a compact structure of non-woven. The acrylic web was first stabilized at 250 °C with a heating rate of 50 °Chr-1. The stabilized web was again raised to high temperature (700 °C, 900 °C and 1100 °C) using charcoal for single stage carbonization and activation. The impact of temperatures on the characteristics of carbon webs was analyzed in terms of yield, dusting, flexibility, XRD (x-ray diffraction analysis) and EDX (energy dispersive x-ray analysis). The EM (electromagnetic) shielding of prepared webs was analyzed by using wave guide method which measures shielding effectiveness at 2.45 GHz (high frequency region). It was found that shielding effectiveness increased from 2.21 dB to 23.71 dB as the carbonization temperature was increased from 700 °C to 1100 °C. Not only the carbonization temperature but the impact of thickness of carbon webs on shielding effectiveness was also observed. The shielding effectiveness increased when the thickness of carbon webs increased because of internal reflections and more absorption of electro-magnetic radiations.

Investigation of the Electromagnetic Shielding Effectiveness of Needle Punched Nonwoven Fabrics Produced from Stainless Steel and Carbon Fibres

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Design and development of non-woven medical product from Wrightia tinctoria fiber

ABSTRACTThis work aims at research on characterization of Wrightia tinctoria fiber, such as fiber content, fiber longitudinal view, cross-sectional view, fiber diameter, moisture content, SEM analysis, surface resistivity, swelling, and also mechanical properties of fiber, such as fiber strength, elongation, linear density, etc. The fiber was used to produce carded webs using the pilot carding machine from blends of Wrightia tinctoria fiber (W) with cotton (C), bamboo (B), and polyester (P) in the blend ratios of 25:75 and 50:50 for required GSM. The produced webs were bonded using spunlace bonding technique to produce required non-woven medical apparel. The produced nonwoven were tested for dressing mass and thickness, absorbency of wound dressing, the dehydration rate of dressing, wettability, vertical wicking, air permeability, potential of hydrogen, water vapor permeability, and anti-bacterial. The test results of the studies were investigated in detail and observed that the product development from Wrightia tinctoria fiber has immense potential for curing various skin diseases as revealed from the test results.

A reliability centred maintenance approach for assessing the impact of maintenance for availability improvement of carding machine

A reliability centred maintenance approach for assessing the impact of maintenance for availability improvement of carding machine

Manufacture of Reclaimed Fiber Non-Woven for Sound Absorption

Recycling is the process of making or bringing out new products from a product that has originally served its purpose. The use of non-woven for noise reduction is based on two major advantages of these materials, namely low production costs and small specific gravity. Through this thesis, an attempt was made and implemented an innovative technique of developing stitch bonded non-woven by using recycled fiber. Knitted wastes were collected from cut and sew knitwear factories and recycled by using fabric opening machine in Adey abeba textile factory. The opened fibers are carded by mechanical carding machine by varying the number of layers. Six nonwoven samples are manufactured by stitching the web structure with core spun yarn. The manufactured reclaimed fiber stitch bonded nonwoven sound absorption coefficients were measured according to ASTM E 1050 standard by an impedance tube. The results revealed that the sound absorption coefficient increased with increasing frequency level of 500 Hz, 1000 Hz, 1500 Hz, 2000 Hz, 2500 Hz and 3000 Hz. Factors influencing sound absorption of nonwoven materials such as fabric thickness, areal density, air permeability and thermal conductivity were tested. The results revealed that while thickness increases the sound absorbing performance also increases. Low frequency sound absorption has direct relationship with thickness. However, at higher frequencies thickness has insignificant effect on sound absorption. Less dense and more open structure absorbs sound of low frequencies. Denser structure performs better for frequencies above 2000 Hz. Air permeability of the stitch bonded nonwoven decreases the sound absorption performance increases. The mechanism of sound absorption was conversion of sound energy in to heat but the effect of thermal conductivity of stitch bonded nonwoven structure was very small.

A reliability centred maintenance approach for assessing the impact of maintenance for availability improvement of carding machine

The complex nature of modern equipment and systems often leads to failures and, as a consequence, an increase in machine downtime, thus affecting production. The failures of machines cause disruptions in production, resulting in the loss of availability of the system and increase the cost of maintenance. This paper presents a reliability centred maintenance (RCM) methodology to improve the availability of carding machine in textile industry. The main objective of this paper is to present a RCM approach for improving the availability of the carding machine and thus maximise the production output. Failure mode and effect analysis (FMEA) is used for analysing the failures in the machine. The preventive measure to reduce the failure frequency and its impact are proposed. The proposed preventive measures result in reduction of about 26% of the total downtime and availability improvement of approximately 1.7%, as compared with the availability due to current maintenance practices.

Effect of alkali treatment on mechanical properties of the green composites reinforced with milkweed fibers

Polymeric composites disadvantages in terms of high price and non-recoverability make them unsuitable for some applications. Otherwise, natural fibers would be degraded easily and their prices are much lower as compared with most of the commonly used synthetic fibers, especially in composite manufacturing. Hollow Milkweed fiber with non-crimped nature is a known natural fiber which could have high potential to be used as composites reinforcements due to its low-density property. Increasing demand for natural fiber-reinforced composites as well as unique characteristics of Milkweed fibers reveal the need to study the mechanical properties of such fiber-reinforced composites. In this study, milkweed fibers were initially fed to laboratory carding machine in order to be formed as a nonwoven layer which was then applied to a low-velocity needle-punching operation. Surface modifications were carried out on the needle-punched nonwovens using 5% NaOH at 50–60 °C and three different treating time levels (30, 60 and 90 min). The produced nonwovens were then treated in a mixture of boiling water and detergent for 1 h. For making composite parts, the modified nonwovens were impregnated in Ploy vinyl acetate (PVAc) resin using the hand-layup method. The alkali treatment effects regarding the process time period on mechanical properties of the natural-reinforced composites were investigated. The findings suggested significant affectability of the composites mechanical properties by varying the time of alkali treatment, NaOH concentration as well as the type of surface modification process which are all mainly resulted in improving the interaction between fibers and matrix phase.

A Study of a Modernized Controlled Electrical Complex for the Production of Bulk Nonwoven Fabric

A compound electromechanical system for control of the self-weight of a carding machine is investigated. A functional diagram of the modernized system for control of the self-weight of a carding apparatus that assures a continuous regime of forming a blanket is developed. Requirements imposed on the electrical drives that assure a given intensity of the start-up and braking regimes as well as correction and matching of the linear velocities of fibrous product are formulated.

Development of a new hybrid yarn construction from recycled carbon fibers (rCF) for high-performance composites. Part-II: Influence of yarn parameters on tensile properties of composites

This article reports the successful manufacturing of hybrid yarns from virgin staple CF (40 or 60 mm) or recycled staple CF (rCF) by mixing with polyamide 6 (PA 6) fibers of defined length. The hybrid yarns are produced using an optimized process route of carding, drawing, and flyer machine. Furthermore, the influence of CF length, CF type (i.e. virgin or rCF), CF volume content, and twist of the yarn are also investigated regarding the tensile properties of unidirectionally laid (UD) thermoplastic composites. The results show that CF length, yarn twist, and CF content of composites play a big role on the tensile properties of thermoplastic composites. From the comparison of tensile strength of UD composites produced from 40 and 60 mm virgin staple CF, it can be seen that the increase of yarn twist decreases the tensile strength. However, the effect of twist on the tensile properties of UD composites manufactured from 40 mm virgin staple CF is insignificant. The tensile strength of UD thermoplastic composites manufactured from the hybrid yarn with 40 and 60 mm virgin staple CF and rCF is found to be 771 ± 100, 838 ± 81, and 801 ± 53.4 MPa, respectively, in the case of 87 T/m containing 50 volume% CF.

Investigating the effects of material and process variables on the mechanical properties of low-density thermally bonded nonwovens produced from Estabragh (milkweed) natural fibers

Uniaxial tensile and bending properties of lightweight thermally bonded nonwoven layers produced from the blends of Estabragh (milkweed)/polypropylene fibers have been focused in this paper. For this, different material variables such as the blend ratio as well as some parameters of thermal bonding process including the calendering speed and temperature were considered in this study. Eighteen fibrous samples from six Estabragh/polypropylene blend ratios of 10/90, 25/75, 40/60, 55/45, 70/30, and 85/15 at three different layer weights (g/m2) were produced on a laboratory-scale carding machine. During needle-punching operation, different punch densities at low levels of 20, 30, and 40 punches/cm2 were applied to the samples in order to increase the layer strength by increasing the fiber entanglement while the fiber breakage remains in such minimized level. Thermal bonding process was then carried out on the produced nonwoven samples using an apparatus equipped with a pair of heated calendering in which three different levels of temperatures as well as three levels of calendering speed were considered as the process variables. Taguchi’s analyzing method was employed for statistical investigations of the results. The findings showed that the blend ratio of fibers, layer weight, and the applied temperature during the thermal bonding process significantly increased the nonwoven layer resistance against axial tensile forces. On the contrary, variables punch density and calendering speed had no significant effects on the breaking force values of the samples. Considering the samples' bending rigidity, it was fount that all the variables except the calendering speed, have significant effects.