SSM COLLEGE OF ENGINEERING,

KOMARAPALAYAM – 638 183.

DEPARTMENT OF TEXTILE TECHNOLOGY

(NBA Accredited & certified by ISO 9001:2008)

LABORATORY MANUAL

TT8411-YARN MANUFACTURE LABORATORY

Name of the Student: ______________________________________

Register Number: ____________________ Roll Number: _____

Year: Semester:

Academic Year: _______________

 TABLE OF CONTENTS

S.NO DATE LIST OF EXPERIMENTS MARKS SIGNATURE

Construction details of ring
1 spinning machine and material
passage
Draft, Twist and production
2 calculations in ring spinning
machine
3 Study of builder mechanism of
ring spinning machine
4 Selection of ring travellers
Construction details of rotor
5 spinning machine and material
passage
Draft, Twist and production
6 calculations in rotor spinning
machine
7 Production of carded

8 Production of draw frame sliver

9 Production of roving

10 Production of yarn using ring

spinning machine
11 Production of yarn using rotor
spinning machine
12 Analysis of MIS reports from
spinning mills
Total
 RING SPINNING

EX NO: 1 DATE:

Aim:
To study the Construction details of ring spinning machine and material passage

Object

The main objects of ring spinning frame are:

1. Drafting: Thinning down or attenuation of the roving or increasing

the length of roving per unit weight.

2. Twisting: Giving positive twist into the drafted material

3. Winding: Winding the yarn over the ring cop or package

4. Building: Building the cop to the required size and shape

Construction details

A spinning frame is a long narrow rectangular, double-sided machine. The upper part
is designed to hold the roving bobbins so that roving may be fed to either side of the
machine. The roving is drawn down to the proper size, given the necessary amount
of twist and then wound over the spinning cops suitable for the next operation.

The machine works continuously for the length of time needed to produce a full bobbin of
yarn, after which these bobbins are removed and the machine is reset to make another set
of bobbins.

The crosswise framing of the ring spinning frame consists of a gear end and off end
with a series of supports by spring pieces at regular intervals. The gear end is a cast
iron case, approximately 39 inches wide, 42 to 50 inches high and 4 inches to 7
inches deep, which forms one end of the machine. The gear end has swinging doors
of cast iron or steel sheet arranged, so that the inside gearing is readily accessible.
The twist gearing, drive from the spindle-driving shaft to the front rolls and the
building motion gearing are located inside the gear end case.

The off end of the frame is a cast iron plate usually about 39 inches wide and 36 to
38 inches high. This plate serves as the other end support of the machine. The
spring pieces are cast iron skeleton frames of a special shape, which serve as a
intermediate supports for the various parts of the machine i.e. spindle rails, roller
beams, creel and the tin roller shaft bearings.

Ordinary commercial length frames have about 11 or 12 spring pieces (440 spindles
machine). In many of the newer frames, the offend and the spring pieces have
adjustable feet to level the frame in a simple operation.

The lengthwise framing consists of the spindle rail and the roller beams. The spindle
rails are made up of cast iron or steel, channel shaped strips of 8 to 9 inches high
and about 3 inches wide. It is fastened to the spring piece about 14 to 16 inches
above the floor level. The flat side of the channel is fastened to the spring pieces so
that the narrow flanges project horizontally outward. The upper flange
accommodates the spindle base. The spacing of the holes for accommodating the
spindles determines the spindle gauge of the ring frame. The spindle gauge is the
distance between the centers of the adjacent spindles. The spacing of the roller
stands must be agreeable with this gauge. The spindle rails are drilled at proper
places for the lifter or poker bar, which will support the ring rails.

The roller beam is a cast iron angle usually 3 inches wide, 2½ to 3 inches deep; one
of which is fastened to both the frame ends and either side of the top of each spring
pieces along the full length of the frame. The upper side of the roller beam
accommodates roller stands, which can be fixed to the roller beam with screws. The
distance between the consecutive roller stands is called staff length or box length.
Usually 8 spindles per box are very common in ring frames.

3.2 Super structure

The ring frame consists of three parts namely the feed part, the drafting zone and the
delivery part. The feed part of the machine consists of the creel, which is necessary
to carry the roving bobbins. The full bobbins containing the roving are placed on the
umbrella type of bobbin holders and held in position by the creel. The roving from the
full bobbins can be easily unwound and fed to the drafting rollers. The polished guide
rods attached to the creel guide the material properly without any entanglement. The
top of the creel is used for keeping additional roving bobbins.

The drafting zone is built at an inclination. It consists of three pairs of drafting rollers, with a
pair of aprons in the front zone for the purpose of drafting the roving fed from the creel. In
the drafting system, each successive pair of drafting rollers will revolve at a higher peripheral
speed from back to the front for drafting the roving fed. The delivery part of the machine
consists of accessories needed for guiding, twisting and winding the material on the cop.
These accessories are thread guides, spindles, bobbin and its assembly, rind rail and its
support, ring and traveller.
Passage of material through a ring frame

The figure shows the section of one side of the ring frame. The roving bobbins are
placed on the umbrella creel or bobbin holder. The roving is withdrawn from the
bobbin, passed over the guide rods, and through a traverse guide, placed behind
the back pair of drafting rollers. Each successive pair of drafting rollers revolving at
relatively higher peripheral speeds from back to the front drafts the roving fed. The
drafting system consisting of 3 pairs of drafting rollers, with a pair of aprons in the
main draft zone helps in controlling the short fibres.

From the front rollers the material is passed through a guide wire placed in a
lappet and this guide wire is kept directly over the centre of the spindle. Each
lappet is hinged to a lappet rail. The yarn is then passed through a small piece of
steel wire bent in the form of the letter C called the traveller, which clips loosely on
the ring flange. The ring is fitted on the ring rail, which is traversed up and down,
to wind the yarn over the bobbin.

The spindle and the bobbin pass through the centre of the ring and after the yarn is
threaded through the traveller and wound round the bobbin. The revolution of the
spindle makes the yarn to run at a very high speed and the yarn holds the traveller
round with it. Each revolution of the traveller introduces one twist on the yarn. The
winding is due to the traveller lagging behind the bobbin. The spindles are usually
driven from the tin roller or spindle driving pulleys by tapes that are guided on the
spindle wharves on the spindle.
 Fig.2 . Passage of Material through a Ring Spinning Frame

A - Roving bobbin B - Guide rod

C - Traverse guide D - Drafting system

E - Thread guide F - Spun yarn

G - Ring rail H - Ring Cop

J - Spindle & Bolster K - Spindle driving pulley

The passage of the material is summarized as below:

Creel

Guide rod

Traverse guide

Drafting rollers

Thread guide

Traveller

Bobbin (or) cop

PRACTICE
To study the functions of following parts of Ring spinning machine

1. Creel
2. Guide rod
3. Traverse guide
4. Drafting system
5. Thread guide
6. Ring rail
7. Ring
8. Traveller
9. Spindle
10. Spindle driving pulley

Result:

Thus the Construction details of ring spinning machine and material passage have been
studied

Marks Allotted Marks Awarded Signature of the staff

10
 RING SPINNING DRAFT CALCULATIONS

EX NO: 2 DATE:

Aim :

To calculate the speed and Draft of ring spinning machine

Machine used

Ring frame

Speed Calculations:

1. Spindle Speed:

Spindle Speed =

2. Speed of Bottom Rollers:

Speed of the front bottom Roller =

 =

 Surface speed of the front bottom roller in inches / min = DN

 Speed of the middle bottom roller =

 Surface speed of the middle bottom roller in inches / min = DN

 Speed of the back bottom roller =

 =

 Surface speed of the back bottom roller in inches / min = DN

3. Draft:

Draft = Surface speed of delivery roller in inches / min

Surface speed of feed roller in inches / min

Break Draft = Surface speed of middle roller in inches / min

Surface speed of back roller in inches / min

=
Main D raft = Surface speed of front roller in inches / min

Surface speed of middle roller in inches / min

Total Draft = Main draft X Break draft

4. Draft constant:

Let us assume Draft change wheel (DCW) = I teeth and back roller rotates at speed

of 1 rpm.

Draft constant =
 Draft constant =

Gearing Diagram of Ring Frame:

5. Draft change wheel:

Draft change wheel = Draft constant

Total Draft

Result:

Marks Allotted Marks Awarded Signature of the staff

10
 RING SPINNING TWIST CALCULATIONS

EX.NO : 3 DATE:

Aim:

To determine the twist and to estimate the production of the ring spinning machine

Formulas:

Calculations:

1. Spindle Speed:

Spindle Speed =

=
 =

 Speed of the front bottom Roller =

 Surface speed of the front bottom roller in inches / min = DN

Twist Calculations:

Spindle speed in rpm

Twist per inch = ---------------------------------------------------------------------

Surface speed of the front roller in inches per min

=
 =

Twist constant:

Let the front roller rotate at 1 rpm and Twist Change Wheel (TCW) = 1 teeth.

Twist constant =

Twist change wheel:

Twist Change Wheel (TCW) = Twist constant

Twist per inch

=
 =

Production Calculation:

Surface speed of front roller in inches / min =

Shift hours =

Efficiency =

No. of spindles =

Count of yarn =

Calculation:

Production per 8 hrs in kgs = π DN x Shift hours x 60 x Efficiency x No.of spindles

36 x 840 x count of yarn x 2.204 x 100

=
Result:

Marks Alotted Marks Awarded Signature of the staff

10
 BUILDER MECHANISM OF RING SPINNING

EX NO: 4 DATE:

Aim :

To study the builder mechanism of ring spinning machine

Machine used :

Ring frame

Objectives :

1. To traverse the ring rail up and down for winding layers of coils.
2. To elevate the commencing point of the chase during each successive layer (short lift).
3. To increase the length of the chase until the formation of the cop bottom and then to
provide a constant chase, till the full bobbin so as to form the tapered nose.
a. LIFT

Lift is the distance between the extreme lowest and highest point on the bobbin.

b. CHASE:

It is the distance between the lowest position of the ring rail and the highest position
during winding of the same layer of coils.

c. WINDING COILS:

It is known as main windings, with the yarn coils laid close to each other,
during slow rise of the ring rail (gradually the rate of transverse is
increased as the ring rail reaches the top).

d. BINDING COILS:

It is known as cross windings with the yarn coils laid far off to each other, during quick
descend of the ring rail. (gradually the rate of transverse is reduced as the ring rail
reaches the bottom).
 e. COP BOTTOM:

It is the curved bottom portion of the cop after yarn building.

Working of the builder motion

Builder motion

The ring rail (R) is suspended by belts from a disc (B) mounted on the shaft
(W). The full weight of the rail is carried by the disc and generates a turning
moment. At the other end of the shaft there is another disc (a); this second
disc, acting via the chain (K) and chain drum (T), presses the lever (H) with
the roller (O) against the heart shaped eccentric (E). Owing to the rotation of
the eccentric, the lever and the chain drum are continually raised and
lowered. This movement is transferred to the ring rail by way of the discs (a
and b) together with the chain and belt, thus giving the transverse movement.
Every time the lever moves down, it presses the catch to release the ratchet
wheel (A), which enables a slight rotation of the drum (T), connected to the
ratchet wheel. A short length of chain (K) is thus wound up on the drum,
these leads to rotation of the disc (a), shaft (W) and disc (b), and finally to a
slight raise in position of the ring rail (R) i.e. the short lift. The shaft (W) also
carries a third disc (c) from which the balloon control rings (B) and lappets (F)
are suspended by belts. These are correspondingly raised and lowered, but
since disc (c) is slightly smaller than disc (b) the stroke length is somewhat
shorter.
 Action of the cam (N) in the builder motion

Building the base

The base of the cop is curved on its outside in order to enable as much yarn
as possible to be taken up on the package. This curvature arises partly from
the specific type of winding itself, but is significantly reinforced by a
mechanical carries). As already explained, raising and lowering of the ring
rail (R) comes about because of the eccentric (E) moves the lever (H) up and
down and thus the disc (a) is continuously turned alternatively to the left and
to the right. Disc (a) carries the cam (N), which projects beyond the periphery
of the disc and thus formed a lobe of larger diameter than the rest of the disc.

At the start of winding of a cop, disc (a) is located in the position shown in the
fig.57 in which the lobe noticeably deflects the chain (K). The effect of this
deflection is that the chain elongation upon raising of the lever (H) is not
wholly transferred to the ring rail; part is lost as deflection at N. The
transverse stroke of the ring rail no longer corresponds to the setting – it is
shorter. However, the length of yarn delivered during each traverse stroke is
the same, the volume per layer is increased, there by generating the
curvature.

Now, in the further course of the spinning operation, the chain take – up disc
(T) is steadily turned to the left in small steps by the ratchet wheel; the chain
is thereby wound up on the disc and thus shortened. Accordingly, disc (a)
turns to the right in the same small steps and the cam is carried out of line
with the chain; finally, the complete elongation of the chain is passed on to
ring rail and there after the cop takes up its normal build, till the cop is full.

PRACTICE
Result :

Thus the builder mechanism of ring spinning machine has been studied

Marks Alotted Marks Awarded Signature of the staff

10
 SELECTION OF RING TRAVELLERS

EX NO: 5 DATE:

Aim:
To study about the Selection of ring travelers in a ring spinning machine
Machine Used:
Ring frame

The Ring

A spinning ring is a small circular flanged track within which the spindle is
centered and on which the traveller moves. The rings are made of special
hardened metal to suit different purposes and to withstand the constant
rubbing action of the steel traveller. They are highly polished, so as to offer
minimum resistance to the movement of traveller.

Ring and Traveller

The traveller in interdependence with the ring and the yarn defines the limit to the
productivity of the ring-spinning machine. The optimal running conditions of a ring frame
depend upon the following:

1. Material of the ring and traveller

2. Surface characteristics of the ring and traveller
3. The form of ring and traveller
4. Wear resistance
5. Smoothness of running
 6. Running in condition
7. Fibre lubrication

Types of ring

Rings are classified into:

 Lubricated ring ( used in woolen and worsted spinning)

 Unlubricated ring

The standard ring of the short staple-spinning mill uses the following types:

 Single sided
 double sided

Single side ring

A single sided ring (fig.44) will have flanges on one side only. Single-sided
rings must be replaced by new ones after they have been worn down.

Fig.44. Single sided ring

Double sided ring

A double-sided (fig.45) ring will have flanges on either side. A double-sided

ring worn on one side can be turned over and used on the second side. The
worn side serves for mounting of the ring while the other side is acting as
traveller guide.
 Fig.45. Double sided ring

But in practice, when a double-sided ring is turned over, the second side has
become unsuitable due to corrosion and other causes. Therefore these rings
are not in use today.

The Anti-wedge ring

This was the first high-performance ring manufactured by the Eadie Bros.
company. Compared with the earlier ring form, it has an enlarged flange
inner side and its top surface is flattened. This change of form permits to use
the traveller with a low centre of gravity and small bow (elliptical traveller),
which in turn allows higher operating speeds. Anti-wedge ring and elliptical
traveller can be used only in combination.

Fig.46. Antiwedge ring

Advantages of Antiwedge ring

1. Antiwedge ring permits higher spindle speeds

2. Increased production per spindle
3. Increased traveller life and hence saving in traveller cost
4. Lesser ring wear
5. Shortened Running in period
6. Increased machine efficiency
7. Reduce the piecer’s work load

Low-crown ring (conventional ring)

In the low crown ring (fig.47), the curvature of the upper surface has been
somewhat flattened compared with rings used earlier. This gives more space
for the passage of the yarn so that the curvature of the traveller can also be
reduced and the centre of gravity is lowered.

In comparison with the anti-wedge ring, low-crown ring has the advantages
that the space provided for passage of the yarn is somewhat larger and that
all-current traveller shape can be applied with the exception of the elliptical
traveller. Today, the low-crown ring is used widely.

. The low-crown
(conventional ring)

SU-Ring

SU - ring

This ring (fig.48) form is a Russian development (SU stands for Soviet
Union). It has two advantages, namely a large surface of contact for the
traveller on the inner flange (with correspondingly good heat transfer to the
ring) and a degree of compensation of forces acting on the traveller.

The tensile force (FZR) exerted in the upward direction by the yarn is counter
acted by a second force (FFK) which arises because the traveller is urged
downwards on to the conical inner flange in response to the high centrifugal
force. SU ring with corresponding traveller permits higher traveller speeds in
the spinning of synthetic fibres and give a slight reduction in traveller wear.

Material for the ring

The ring should be always being tough and hard on its outer surface. The
running surface in particular requires the closest attention. The surface layer
must have high and even hardness in the range 800 – 850 Vickers. The
traveller hardness should be lower (650 – 700 Vickers), so that wear occurs
mainly on the traveller, which is cheaper and easier to replace.

Surface smoothness is also important. It should be high, but not too high,
since otherwise a lubricating film cannot build up on it.

The following materials are used:

 Flame or induction-hardened steel, to some extent

 Nitrided steel ; this is now rare since ablation can arise owing to the high
surface hardness
 Carbo-nitrided steel; this is the most common
 Chrome steel; this is found more rarely

Fibre lubrication on the ring

The contact between the ring and traveller involved metal-to-metal friction.
This metal-to-metal friction would probably limit the traveller speeds to about
28-30 meters/sec.

In reality, the traveller moves on a lubricating film, which it builds up itself and
which consists primarily of cellulose and wax. This film arises from material
abraded from the fibres. If fibre particles are caught between the ring and the
traveller, then at high traveller speeds and correspondingly high centrifugal
forces, the particles are partially ground to a paste of small, colourless,
transparent and extremely thin platelets. The traveller smoothes these out to
form a continuous running surface.

The adherence of the platelets to the ring and the cohesion within the film are
very variable. Accordingly, the platelets are continuously scraped off; equally,
they are continuously being replaced.

The position, form and structure of the lubricating film is dependent upon the
following factors:

 Yarn fineness
 Yarn structure
 Fibre raw material
 Traveller mass
 Traveller speed
 Height of the traveller bow

In spinning of yarns finer than 80s, no fibre lubrication (or very little) can be
expected because traveller mass and hence centrifugal force is low.
Maximum traveller speed is therefore lower than in spinning of coarser yarns.

Modern ring/traveller combinations with well functioning fibre lubrication

enable traveller speeds in extreme cases up to 40 meters/sec.
Running in a new ring

If a damaged ring is replaced by a new one, fibre lubrication is absent in the

new ring. Up to a certain period, only metal-to-metal friction is present at the
contacting surfaces of the ring and the traveller. This is very serious because
the new ring will be damaged due to pitting and welding.

So, the ring manufacturers have established precise rules for this running in
phase, during which the surface is smoothed and oxidised, and fibre
lubrication film is built up. The running-in-procedure followed is as follows:

1. New rings should not be degreased, but only rubbed over with a dry cloth
2. Use either the correct traveller with a 15-20% less spindle speed or the normal
spindle speed with a traveller 1-2 numbers lighter than usual.
3. The first traveller change should be carried out after 15 minutes
4. The second traveller change should take place after 30 minutes
5. The third traveller change should be made after 1 to 1½ hours
6. The fourth traveller change should be made after the first doff
7. Further traveller changes are made after the second and third doff
8. Traveller changes should again take place after the fifth and eight doffs

Between times, the spindle speed can be increased in steps.

In spinning yarns finer than 80s, running is still more serious. In this case
speeds should be reduced by 20-30% and the rings cleaned from time to
time with a piece of felt soaked in oil.

Ring Size

The size of the ring is designated by two factors, namely:

 Its internal diameter

 Flange width
Ring diameter

The diameter of the ring is the distance across the ring inside the flanges.
The rings are available in the following diameters (in mm):
3 3 4 4 4 4 5 5
6 8 0 2 5 8 1 4

Small ring diameters are used for spinning fine yarns and larger diameter
rings for coarse counts.
Flange width
Ring flange sizes are numbers given to indicate the overall width of the
flange measured horizontally
 Ring flange

The flange numbers are as follows:

Flan
Width in mm Width in mm
ge
Conventional ring Antiwedge ring
No.
0 2.3 -
½ 2.7 -
1 3.2 3.2
1½ 3.6 -
2 4.0 3.78
3 4.7 -
5 6.3 -

Traveller

The functions of the traveller are:

1. To introduce twist in to the yarn
2. To receive the yarn from the thread guide and to guide it on to the bobbin
3. To control yarn tension during winding
4. To help in building and winding of the bobbin
5. To control the ballooning by controlling the yarn tension for a particular count
spun
6. To get a compactly built bobbin

The traveller moves over the ring, at almost the same speed as the spindle. It
moves round the ring at a speed varying from 60 to 80 feet/sec. Travellers
are made from hardened steel wire so that they are able to withstand the
heavy frictional resistance and wear to which they are subjected.
Types of traveller

According to the shape, the traveller can be classified as follows:

1. C – traveller
2. Flat or oval traveller
3. Elliptical traveller
4. N - traveller
5. SU - traveller
6. Ear shaped traveller

In the above types, only, C, flat or oval, elliptical, N and SU travellers are
used in the cotton spinning system. The ear shaped traveller is used in the
heavy industrial doublers.

The travellers used in cotton spinning can further be classified as:

1. Small bow type
2. Large bow type

The fig.51 illustrates the different types of travellers used along with the ring.

Traveller types: (a) C-traveller, (b) flat traveller (normal traveller),

(c) elliptical traveller, (d) N-traveller
The small bow traveller fits tightly on the ring flange. So the friction is high.
Whereas the large bow traveller fits loosely over the ring and moves freely.
The small bow is preferred for stronger yarn and large bow traveller for
weaker yarn. The traveller size to be changed according to the fineness
(count) of the yarn spun. The elliptical traveller is used in the antiwedge ring.
The weight of the traveller determines to some extent the yarn tension, and
so the actual count of traveller to be used for a certain count spinning
depends on the following:

 The count of yarn

 The size or diameter of ring
 Speed of spindles

Normally finer the yarn, less should be the traveller weight. Bigger the size of
the ring, lighter should be the traveller. For higher spindle speed
corresponding lightweight traveller should be used. When spinning different
counts, the traveller should be changed according to the count. The change
is largely decided by trial and error and the correctness of traveller is decided
by the correct ballooning of the yarn. this allows the machine to run with
minimum end breakages.

8.2 The wire profile of the traveller

The cross section or wire profiles of the traveller influence both the behavior of the
traveller and certain yarn characteristics. They are:

 Contact surface of the ring

 Smooth running
 Thermal (heat) transfer
 Yarn clearance opening
 Roughening effect
 Hairiness

Various profile types are shown in the fig.

 For Cotton

Flat wire types are preferred because a good

f seating on the ring is achieved and the yarn is
cleaned

For Cotton only

Best remedy for hairy yarns and bobbins.

Only applicable for traveller speeds of over 28
S meters / second and yarns coarser than Nm
100 ( Ne 60).

For Cotton

Extremely wide traveller resulting in a very

udr good guidance. The large surface allowing
heat to be conducted away rapidly for very
high performance.

For Synthetics and blends (also for Cotton

under certain conditions)

dr Travellers with a half round profile allow high

speeds as a result of the good seating upon
the ring profile keeps yarn free from damage.

For synthetics

Combination profile fr (flat round) is flat at the

toe. The larger contact area giving better
fr guidance. The Round profile where the yarn
passes avoids damage to the yarn.

For Wool and Synthetics

Travellers with a round wire profile do not
r roughen the yarn. (disadvantage of C type
Travellers is the small area of contact with the
ring which can lead to instability)

For Wool and Synthetics

Profile is only used for heavy ear shaped
hf Travellers since the round profile normally
used cannot be bent to shape without
 problems.

Traveller wire profiles

The Material of the traveller

The material that is used to produce the traveller should have the following property:

 Generate as little heat as possible

 Quickly distribute the generated heat from the area where it develops (contact
area) over the whole volume of the traveller
 Transfer the heat rapidly to the ring and the air
 Be elastic, so that the traveller will not break when it is pushed on to the ring
during traveller change
 Posses high wear resistance but at the same time somewhat less hard than the
ring. Otherwise the traveller will wear out the ring

Because of the above requirements, the travellers are normally made of

steel. However, pure steel does not optimally fulfill the first three
requirements. Hence to improve the running properties, the traveller
manufacturers have developed many surface treatment processes, they are:

 Electroplating, in which the traveller is given one or more layers of metallic

coating. e.g. Nickel or Silver
 Chemical treatment of the surface to reduce friction and pitting

The Bracker Company has developed a new process in which certain finishing components
diffuse into the traveller surface. The resulting layer reduces temperature raise and
increases wear resistance. e.g. Sapphire traveller

Traveller mass or weight

Traveller mass determines the amount of frictional forces between the traveller
and the ring. This in turn determines the winding and ballooning tension.

If traveller mass is too small, the balloon will be too big and the cop too soft and the material

take-up in the cop will be low. High traveller mass leads to high yarn tension and many end

breaks. So the mass of the traveller must be matched exactly to both the yarn count,
strength and spindle speed. Normally a heavier traveller is selected than the lighter to get

greater cop weight, smooth running of the traveller and better transfer of heat out of the

traveller.

Traveller count, size or number

Travellers are represented by a number or a combination of numbers, which are called their

count, size or number.

The traveller numbers are represented based on weight of travellers in grains or grams.

1. English system
2. Metric system (ISO)

English System

In the English system the travellers are numbered based on the weight of 10 travellers in

grains. Number 1 traveller is the one in which 10 travellers weigh 10 grains. The count or the

number of the traveller varies from 1 to 50. The traveller number increases with the increase

in weight. By increase in 2 grains the traveller number increases by one number on an

average, but not fixed.

If the weight of 10 travellers is less than 10 grains they are numbered as 1/O, 2/O, 3/O etc.

These are called Naught travellers. The number decreases as the weight decreases in a

varying range of steps of 1 grain per number, ½ a grain per number and finally ¼ grain per

number until the finest commonly used weight about 1 grain per 10 travellers.
Metric system (ISO)

In the metric or ISO system the traveller number is the weight in grams of 1000 travellers.

For example, number 63 means, the weight of 1000 travellers is 63 grams.

Traveller table

Yarn Count in Ne Equivalent count in Equivalent count in Suggested

Nm Tex Traveller No.

4 7 150 26

5 8 120 22

6 10 100 18

7 12 85 14

8 14 70 12

10 17 60 10

12 20 50 8

16 28 36 6

20 34 30 4

24 40 25 2

30 50 20 1/O

33 56 18 2/O

36 60 17 3/O

42 70 19 4/O
 48 80 12.5 5/O

54 90 11 6/O

60 100 10 8/O

70 120 8.3 10/O

80 140 7.1 12/O

95 160 6.2 14/O

105 180 5.5 16/O

120 200 5 20/O

The above recommendations are for guidance only. For mixtures of synthetics and cotton, 4

to 6 numbers heavier travellers should be used.

In general, lighter traveller for higher traveller speed, and heavier traveller for lower traveller

speed to be used.

PRACTICE
CONCLUSION:
The study about Selection of ring travellers are studied and understood

Marks Allotted Marks Awarded Signature of the staff

10
 ROTOR SPINNING MACHINE

EX.NO: 6 DATE:
Aim:
To study the Construction details of rotor spinning machine and material passage
Machine Used:
Rotor spinning
Principle of operation - rotor spinning

The feed stock from the first or second passage draw frame sliver runs from a can
kept beneath the spinning unit into the feed trumpet (14). A feed roller (2) grips the infeed
sliver (1) and pushes it over the feed trough (3) into the region of the opening roller (5). A
spring (4) ensures firm gripping of the sliver, by pushing the trough towards the feed roller.
During an end break, the feed unit is stopped by stopping the feed roller rotation and the
sliver infeed stops automatically. This signal pulse causing this effect is generated by a yarn-
sensing arm (Thread Monitor or stop motion).

The fibre strand is well opened by the opening roller (5), which is clothed with saw
teeth, combs through the fibre bunch from the nip between the feed roller and the trough.
The opening roller transports the plucked fibres in to the feed tube (8). The air flow
generated by a central fan draws air by suction through the opening (13) from each rotor box
(15). This rotor box must be sealed to facilitate fibre transport. The air stream in the feed
tube (8) lifts the fibres from the opening roller surface and leads them to the rotor (9).
The Rotor Spinning Principle

1. Feed sliver in spinning unit

2. Feed roller
3. Feed trough - pivoted
4. Spring
5. Opening Roller
6. Opening (Trash to fall)
7. Trash under suction
8. Convergent feed tube
9. Rotor
10. Free Yarn end
i.e., open yarn end

11. Glass tube

12. Rotor spun yarn
13. Opening
14. Feed trumpet
15. Rotor box
16. Navel
17. Withdrawal rollers
18. Rotor groove
19. Binding - in region
Formation of rotor Spun yarn
 Both the air and the fibres are accelerated due to convergent form of the feed tube,
representing the second draft zone. The first drafting takes place between feed roller A to
the opening roller. A third draft arises upon arrival of the fibres on the rotor wall, since the
peripheral speed of the rotor is several times greater than the fibre speed. This contributes to
good orientation of the fibres. The last straightening takes place as the fibres slides down the
rotor wall into the groove under the influence of the enormous centrifugal forces at work
within the rotor

On an average 1 to 5 fibres (in section) emerge simultaneously from the feed tube
(8). After sliding down the rotor wall, the fibres come to rest in longitudinally oriented form in
the rotor groove (18). As the rotor (9) is rotating steadily under the stationary feed tube,
continuous deposition of fibres in the groove is achieved. i.e fibre is laid on fibre. In this way,
a continuous fibre ring is built up in the rotor groove. This operation is called “back-
doubling”. If the fibres are not removed, choking takes place inside the rotor within no time.
To convert these fibres into a new yarn, a free yarn end (10) is allowed to extend from the
rotor axis to the periphery. Centrifugal force (more than 1 lakh times the fibre weight) acting
at this point, presses the yarn and firmly against the wall of the collection groove. The yarn
end now adheres to the rotor wall. As the rotor turns, the yarn end also rotates, around the
rotation hub (navel) like one arm of a crank.

Every revolution of the rotor generates one real twist in to the yarn. (if there is no
slip). When the yarn reaches its maximum twist level, the yarn end begins to turn about its
own axis, ie., yarn end rolls in the rotor groove. Now, the open yarn end rest in the binding-in
region (19) with more or less parallel fibres. Rolling of the yarn end, therefore causes the
brush - like yarn end to grasp fibres from the ring and twist them in, and so on. A yarn is thus
spun continuously. Now it is necessary to pull this yarn out of the rotor by means of a pair of
withdrawal roller (17) and it is wound into a cross-wound package.

In brief the material passage in rotor spinning machine is: Feed can - in feed trumpet
- feed roller and feed trough - opening roller - feed tube - rotor wall - rotor groove - forming a
new strand - free yarn end - twist insertion - open end withdrawn through navel - glass
tube(11) - withdrawal rollers - yarn tensioner - cross wound package.
Speed of important Components in Rotor Spinning Machine:

Normal and maximum speeds are

Opening roller = 5000 to 10000 rpm.

Rotor = Upto 1 Lakh rpm.

Yarn Delivery Speed = Upto 200 metres/min.

PRACTICE
Conclusion:
The Construction details of rotor spinning machine and material passage are studied
and understood.
Marks Alotted Marks Awarded Signature of the staff

10
 ROTOR SPINNING CALCULATIONS

EX.NO: 7 DATE:

AIM

To calculate the Draft, Twist and production of rotor spinning machine

Given Data:

Rotor speed =

Opening Roller speed =

Count =

Sliver hank =

Twist multiplier =

Calculation:
Speed particulars

Result:

Thus, the draft, production and twist of Rotor spinning are calculated.

Marks Alotted Marks Awarded Signature of the staff

10
 PRODUCTION OF CARDED SLIVER

EX NO: 8 DATE:

Aim:
1. To draw the passage of material through carding machine
2. To study the general particulars of the machine.
Machine Used:
High Production Card.
Apparatus Required:
Caliper
Meter Scale
OBJECTS OF CARDING;

1. To open small tufts of cotton to a state of individual fibres or fibre to fibre separation.
2. To clean the cotton by removing impurities such as seed bits, broken leaves, short fibres,
fine sand etc.
3. To convert lap into a sliver suitable for next process.
Working
A diagram of the principal elements of the carding machine is given in fig. The lap
produced in the Blow room is taken for processing at the carding machine. The lap is placed
upon a slowly revolving lap roller and is unwound through the friction produced by its own
weight. The sheet of cotton passes over the smooth surface of the feed plate and in between
the curved portion of the feed plate and the feed roller.
The nose end of the feed plate is specially shaped, so as to give an effective opening action.
The feed roller is heavily loaded at each end to grip the cotton fleece.
The slow revolution of the feed roller ( about 1 to 2 feet/min) brings the cotton in to
contact with the saw tooth of the revolving licker-in or taker in which is about 91/4”in dia.
And its surface speed is about 1000ft/min. The material receives a very effective opening at
this point, because of the saw tooth wires, and the sharp edges of the mote knives separates
the fibres from the trash particles. Majority of the impurities like seed bits, leaf particles, fine
dust etc, are removed here and it is called motes. The loosened fibres are carried around the
large wire covered cylinder, whose surface speed is (about 2000 ft/min. and 50” in dia double
the amount, enables it to strip the cotton fibres and carries them forward. Surrounding almost
1/3rd of the cylinder surface is a series of flats which are set very close to the cylinder wire
points and the flats them-selves are also clothed with metallic wire, and they oppose the
direction of the cylinder wire points.

A-Lap roller B-Lap C-Lap stand D-Feed plate E-Feed roll F-Lickerin G-Mote knives
H-Licker in under casing I-Cylinder J-Flats K-Flat comb L-Back plate M-Front plate
N-Doffer O-Doffer comb P-Web Q-Trumpet R-Calender rolls S-Coiler trumpet
T-Coiler calender rolls X-Can

The movement of the flats is extremely slow approximately 4” per minutes, and
moves in the same direction of the cylinder. They apart a large and almost stationary
combing surface to the cotton fibres and they are brought around the cylinder. Actual carding
takes place between the flat wire points and the cylinder wire points.
The carded cotton is now transferred to the surface of the doffer, (about 27” in
diameter) moving at a surface speed of 75 to 100 feet/min. covered with similar wire points.
The transferred cotton is carried round the doffer to the front of card, where a rapidly
oscillating comb, operating close to the doffer surface, removes the fibres in the form of a
thin sheet. This sheet, known as the „web‟ is gathered together by passage through a trumpet
in the form of a sliver. This is carried forward by a pair of calendar rollers and carried to the
coiler head, there it is deposited into a sliver can.
SPEED OF VARIOUS PARTS IN A CARDING MACHINE:
1 Feed roller (2 ¼ “ dia ) - 1 to 2 feet / min
2 Taker in or Licker in 9 ¼” dia - 350 to700 rpm
3 Cylinder ( 50 “ dia ) - 160 to 170 rpm
4. Doffer ( 27” dia. ) - 6 to 12 rpm
5 Doffer comb - 1200 to 1600 vibrations / min
6 Flats - 2 to 6 inches / min.
7 Total draft in carding - 80 to 120
8 Total flats - 160 to 110 and 40 to 42 Fats in working
condition

RACTICE
CONCLUSION:
The Material passage and general particulars of the HP card are studied and understood

Marks Allotted Marks Awarded Signature of the staff

10
 PRODUCTION OF DRAWFRAME
EX. NO:9 DATE:

AIM :

1. To draw the neat sketch of passage of material through draw frame

2. Study the functions various parts in Draw frame

PROCEDURE :

1. Describe the passage of material through a Lakshmi Rieter High Speed Draw Frame.

2. Indicate all the parts.

Objects of Draw frame

1. To improve the uniformity of the slivers fed.

2. To straighten the fibres composing the sliver and making them more nearly parallel to each
other.
3. Draw frame blends several slivers to get single sliver (suitable for polyester / Cotton Blends)
4. To remove the dust, dirt from the draft zone and thus making a cleaner sliver.

Working

The figure shows the material passage in a DO/2 model Lakshmi Rieter High speed Draw Frame. The
sliver can from the card or from the first passage draw frame is placed beneath the table type of
extended creel. The sliver through suitable guides being lifted by means of a pair of lifting rollers of
which the

Bottom roller is driven positively. The slivers are made to pass over the polished guide plate and
enter the drafting zone, as the sliver guide peg guides the sliver.

A suction cleaning motor sucks the air from the drafting zone and keeps all the top and bottom
rollers clean. The material is getting drafted due to the higher

Relative surface speeds of the successive pairs of rollers and is passed through a polished guide
funnel. Now the material is drawn off by means of a pair of calender rollers through a delivery
trumpet mounted on a funnel plate and through a delivery trumpet mounted on a funnel plate and
through an exchangeable condenser which is then fed to the coiler wheel and the material is laid
into the can in the form of coils. The production rate is upto 250 M/ Min.

PRACTICE
To study the functions of following parts:

1. Creel
2. Lifting rollers
3. Arrangement of drafting rollers
Front
Middle
Back
4. Asymmetric web condenser
5. Exchangeable condenser
6. Calender rollers
7. Tube wheel
8. Can bottom

RESULT
The material passage and functions of each parts are studied and understood.
Marks Allotted Marks Awarded Signature of the staff

10
 PRODUCTION OF ROVING
EX.NO: 10 DATE: