Cards
Cards
Cards
Prof. R. Chattopadhyay
Department of Textile Technology
Indian Institute of Technology, Delhi
Lecture – 03
Carding Zone
So, the carding section consist of cylinder, a chain of flats, carding bars, front and back
plates, doffer, under casing and suction system. Now, we can see the cylinder and the
associated parts around the cylinder; that the cylinder is actually enclosed from all sides.
And therefore, whenever the cylinder rotates, the air which is surrounding this cylinder
also rotates along with it.
(Refer Slide Time: 01:09)
Now, we go to the next slide; a cylinder is basically a cast iron shell machine internally
at both ends to accommodate the cast iron spider with spokes and hubs. You see the
picture and I will and see that that the cylinder is supported on a main shaft; the shaft is
here, here is the shaft and its rest on a roller bearing on pedestal bracket. So, these are the
pedestal bracket here is the roller bearing, this side also we have roller bearing. The sides
are covered by metal sheet, so these are the metal sheets which is covering the sides of
the cylinder.
Cylinder has a typical diameter which varies between 1280 to 1300 millimeter and this is
the diameter of the cylinder, this is a cross sectional view what we can see it here. And
which is roughly the diameter turns out to be around 50; 3 by fourth inch, but it may vary
from manufacturer to manufacturer to some extent. The length is around 1000 millimeter
or little be little bit more than there.
The speed of the cylinder could be around 200 to 600 rpm depending upon the type of
fiber that we are going to process, we adjust the speed. But the flexibility is there and the
speed can be maintained between 200 to 600 rpm. The concentricity of the cylinder is
very very important and it must be maintained within extreme narrow limits; that is why
manufacturing part of a cylinder is not easy from the mechanical engineering point of
view. Then entire cylinder surface is covered with large number of fine needles or pins
that is all about the construction part of the cylinder.
(Refer Slide Time: 03:26)
Now, we go to the next slide; where we see how the various parts associated with a
cylinders are located around the periphery of the cylinder and this is what is known as
geometry of the carding zone. So, we can see that the chain; this carding machine or the
cylinder is actually surrounded by chain of flats, by carding bars, by front and back
plates, by doffer on this side; this side we have doffer, this side we have licker in, there is
under casing at the bottom and there are suction systems, locations are here, here, here
and here; so, it is enclosed from all side.
Total peripheral length which is available around a cylinder could be around 405
centimeter; this pi into diameter of the cylinder. And the carding zone which we see it
here it is around 158 centimeter; so, the angles corresponding to different zones are also
shown in the diagram; we can see that the angle corresponding to the licker in zone is
alpha 1, then pre carding zone is alpha 2, then carding zone is alpha 3, then the front or
post carding zone is around alpha 4, the doffer interactive zone is around alpha 5 and the
under casing is around beta. Therefore, if I add all these alpha 1, alpha 2, alpha 3, alpha
4, alpha 5 and beta this is going to be 360 degree.
Now, the peripheral length is basically fixed and decided by the diameter of the cylinder.
And the locations of the licker in, doffer if we change we can vary the angles alpha 1,
alpha 2, alpha 3, alpha 5 and beta. So, the overall peripheral length is fixed depending
upon how much zonal lengths we required in order to ensure and the carding takes place
quite efficiently, we can decide about the angles alpha 1, alpha 2, alpha 3, alpha 4, alpha
5 and beta. So, typically the angles corresponds to alpha 3 on a machine could be around
148 and or 43 degree, but this will vary from manufacturer to manufacturer.
From here we go to the next slide and let us look at the flats. The flats are basically cast
iron bar as shown it here and it has a inverted T shaped cross section, the lower surface is
smooth and contains wire points. So, these are the wire points that you see here.
The flat width typically is 32 mm from here to there this length is 32 and the wire points
are spread over 22 millimeter. So, these are the individual wire points on the flat surface
it is a long part the cross sectional view is shown here and these wire points is spread
over a length of around 22 mm. There are number of flats, the total number of flats is
roughly from around 80 to 110 which also varies from manufacturer to manufacturer, but
it could lie somewhere between 80 to 110. There all linked together by a chain and the
flat rest on a metallic strip known as flexible bend.
So, here is the flexible bend the flats will be actually resting on the flexible bend and the
flexible bend in turn rest on the side frame of the machines. The curvature of the flexible
bend and the curvature of the cylinder almost match each other.
(Refer Slide Time: 08:18)
From here we go to then next slide and we see that how the flats ends are supported.
There are 2 types of supports which are possible one is flat ends supported at the both the
ends of the flat is a basically, a flat is a long bar T shaped cross sections and the 2 ends of
the flat rest on the flexible bend.
And there the here it will be shown, how it is resting on the flexible bend. This type of
arrangement is known as single point support of the flat that is the contact area is only
here over a narrow zone for almost at a single point. Whereas, in this case in the other
case what you see it here it is a two point support that is a support here and there is
support there. Now, this two point supports are superior in comparison to be single point
support because, when the flats start moving over the flexible bend, then the movement
becomes smooth if the 2 ends; these 2 ends of the flats have a support over the flexible
bend, so this is the flexible bend. A single point support if is there another flats are
dragged over the flexible bend, there is a chance they start rocking and therefore, the
flats may move up and down.
And this kind of movement will actually affect the setting between the flat wire points
and the cylinder wire points and therefore, it can affect the opening action of the fibers
between the cylinder and flat. The other important thing about the flat is heel and toe
arrangement. Now what is heel and toe arrangement? The diagram is shown here now
what you see if you look at this element of the flat wire points and the cylinder wire
points, then you will see that the way they are been placed that the narrow gap that exist
between the water points of flat and cylinder at these gap, this gap is converging; that is
it will little more at the entry side and less on the exit side. This is how the flats are, have
been designed.
The idea is that it will facilitate gradual increase in the intensity of the opening actions of
the tufts. So, as soon as soon as the tuft which is here let us say enters; this space initially
there is a large gap between the 2 wire points, it will enter this gap and gradually it will
be opened out. If the gap remains constant throughout then there is a sudden impact on
the tuft and the fibers may break.
Therefore we need to make sure that the gap that exist between the wire points of the flat
and the cylinder, for each and every flat it is large at the entry point of the tuft and as it
moves out of this one single flat zone; then this is little less and therefore, the fibers are
going to receive mild opening actions and chances of breakage will reduce.
The other important things about flat is the flats will be considered as a beam supported
at two points at their ends. So, here we see it this is the flat this is the flexible bend and
here the cylinder is there; so this is our cylinder.
And the wire points of the flats and the wire points of cylinder you can see there is a
small gap between them. So, the flat to 2 ends of the flats are supported on 2 flexible
bends, this bend a bend number 1 and let us say this is bend number 2. The gap between
the flat and the cylinder must remains constant; at these gap from one end of the machine
to the other end for a particular flat should remains constant. Now what happens? At the
if the bending rigidity of the flat is not enough then the then the flat rod may bend like
this shown in the this diagram. And it bends then this gap that exists between this
cylinder and the flat, you see the bending is more at the middle point and therefore, the
gap will be minimum here and the gap at the 2 ends will be larger.
So, the tufts which are here; the tufts which are here there will receive less opening
action whereas, the tufts which are here at the middle the gap being less there will be
intensive opening on them. And hence, such kind of situations we have to avoid and
therefore, the bending rigidity of the material, which is used to make the flats and the
cross sectional shape of the this flat becomes very important. Because we have to ensure
that this bending is really minimum. So, this is and therefore, we go for T shaped cross
sections of the flat from here we go to the next slide.
Now, what are the function of the flats now? We know this flats and the cylinder wire
points these are the 2 wire points which participates in carding actions. And therefore,
the wire point geometry the other associated parts of the wire points of both cylinder and
flats are extremely important.
Separations of the fiber tufts including neps to an individual state known as carding
action is what is performed by the flats. So, cylinder on its own cannot really open and
separate the fiber tufts; flats only you shown also cannot do it. Their interaction between
the 2 wire points actually serves the purpose of separating the fiber tufts into fine
individualized fibers and they can also remove the neps.
Second thing what they do? Extraction of short fiber, trash particles and dust that is also
performed by the flats because after carding action part of the fibers are transferred to the
flats and the trash particles which are there they are thrown by the cylinder because of
the centrifugal actions. And the flats surface which is filled up with fibers, they will
absorb those trash particles and dust. And therefore, it helps in cleaning action also.
Generally both the actions that is separation of fibers as well as the; the cleaning part that
takes place simultaneously; however, carding action is completed within first few flats.
And the cleaning action continues over the entire flat region, we will discuss this point in
more detail later that, why do you need so many flats on the cylinder surface; even
though the carding action has been shown to be completed within first 10 to 15 flats. So,
therefore the next of the flats are basically participate in cleaning the material rather than
opening or separating the fibers.
Now, why such little movement is required? The movement is so slow that at times it
may appear that the flats are not really moving at all. But if somebody goes near the
machine and carefully looks at the flats, then you will find that the he or she will find
that the flats are moving slowly in the forward directions. The reasons are the flats would
get loaded progressively with fibers and impurities as a result of carding action. And
therefore, after some time they will lose; their opening capability or carding ability.
With a stationary carding surface if the operation has continued; it will be hindered since
flats have to be taken out from time to time for cleaning, that is if I do not allow the flats
to move, then once the flats get completely loaded with fibers or trash or impurities; then
we have to stop the machine, we have to remove the flats, clean them and put them back.
This is the problem with stationery flats; the wire points of the top carding surface also
need to be sharpened from time to time. And therefore, because with time the wire points
or the pins on the cylinder and the flats both they get roughened. And therefore, we need
to sharp them from time to time and for this also, we need to move the flats. And actually
you will see that we can then sharpen them when the flats are moving.
Chain of flats can be driven slowly which would permit necessary cleaning actions as
soon as they move out of the carding zone. So, if we allow the flats to move slowly; then
as soon as they move out of the carding zone, we can have a means to clean the flats or
you can remove fibers from the flats and make them available for carding. So, once the
flats are cleaned; they may be fed back to the carding zone again and the flats can
participate in carding actions. So, therefore, what we need is movement of the flats; after
this now we will discuss the theory of the carding actions.
(Refer Slide Time: 21:01)
Now, the classical theory states that a fiber can be carded provided the inclination of the
wire points is such that; the sliding component of tension acting on the fiber is strong
enough to move the fiber down the wires towards its base; this is the condition that we
have to met.
And this condition can be fulfilled when cot alpha is greater than mu. This has already
been stated earlier where alpha is the inclination angle of the wire point and mu is the
coefficient of friction between fiber and the wire. So, this is the classical theory of the
carding and East’s talks about the inclination angle of the wire points and which is
related to the fiber to metal friction.
The classical theory it does not take into account this centrifugal force that is acts on the
fiber. And, the second thing is it does not take into account the presence of air current
due to the rotating elements of the carding machines.
(Refer Slide Time: 22:12)
So, from that we go to the next theory which is known as Strang’s theory which was
proposed by Strang’s. Here if we look at this diagram we find that we already seen at the
cylinder is surrounded from all sides. And, as soon as it starts is rotation; then the air that
exist between the cylinder surface and the flats that air also start moving. So, this is the
air which is there; this air we can imagine this air layer we also start moving.
The air which is in contact in the cylinder surface, the layer which is contact with
cylinder surface will have base velocity equal to the velocity of the cylinder. And the
layer of air which is contact with the flats will have velocity almost equal to 0. And in
this narrow zone the airs layers are moving at different velocities. The velocity profile of
the boundary layer of air is shown in this diagram which is represented by this arrows.
So, the length of the arrows basically, indicate the velocity of the boundary layer of air.
Now, in this zone we introduce a tuft; a tuft is introduced into these boundary layer is
subjected to a terrific force F caused by the shearing action of the air moving with
different velocities in the narrows space between cylinder and flat. And the force which
will act on it is represented by this formula F which is equal to RV A by s, where R
indicates the coefficient of viscosity of the air at a given temperature, V is the velocity of
the air current and A is the projected area of the fiber tuft in the direction perpendicular
to the airstream and s is the depth of the boundary layer.
And therefore, what happens that the tuft is sheared because one part of the tuft will be
experiencing a higher force and the other part will be experiencing less force. If this is
the suppose is the tuft this part will explain some velocity, the other part will explain less
velocity because this stream line of air are moving at different velocities from bottom of
the tuft to the top and therefore, the tuft is going to be sheared. So, it will be broken into
pieces. So, this theory only talks about the role of air current in shearing action of the
tufts.
Now, there is another theory proposed by Kaufmann known as Kaufmanns theory. In this
theory, what is stated is that the air current is not solely responsible for opening the tufts;
because even at very very low velocity of the cylinder we have found carding action to
occur. That is as they cylinder speed is reduced the velocity of the air we also reduce it
has been found that if we bring down the cylinder speed to a very very low level.
Suppose around 10 rpm or may be 20 rpm; we can still find carding action to takes place.
Therefore, it was proposed that it is not only the air current that is responsible for
opening the fibers or tufts. So, what it is here? The tufts held on cylinder surface
approach the cylinder flat zone at very high speed and are introduced into the narrow gap
between the flat and cylinder. So, from this side here is a tuft, this tuft is coming from
this side because this is sitting on the cylinder.
And as soon as it comes near the cylinder flat zone, the lock it tufts is forced into a
narrow zone. And as soon as it enters this zone, compressive force will develop on the
tufts which will force the fibers into the wire clothing of both flat and cylinders.
Therefore, compressive force will develop on them and the tuft will get into the wire
points of flat and also the wire points of the cylinder. Since, flats are practically
stationary as compared to the first moving cylinder surface, the loading factor of
compression force against the flat is much more than against the cylinder. A cylinder
presents a large surface area for the same compression force; see practically flats are
almost stationary in comparison to the surface speed of the cylinder.
And therefore, the same compressive force will act on a larger surface area for cylinder
in compression to flat. And therefore, we can say the loading factor of the flat will be
more in compared to cylinder. The penetration of the teeth into the tuft is immediately
followed by shearing actions; due to great differences in speed between flat and
cylinders.
So, the as soon as the tuft enters the narrow gap, the air points will be penetrating the
tuft. Now the bottom part of the tuft, in the top part of the tuft are moving at 2 different
velocities, V c is the velocity of the cylinder and V f is a velocity of the flat. But the
velocity of the cylinder is extremely high in comparison to that of flat and hence the tuft
will be sheared immediately. And the tuft may be shared somewhere here at the middle
or any other locations.
The part which remains on the cylinder will move forward and it will be introduced into
the subsequent cylinder flat zone. And again the same compression will takes place on
the flat on the tuft and the same process will repeat. And, this process of compression
penetration followed by shearing will repeat itself; as long as the cylinder is carrying the
tufts along the carding zone.
As a result of this, the same tuft will be diminishing in size and the big tuft will be it
subdivided into number of small and small tufts. This is how the opening action is
happening in the case of a carding action in the case of carding. So, these are the 3
different theories proposed.
(Refer Slide Time: 30:55)
Now, we go to the licker in and flat region. So, this region is shown this diagram. This is
the place which is called licker in flat region, this region also is covered by precarding
segments consisting of mote knife, suction hood and adjustable bracket known as back
plate.
What is the purpose of this zone? The licker in is here for the licker in tufts are fed onto
the cylinder. Cylinder will carry the flats of this tufts to the flats. Now, the tufts which
are laid on the cylinder surface they are of varying size. And they may be distributed non
uniformly on the surface of the cylinder and therefore, what we need is to keep a mild
opening treatments to the tufts and to orient them and distribute them evenly on the
cylinder surface; that is one of the purpose why we have a carding plate over here.
That is in this zone little space is available, we make use of this space in terms of further
opening the tufts; before they are introduced into the very narrow gap between cylinder
and flat. And therefore, we have the carding plates, the suction hood also because as soon
as opening takes place there will be always liberation of dust and we make use of this
situation in terms of sucking out part of the dust.
Further because of centrifugal force; lot of fibers may be thrown; therefore, these zone
needs to be covered. We cannot leave it empty, otherwise we will lose lot of fibers and
that could be also a chance of accidents. And as soon as there covered, it can prevent un
control air current which can disturb the arrangement of fibers on the cylinder.
So, therefore, these zone is covered and we make use of this zone in terms of cleaning
and opening the fiber tufts. The cleaning is required when you process cotton, but when
you do not process cotton; then cleaning is not really important. But, uniform distribution
of the tufts from licker in on to the sender surface is important. And hence we must have
some carding bars there precarding bars. The carding bars have a special type of
clothing. So, that they do not get loaded with fibers and it does not need cleaning
frequently. Otherwise if the whole too many fibers with them and do not allow the fibers
to move out; in that case all these carding bars will lose their opening capability very fast
and it may lead to generation of neps.
And hence the design of the wire points over the carding bars is very very important.
There wire point geometry the kind of finish which is given to the wire points, their
angle, their densities everything is important; this will be discussed in more details in
some other lectures. We have discussed the licker in flat region, we stop today.