TEX 2011SOUTHEAST UNIVERSITYSpring 2012

Physical properties of raw material (cotton):Fibre Length:Short staple1 in. or lessMedium staple1 1/32- 1 1/8 in.Long staple1 5/32- 1 3/8 in.Extra Long Staple1 13/32 in. above.Fibre Fineness:Micronaire ValueFinenessup to 3.1Very fine3.1 to 3.9fine4.0 to 4.9Medium5.0 to 5.9Slightly Coarse6.0 & aboveCoarse

Fibre Strength: Pressley valueGrading93 & aboveExcellent87 to 92Very strong81 to 86Strong75 to 80Medium strong70 to 74Fair strongBelow 70Weak

Fibre Cleanliness:Trash %Grading

Up to 1.2%Very clean1.2 to 2%Clean2 to 4%Medium4 to 7%Dirtyabove 7%Very dirty

Dust:Gradingparticle size (micro meter)

Trashabove 500Dust50-500Micro dust15-50Breathable dustbelow 15Chemical deposits:Secretions: HoneydewFungi and BacteriaDecomposition productsVegetable substancesSugar from plant juices, leaf nectar, overproduction of waxFats, oil Seed oil from ginning, pathogensSynthetic substancesdefoliants, insecticides, fertilizers, oil from harvesting machines.

Flow chart of carded yarn:

Flow chart of combed yarn:

Mixing and blending of cotton fiber in blow roomMixing:If different grade of same fibers are kept together, then it is called mixing.

Types of Mixing:1. volume mixing 2. weight mixing 3. hand stock mixing 4. bin mixing 5. mixing by hopper 6. lap mixing 7. card mixing 8. sliver mixing

Blending:When different fibers of same or different grades are kept together, then it is called blending.

Types of Blending:1. hand stock blending 2. bin blending 3. lap blending 4. card blending 5. draw frame blending

Model of optimum cotton mixing:The program is written on the basis of principles of linear programming. The constraints of the mixing used in the program are cotton fiber minimum length in mm, strength in grams per Tex, Micronaire value in a range, maximum trash percentage, and price per kilogram of the cotton. Also some of the practical constrains are considered while formulating the mixing like maximum and minimum bales to be taken for mixing from a lot.

The software generated system is, in generally, known as Bale Management. Some branded software are BIAS, Bale Manager.

BLOW ROOM

Blow room: Cotton fibre is compressed in a bale of 200 to 250 kg. This highly compressed cotton firbe need to be open at first as a part of yarn manufacturing. And there are 1.5% to 7% trash in cotton bale which is also needed to be removed before further processing. This process of opening & cleaning is knows as blow room process. Blow room consists of a number of m/c used in succession to open & clean the cotton fibre to the required degree. 40% to 70% of total trash is removed in this section.

Number of opening machines Type of beater Type of beating Beater speed Setting between feed roller and beater Production rate of individual machine Production rate of the entire line Thickness of the feed web Density of the feed web Fibre micronaire Size of the flocks in the feed Type of clothing of the beater Point density of clothing Type of grid and grid settings Air flow through the grid Position of the machine in the sequence Amount of trash in the material Type of trash in the material Temp and relative humidity in the blow room department Process parameter in the blow room:

Objects of blow room process:To open the compressed layer of bale of cotton or any staple fibres with minimum damage to the fibres.To remove the impurities like sand, seed, bits, neps & short fibres present in the cotton with minimum loss of lint by opening & blending.To effect a through blending with minimum neps formation.To convert the mass of cotton fibres into a uniform thick sheet of cotton both longitudinally & transversely & fed as it in the case of chute feed system or wound in the form of a compactly built lap with minimum lap rejection.Intensive de-dusting of cotton fibres to extract micro- dust in order to improve the working of opened spinning m/c.Fibre recovery from the waste produced by the various processes during the conversion of fibre to yarn in order to reduce the consumption of raw material.

Technological performance of ablow room line and influencing factors

Opening: The first operation required in the blowroom line is opening. Tuft weight can be reduced to about 0,1 mg in the blowroom. The figure indicate that the degree of opening changes along ablowroom line. This line is atheoretical layout for study purposes only. The flattening of the curve toward the end shows that the line is far too long. It should end somewhere at machine No.3 or (at least) No.4. The small improvements by each of the subsequent machines are obtained only by considerable additional effort, stressing of the material, unnecessary fiber loss and astriking increase in neppiness. Openness of the fiber material after the various blowroom machine stages; axis A: Degree of opening (specific volume); axis B: Blowroom stagesBasic operation in blow room:

Cleaning: Ablowroom installation removes approximately 40-70% of the impurities. The result is dependent on the raw material, the machines and the environmental conditions. The diagram by illustrates the dependence of cleaning on raw material type, in this case on the level of impurities.Figure: Degree of cleaning (A) as afunction of the trash content (B) of the raw material in % The cleaning effect is amatter of adjustment. It is shown in bottom figure that, increasing the degree of cleaning also increases the negative effect on cotton when trying to improve cleaning by intensifying the operation, and this occurs mostly exponentially. Therefore each machine in the line has an optimum range of treatment. It is essential to know this range and to operate within it. Figure: Operational efficiency and side effects Normally, fibers represent about 40 - 60% of blowroom waste. Since the proportion of fibers in waste differs from one machine to another, and can be strongly influenced, the fiber loss at each machine should be known. It can be expressed as apercentage of good fiber loss in relation to total material eliminated, i.e. in cleaning efficiency (CE): AT = total waste (%); AF = good fibers eliminated (%).

For example, if AT = 2.1% and AF = 0.65%:

Almost all manufacturers of blowroom machinery now offer dust-removing machines or equipment in addition to opening and cleaning machines.

Dust removal is not an easy operation, since the dust particles are completely enclosed within the flocks and hence are held back during suction.

It is mainly the suction units that remove dust (in this example 64%), dust removal will be more intensive the smaller the tufts.

It follows that dust elimination takes place at all stages of the spinning process as shown in figure.Dust Removal:Fig. 5 Dust removal as apercentage of the dust content of the raw cotton (A) at the various processing stages (B): 1 - 5, blowroom machines; 6, card; 7, draw frames; (a) filter deposit; (b) licker-in deposit; I, dust in the waste; II, dust in the exhaust air.

Blending:intensive blending in asuitable blending machine must be carried out after separate tuft extraction from individual bales of the layout. This blending operation must collect the bunches of fibers arriving sequentially from individual bales and mix them thoroughly. Multi mixer is the machine of blow room where the uniform blending is carried out. Figure Sandwich blending of raw material componentsIn conventional machineries, lap blending was the most significant one. doubling scutcher is required in this case; this has a conveyor lattice on which four to six laps (L) could be laid and jointly rolled-off. Lap blending produces very good transverse blends and also a good longitudinal blend, Figure Lap blending on an old scutcher

Even feed of material of the card: Finally the blow room must ensure that raw material is evenly delivered to the cards. Previously, this was carried out by means of precisely weighed laps from the scutcher, but automatic flock feeding installations are increasingly being used. While in the introductory phase such installations were subject to problem regarding evenness of flock deliver, today they generally operate well or at least adequately.

Introduction of blow room line:Figure Rieter blowroom line; 1. Bale opener UNIfloc A11; 2. Pre-cleaner UNIclean B 12; 3. Homogenous mixer UNImix B 75; 4. Storage and feeding machine UNIstore A 78; 5. Condenser A 21; 6. Card C 60; 7. Sliver Coiler CBA 4

Components of the blow room machine:Feeding Apparatus:Feed to abeater with two clamping rollers Feed with an upper roller and a bottom table Feed with a roller and pedals Operating with two clamping cylinders gives the best forward motion, but unfortunately also the greatest clamping distance (a) between the cylinders and the beating elements. In adevice with afeed roller and table the clamping distance (a) can be very small. This results in intensive opening. Where pedals are used (Fig. 12), the table is divided into many sections, each of which individually presses the web against the roller, e.g. via spring pressure. This provides secure clamping with asmall clamping distance (a).

Opening devices:Opening units can be classified as: endless pathgripping devices rotating assemblies Depending on their design, construction, adjustment, etc., these assemblies exert enormous influence on the whole process.1. End less path device:Spiked lattices is known as endless path device. It serves as forwarding and opening devices in bale openers and hopper feeders. They consist of circulating, endless lattices or belts with transverse bars at short intervals. The bars are of wood or aluminum; steel spikes are set into the bars at an angle and at greater or lesser spacing. The intensity of the opening action is dependent upon:the distance between the devices; the speed ratios; the total working surface;the number of points.

2. Gripping elements (plucking spring):Some manufacturers, for example former Schubert & Salzer and Trtzschler, have used plucking springs for opening. Two spring systems, facing each other like the jaws of apair of tongs, are parted and dropped into the feed material and are then closed before being lifted clear. They grasp the material like fingers. This type of gripping is the most gentle of all methods of opening, but it produces mostly large to very large clumps of uneven size. This type of opening device is therefore no longer used.

3. Rotating Devices (Roller with teeth, blades or spikes):Flat, oval or round bars are welded, riveted or screwed to closed cylinders.

The rollers are therefore called spiked rollers. Various spacing of the striker elements are used. These devices are incorporated mainly in modern horizontal cleaners, chute feeds, mixing bale openers, step cleaners, etc., which are located from the start to the middle of the blowroom line.

At the start of the line, the spacing of the striker elements on the roller is greater; finer spacing are used in the middle (to the end) of the line. The rollers rotate at speeds in the range of 600 - 1000 rpm.

The grid:In the final analysis, it is the grid or agrid-like structure under the opening assembly that determines the level of waste and its composition in terms of impurities and good fibers. Grids are segment-shaped devices under the opening assemblies and consist of several (or many) individual polygonal bars or blades (i.e. elements with edges) and together these form atrough. The grid encircles at least 1/4, at most 3/4 and usually 1/3 to 1/2 of the opening assembly. The grid has amajor influence on the cleaning effect via: the section of the bars; the grasping effect of the edges of the polygonal bars; the setting angle of the bars relative to the opening elements;the width of the gaps between the bars; the overall surface area of the grid.Figure:Two-part grid

The following elements can be used in the grid:

slotted sheets (a): poor cleaning;perforated sheets (b): poor cleaning;triangular section bars (c): the most widely used grid bars;angle bars (d): somewhat weak;blades (e): strong and effective. These elements can be used individually or in combination. Modern grids are mostly made up of triangular bars. They are robust, easy to manipulate and produce agood cleaning effect. The same is true of blade-grids.

Blades have been used as grid elements for along time (the mote knife), almost always in combination with triangular section bars.

Grid adjustment:

Three basic adjustments:

Distance of the complete grid from the beater;

width of the gaps between the bars (a=closed, b=open);

setting angle relative to the beater envelope

Conventional Machine of Blow room line:Bale breaker:Opening is mainly emphasized in this machine rather cleaning.

This machine is designed to take layer of cotton directly taken from bale and tear them apart leaving the cotton partially opened.

Porcupine opener:The cotton fed by the previous opener is carried forward by the feed lattice.

16 circular disc are mounted on the shaft of this opener. 14 to 18 striker blades are riveted alternatively on each circular disc. The compressed sheet of cotton delivered from the feed roller is heavily beated by the rapidly revolving striker of the porcupine beater against grid bar.

Because of this beating action, the cotton is effectively opened and extracted trash particles are passed through the spacing of the grid bar.

Step cleaner:The material falls into the feed hopper and passes to the first beater.

From there it is transported upward by the six (sometimes three or four) beater rollers, each carrying profiled bars.

The beaters are arranged on aline inclined upward at 45.

Elimination of impurities takes place during the continual passage of the material over the grids arranged under the rollers

Air Jet cleaner:Object of this cleaner is to open and clean the cotton, but this cleaning unit introduces the idea of dirt separation from cotton by air force.The function of the Kirschner beater section is to open and clean the cotton and prepare the cotton for air jet section.The tuft of cotton from the kirschner beater section is entered in to the aero dynamic constricting duct.

The air current from the booster fan carry the cotton toward the bend in the duct.The duct makes a sharp turn of about 120 degree.

Axi flow Cleaner:This is known as dual roller cleaner.

This machine has two beaters having 6 to 8 rows of spikes with flattened edge which perform cleaning action.

Beater speed is 400-600 rpm.

Material through entire length of first beater pass over the grid bars where trash is collected and comes in contact with second beater.

Scutcher:

To feed the material to card is very important because it should be homogeneous, uniform from card to card, fulfill this requirement scutcher machine is used.

It is less problematical. No need of using pipes to provide the material to separate machine. It can be provide universally and this can be used with many blends.

Less economical as compared to chute feed system.

Its function is to clean the material and form a uniform lap for card.

Kirschner beater:In this type of beater, instead of beater bars, pinned bars (pinned lags) are secured to the ends of the cast-iron arms.

The relatively high degree of penetration results in good opening. Kirschner beaters were therefore often used at the last opening position in the blowroom line.Modern Kirschner openers are often designed as closed rollers rather than three-armed beater units. The design is simpler and the flow conditions are more favorable.Beaters with pinned bars Rollers with pinned bars

Modern Blow room lineABO= Automatic Bale OpenerCPC= Crosrol Pre-CleanerCBO= Crosrol Blending OpenerCFC= Crosrol Fine CleanerCDR= Crosrol Dust Removal

Trutzschler Blow room line:1234561= Automatic Bale opener BLENDOMAT BO-A2= TUFTOMAT SYSTEM3= Metal Detector4= Universal Mixture MX-U5= SECURO PROOF SP-FPU6= Universal Cleaner CP-U

Rieter Blow room line: The UNIflocA11 processes the fiber material gently and efficiently into microtufts, from which impurities can be removed very readily in the subsequent processes. The UNIfloc is designed for output of up to 1400kg/h (cardedsliver).Bales are laid down over a length of 7.2 to 47.2meters. The UNIfloc can process up to 4 assortments simultaneously.The width of the take-off unit can be selected between 1700 and 2300 mm.

Uniclean B12The UNIcleanB12 pre-cleaner cleans the microtufts in the first cleaning stage immediately after the UNIflocA11The UNIclean is designed for output of up to 1400kg/h (cardedsliver).Fiber yield with simultaneous efficient cleaning is up to 2% higher than on conventional units. Pre-cleaning without nipping and the use of mote knives results in fiber-preserving cleaning.The large dedusting surface ensures intensive dedusting even at high production performance.

Unimix B76The B72 / B76 mixing machine guarantees homogeneous, intimate mixing of the bale feed in a minimum of space, even with unfavorable bale lay-down.Eight mixing chambers ensure not only effective mixing, but also high production performance. The easy addition of an opening or cleaner module provides flexibility with the capability to respond to changes in market conditions.Bypass facility for the cleaner module (e.g. with man-made fibers) for rapid mix change.

Uniflex B601= Filling Chute2= Perforated drum3= Feed zone4= Grid5= Opening Cylinder6= DeliveryMaterial comes from preceding machine and then filling the chute. Thus in the chute, a very homogeneous batting lay down is formed both lengthwise and crosswise.

The material is carried further by a perforated drum (2) and a plain drum.

The feed roll (3) supplies the material to the opening cylinder (5).

A grid (4) made of carding segments and knives forms the cleaning surface and extracts impurities.

Jute spinning procedure

Carding Machine

Carding Machine

In modern installations, raw material is supplied via pipe ducting into the feed chute (of different designs) (2) of the card. An evenly compressed batt of about 500 - 900 ktex is formed in the chute. A transport roller (3) forwards this batt to the feed arrangement (4).

This consists of a feed roller and a feeder plate designed to push the sheet of fiber slowly into the operating range of the licker-in (5) while maintaining optimal clamping. The portion of the sheet projecting from the feed roller must be combed through and opened into tufts by the licker-in. These tufts are passed over grid equipment (6) and transferred to the main cylinder (8).

In moving past mote knives, grids, carding segments (6), etc., the material loses the majority of its impurities. Suction ducts (7) carry away the waste. The tufts themselves are carried along with the main cylinder and opened up into individual fibers between the cylinder and the flats in the actual carding process.

Operating Principle of carding machine

The flats (10) comprise 80 - 116 individual carding bars combined into a belt moving on an endless path. Nowadays some 30 - 46 (modern cards about 27) of the flats are located in the carding position relative to the main cylinder; the rest are on the return run.

During this return, acleaning unit (11) strips fibers, neps and foreign matter from the bars. Fixed carding bars (9) and (12) are designed to assist the operation of the card.Grids or cover plates (13) enclose the underside of the main cylinder. After the carding operation has been completed, the main cylinder carries along the fibers that are loose and lie parallel without hooks.

However, in this condition the fibers do not form atransportable intermediate product. An additional cylinder, the doffer (14), is required for this purpose. The doffer combines the fibers into aweb because of its substantially lower peripheral speed relative to the main cylinder.

Astripping device (15) draws the web from the doffer. After calendar rolls (16) have compressed the sliver to some extent, the coiler (18) deposits it in cans (17). The working rollers, cylinder and flats are provided with clothing, which becomes worn during fiber processing, and these parts must be reground at regular intervals.

Licker-inThis is acast roller with adiameter usually of around 250mm. Saw-tooth clothing is applied to it. Beneath the licker-in there is an enclosure of grid elements or carding segments; above it is aprotective casing of sheet metal. The purpose of the licker-in is to pluck finely opened tufts out of the feed batt, lead them over the dirt-eliminating parts under the roller and then deliver them to the main cylinder. In high-performance cards, rotation speeds are in the range of 800-2000rpm for cotton and about 600rpm for synthetics.

Carding BarAn aluminium carding profile (1) consists of 2 carding bars (2). One of the advantages of bars is that they can be provided in different finenesses, e.g. they can become finer in the through-flow direction. Different manufacturers use differing numbers of elements (between one and four) per position. Special clothing is required that must not be allowed to choke. Most modern high-performance cards are already fitted with these carding aids as integral equipment; all other machines can be retrofitted by, for example, Graf of Switzerland or Wolters of Germany. In use are also other carding devices of different design and with different components, e.g. mote knives (4) with guiding element (5) and suction tubes (3), etc.

CylinderThe cylinder is usually manufactured from cast iron, but is now sometimes made of steel. Most cylinders have adiameter of 1 280 - 1 300 mm (Rieter C 60 card 814 mm, speed up to 900 rpm) and rotate at speeds between 250 and 500 (to 600) rpm. The roundness tolerance must be maintained within extremely tight limits the narrowest setting distance (between the cylinder and the doffer) is only about 0.1 mm. The cylinder is generally supported in roller bearings. Clothing configuration between main cylinder and doffer

flat

The cylinder is followed by the doffer, which is designed to take the individual fibers from the cylinder and condense them to aweb. The doffer is mostly formed as acast iron (or steel) drum with adiameter of about 600-707mm. (680mm on Rieter machines) . It is fitted with metallic clothing and runs at speeds up to about 300m/min. Doffer

Point density (Number of points per unit surface area)The populations of the main cylinder and doffer clothing have to be adapted to each other. In general, the higher the point population, the better the carding effect up to acertain optimum. Above that optimum, the positive influence becomes anegative one. This optimum is very dependent upon the material. Coarse fibers need fewer points, as they need more space in the card clothing; finer fibers must be processed with more points, since more fibers are present if the material throughput is the same. Point density is specified in terms of points per square inch or per square centimeter, and can be calculated as follows:

Base width (a1) This influences the point density. The narrower the base, the greater the number of turns that can be wound on the cylinder and, correspondingly, the higher the point population. Height of the clothing (h1) The height of metallic clothing on the cylinder today varies between 2mm and 3.8mm. The height must be very uniform. It can also exert an influence on the population, since shorter teeth for agiven tooth carding angle leave space for more teeth. Where shorter teeth are used, the fibers are less able to escape into the clothing during carding and better carding over the total surface is obtained. Clothing with smaller teeth is also less inclined to choke with dirt particles. Tooth pitch (T)The population is also determined by the tip-to-tip spacing.

Carding Angle () This is the most important angle of the tooth as it determines : the aggressiveness of the clothing; and the hold on the fibers The angle specifies the inclination of the leading face of the tooth to the vertical. It is described as positive , negative or neutral. The angle is neutral if the leading edge of the tooth lies in the vertical (0). Clothing with negative angles is used only in the licker-in when processing some man-made fibers. Since the fibers are held less firmly by this form of tooth, they are transferred more easily to the cylinder and the clothing is less inclined to choke. Carding angles normally fall into the following ranges:licker-in: +5 to -10 Cylinder: +12 to +27 Doffer: +20 to +40

Fig. Positive (a) and negative (b) carding angle

The tooth pointCarding is performed at the tips of the teeth and the formation of the point is therefore important. For optimum operating conditions the point should have asurface or land (b) at its upper end rather than aneedle form. This land should be as small as possible. To provide retaining power, the land should terminate in asharp edge (a) at the front. Unfortunately, during processing of material this edge becomes steadily more rounded; the tooth point must therefore be re-sharpened from time to time. Formation of aburr at the edge (a) must be avoided during re-sharpening. The tooth must only be ground down to agiven depth, otherwise land (b) becomes too large and satisfactory carding is impossible the clothing has to be replaced. Fig. The tooth point

The base of the toothThe base is broader than the point in order to give the tooth adequate strength, and also to hold the individual windings apart. Various forms can be distinguished. In order to mount the wire, the normal profile ((a) for the licker-in, (b) for the cylinder) is either pressed into agroove milled into the surface of the licker-in (a) or is simply wound under high tension onto the plain cylindrical surface of the main cylinder (b). (d) represents alocked wire and (c) achained wire. Both can be applied to asmooth surface on the licker-in; in this case amilled groove is no longer necessary.

Fig: Formation of the tooth base and mounting on the drum

Tooth hardness In order to be able to process as much material as possible with one clothing, the tooth point must not wear away rapidly. Accordingly, avery hard point is needed, although it cannot be too hard because otherwise it tends to break off. On the other hand, to enable winding of the wire on around body, the base must remain flexible. Each tooth therefore has to be hard at the tip and soft at the base. Amodern tooth has hardness structures as shown in Fig(Graf).

Fig. Metal hardness at various heights in the wire: A, hardness (A1 = Rockwell, A2 = Vickers); B, tooth height from the tip to the base

The material supply should operate with the greatest possible degree of accuracy as it has adirect effect on sliver evenness. The main regulating position is the feed; adjusting the feed roller speed (5) usually performs auto leveling. Virtually all auto leveling devices exploit this possibility; adjustment of the delivery speed is hardly ever used. Adistinction should also be drawn between:short-term leveling systems, regulating lengths of product from 10-12 cm (rarely used in carding);medium-term leveling systems, for lengths above about 3m;long-term leveling, for lengths above about 20m (maintaining count).

In addition, regulating can be performed by open-loop or closed-loop control systemsAuto leveling equipment for carding machine

Medium term auto leveler:An optical measuring device detects relative variations in the cross-section of the fiber layer on the main cylinder over the whole width of the cylinder. The measuring device is built into the protective cover above the doffer. The device measures reflection of infrared light from the fibers. After comparison with the set value, a difference signal is generated and passed to an electronic regulating unit. This operates via a regulating drive to adjust the infeed speed of the card so that the depth of the fiber layer on the main cylinder is held constant.

Long term auto leveler:This is the most commonly used principle of card autoleveling and serves to keep the sliver count constant. Measuring is performed by asensor in the delivery (at the delivery roller). The pulses derived in this way are processed electronically so that the speed of the infeed roller can be adapted to the delivered sliver weight via mechanical or electronic regulating devices.Long-term autoleveling is an integral part of modern cards, and in any case used in production of carded yarns and in the rotor spinning mill.

Technical data of three high performance card

Grinding:The operating life of clothing is quoted in terms of the total throughput of material. For the cylinder it normally lies between 300000 and 600000kg, but it can be higher in some circumstances.

Processing of materials therefore considerably wears down the teeth they become rounded at the top and lose their aggressiveness.

The direct result is acontinuous increase in the nep content of the sliver.

The points must therefore be sharpened from time to time, in order to give abetter shape to the edges by grinding them. Each new grinding operation reduces the number of neps, but the level never returns to that prior to the previous grinding

Cylinder Flats First grinding after [kg] 80000 - 150000 80000- 150000 Each additional grinding after [kg] 80000- 120000 80000- 120000

The deterioration in quality from one grinding interval to the next arises from the fact that the teeth are ground down to successively lower heights, the lands at the teeth points become steadily larger, and softer metal layers are gradually exposed. The interval is best selected depending on the mills nep limit (c). Since the doffer clothing works much less than that of the cylinder, it should be ground only half as often, or even less frequently. The clothing on the licker-in should not be ground; it should be renewed after a throughput of 100000- 200000kg.Frequency of grinding:Fig. Increase in neps between grinding periods: A, number of neps in the web; B, grinding interval; b, general rise of the lower nep level; c, mills limit for neps

Draw Frame

Main task of D/FEqualizing: One of the main tasks of the draw frame is improving evenness over the short, medium and especially long term. Card slivers fed to the draw frame have a degree of unevenness that cannot be tolerated in practice. Parallelizing: To obtain an optimal value for strength in the yarn characteristics, the fibers must be arranged parallel in the fiber strand. It is mainly the draw frame's task to create this parallel arrangement.It fulfills this task by means of the draft, since every drafting step leads to straightening of the fibers. The value of the draft must be adapted to the material, i.e. to several fiber parameters, mainly: the staple length; the mass of the fibers; the volume of the strand; the degree of order (parallel disposition).

Blending: In addition to the equalizing effect, doubling also provides a degree of compensation of raw material variations by blending, which occurs simultaneously. This result is exploited in particular in the production of blended yarns comprising cotton/synthetic or synthetic/synthetic blends.For example, to obtain a 67:33 blend, four slivers of one component and two of the other are fed to the draw frame. Of course, these slivers must have the same hank.Dust Removal: Dust is steadily becoming a greater problem both in processing and for the personnel involved. It is therefore important to remove dust to the greatest practical extent at every possible point within the overall process. Dust removal can only be carried out to a significant degree when there are high levels of fiber/fiber or fiber/metal friction, since a large proportion of these very small particles (dust) adhere relatively strongly to the fibers. Such friction arises especially on thecard and the draw frame; in the latter case, mainly owing to the drafting operation. The draw frame is therefore a good dust-removing machine. On high-performance draw frames equipped with appropriate suction systems, more than 80% of the incoming dust is extracted.

DraftFactors dependent upon the fiber material:mass of fiber in the strand cross section;degree of order of the fibers (parallel disposition);shape of the cross section of the fiber strand;compactness of the fiber strand;adhesion between the fibers dependent uponsurface structure,crimp,spin finish,compression of the strand;fiber length;evenness of distribution of fiber lengths (staple form);existing twist in the fiber strand.

In all types of drafting arrangement, the factors that affect the draft are:

Factors dependent upon the drafting arrangement: diameter of the rollers; hardness of the top rollers; pressure exerted by the top rollers; surface characteristics of the top rollers; fluting of the bottom rollers; type and form of fiber guiding devices, such as pressure rods, pin bars, aprons, condenser etc.; clamping distances (roller settings); level of draft; distribution of draft between the various drafting zones.

Draft through a roller drafting arrangementThe Drafting Operation:During drafting, the fibers must be moved relative to each other as uniformly as possible by overcoming the cohesive friction.

Uniformity implies in this context that all fibers are controllably rearranged with a shift relative to each other equal to the degree of draft. But what is practical, drafting operations always run irregularly, and each draft stage will therefore always lead to an increase in unevenness.

Drafting is mainly done by roller-drafting arrangements (above figure). The fibers are firmly nipped between the bottom steel rollers and the weighted top pressure rollers. If the rollers are now rotated in such a way that their peripheral speed in the through flow direction increases from roller pair to roller pair, then the drawing apart of the fibers, i.e. the draft, takes place. This is defined as the ratio of the delivered length (LD) to feed length (LF), or the ratio of the corresponding peripheral speeds:

where v = peripheral speed of cylinder, D = delivery and F = feed. The drafting arrangement illustrated has two sub drafting zones, namely: a break draft zone (B): VB = v2 / v3, and a main draft zone (A): VM = v1 / v2 The total draft is always the product of the individual drafts and not the sum: How the draft is happened:

Auto Leveler:Classification of Auto leveler:1. open-loop control can compensate variations of short (to medium) wavelength, 2. closed-loop control can compensate only medium and long-term variations. Fig Leveling draw frame with open-loop controlThis system permits very precise leveling of very short lengths. A second advantage is the ability to measure far greater sliver masses due to the lower in feed speed (corresponding to the amount of draft). Recording becomes more precise. In practice, draw frame leveling using open-loop control is now predominant.