Ym Lab Manual

NATIONAL TEXTILE UNIVERSITY Yarn Manufacturing Department

YM-4015

Spinning Calculations

Semester 8

Fall 2012

Laboratory Manual

Prepared by:

Mr. Uzair Hussain (Lecturer)

National Textile University, Faisalabad

http://www.ntu.edu.pk

Fall 2012 ii Spinning Calculations Lab Manual

National Textile University

Sheikhupura Road Faisalabad

Copyright 2009 National Textile University

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in

any form or by any means without written permission from the National Textile University.

Fall 2012 iii Spinning Calculations Lab Manual

LABORATORY SCHEDULE

COURSE CODE YM-4015 SEMESTER: 8TH

COURSE TITLE: SPINNING CALCULATIONS

ACTIVITY: PRACTICAL DEPTT: YMD

SR.

NO. TITLE OF PRACTICAL WEEK

AUTHOR NAME

1 Study of gearing on bale opener 1st

2 Study of gearing on scutcher 2nd

3 Study of gearing on card 3rd

4 Study of gearing on draw frame 4th

5 Study of gearing on lap former 5th

6 Study of gearing on comber-1 6th

7 Study of gearing on comber- 2 7th

8 Study of draft and twist gearing mechanism of

simplex for making the given roving 8

th

REVIEW & COMPLETION OF RECORD

MID EXAM 9

th

9 Study of lifter and tension gearing mechanisms

of simplex for making given roving 10

th

10 Study of gearing on ring frame-1 11th

11 Study of gearing on ring frame- 2 12th

12 Study of gearing on doubling frame 13th

13 Study of driving mechanisms on mach coner 14th

14 Study of gearing on open end machine 15th

REVIEW & COMPLETION OF RECORD 16th

FINAL VIVA BY FACULTY 17th

FINAL EXAM 18th

Semester: 8th

Fall 2012 1 of 18 Spinning Calculations Lab Manual

PRACTICAL # 1

Study of gearing on bale opener

Objectives:

1. To become familiar with the gearing diagram

2. To know different change places

3. To make gearing diagram and calculate the followings:

(i) Rotary and surface speeds of different rollers

(ii) Beats per min and beats per inch

(iii) Production in lbs per hour

Equipment, tools and materials:

Bale opener (BF opener by TOYODA), Tool box, Measuring tape, White chalk, Copy

and Pencil

Procedure:

Note the gearing drive of BF opener a draw a neat and clean sketch of the gearing

of the machine.

Count the number of teeth of different gears.

Measure the diameter of bowl by using cage and measuring tape.

Note the rpm of motor and determine the rotary speed of rollers (evener roller,

stripped roller and clearer roller) using gearing drive.

Determine the surface speeds of different lattices by using the surface speed of

bowls.

Find out the linear speed of lattices.

Safety measures:

Calculate the number of teeth of gears precisely.

Measure the diameter of bowl accurately.

Operate with the machine with a great care and in switched off condition of

machine.

Questionnaire:

What is the function of Evener Roller?

How production is controlled?

What type of faults may occur?

What are the remedies of these faults?

Conclusions:

Briefly describe your findings.

Semester: 8th


PRACTICAL # 2

Study of gearing diagram of scutcher

Objectives:


2. To know different change places of scutcher


(iv) Rotary and surface speeds of different rollers

(v) Individual and total drafts, range of draft as well as draft constant

(vi) Beats per min and beats per inch

(vii) Shell roller acceleration at doffing and doffing time

(viii) Production and production constant

(ix) Lap length in yds and lap length constant

(x) Size of length change wheel for a lap length of 40 m

(xi) Production in lbs per h if lap weight per yd is one pound

Equipment, tools and materials:

Scutcher installed in spinning lab, tool box, calipers, copy, pencil and chalk

Procedure:

- Open the covers to become aware about the hidden parts and mechanisms.

- Make the sketch of gearing diagram.

- Check the change points of scutcher.

- Count the teeth of gears, measure the diameter of pulleys, rollers and belt

thickness

- Close the covers.

Safety measures:

Cut off the electrical connections before opening the covers

Remove the belts before touching any gear or moveable part of the machine

Use gloves to touch any oily and greasy part

Make measurements and counting carefully

Questionnaire:

What is the function of piano motion?

How lap length is controlled?

What type of lap faults may occur?

What are the remedies of these lap faults?

Conclusion:


Semester: 8th


PRACTICAL # 3

Study of gearing on card machine Objectives:


2. To know different change places of card



(ii) Individual and total drafts, range of draft as well as draft constant

(iii) Production and production constant

(iv) Production in lbs per hours

Equipment, Tools and Materials:

Tool box, Measuring tape, White chalk, Paper and pencil, Platts card machine

Procedure:

Draw the gearing sketch of Platts card.

Calculate the teeth of various gears that involve in the drive to different carding parts.

Measure the speed of motor.

Measure the thickness of various belts and calculate the diameters of pulleys.

Observe the type of gears used in the machine and also observe the gears involved in the drive to

different gears.

From these parameters calculate the rotary speed of rotating gears, surface speeds of rotating

organs, draft, tension drafts and other drafts.

Also calculate the transfer ratio, carding power and condensation ratio using following formulas:

o Transfer ratio = Surface speed of Cylinder / Surface speed of Taker-in

o Condensation ratio = Surface speed of Cylinder / Surface speed of Doffer

o Carding power = Surface speed of Cylinder / Surface speed of Flats

o Coiling ratio = rpm of coiler plate / rpm of can plate

Safety measures:

Operate with the machines with great care.

The machines shouldn’t be used for sketching of gearing diagram in running condition.

Carefully observe the gearing drives to different parts of the card machine.

Questionnaire:

What is the function of top set?

How draft is controlled?



Conclusion:


Semester: 8th


PRACTICAL # 4

Study of gearing on Draw frame Objectives:


2. To know different change places


(v) Rotary and surface speeds of different rollers

(vi) Individual and total drafts, range of draft as well as draft constant

(vii) Production and production constant

(viii) Production in lbs per hours


Tools box, White chalk, Copy and Pencil, Platts MDF-5 Draw frame

Procedure:

First draw the complete gearing diagram of MDF-5 drawing frame showing drives to drafting

rollers, calendar rollers, assisting rollers and to the coiling assembly.

Note the rpm of motor.

Measure the diameters of pulleys and thickness of belt.

Calculate the number of teeth of all driving gears.

Measure the diameters of drafting rollers.

Calculate the rotary speeds (rpm) of all rollers.

Then calculate the surfaces speeds of all those rollers using formula:

Surface speed = * D * N

Calculate the individual drafts and total draft and also draft constant.

Calculate the size of prevailing DCP.

Then change the count and hence change the draft theoretically from which calculate the new

DCP.

Replace the old DCP with the new one and calculate the draft practically and verify the

theoretical results.

Calculate the rotary speeds of coiling tube and can.

Calculate coiling ratio between coiling tube and can.

Also calculate production (yds/hour) and production constant.

Comparison:

There is 5/4 drafting system in TOYODA DHY-500C while 3/3 drafting system in Platts MDF-

5.

In Platts draw frame, there is suction pipe installed for suction of the waste fibers from the cloth

clearer while suction dusts are designed in DYH-500C for suction from the clearers on the

rollers.

The motors of both draw frames are of different KW.

Safety measures:

Operate with the machine carefully when the machine is OFF.

Show the correct drives in the gearing diagram.

Calculate the accurate diameters of rollers and their rotary speeds.

Semester: 8th


Questionnaire:

What is the function of different parts?

How draft is controlled?



Conclusion:


Semester: 8th


PRACTICAL # 5

Study of gearing diagram of lap former

Objectives:


2. To know different change places of the lap former

3. To understand length measuring, calendering, hardening and doffing mechanisms



(ii) Individual and total draft as well as range of draft


(iv) Lap length in yds and lap length constant

(v) Size of length change wheel for a lap length of 100 m

(vi) Weight of sliver/yd for getting 10% more production


Copy, pencil, tool box, calipers and chalk, Lap former installed in spinning lab

Procedure:

Open the covers to become aware about the hidden parts and mechanisms.

Make the sketch of gearing diagram.

Check the change points

Count the teeth of gears, measure the diameter of pulleys, rollers and belt thickness

Close the covers.

Questionnaire:

Describe the methods of lap preparation for comber

What are the points which are considered important for making comber lap?

Conclusion:


Semester: 8th


PRACTICAL # 6

Study of gearing diagram of Hartford comber-1

Objectives:


2. To know different change places of the comber


(i) Nips per min

(ii) Feeding rate in inches per nip

(iii) Net amount delivered by detaching rollers


Copy, pencil, tool box and chalk Hartford comber installed in spinning lab

Procedure:



Check the change points of comber


Close the covers.

Questionnaire:

What is speed of Hi-performance comber?

What type of faults may occur on comber and how these are cured?

What is range of feeding rate at this comber and latest comber machine?

Conclusion:


Semester: 8th


PRACTICAL # 7

Study of gearing diagram of Hartford comber-1I

Objectives:

1. To calculate the followings:

(i) Rotary and surface speed of different rollers

(ii) Individual and total draft as well as range of draft


(iv) Production in lbs per hour at 80 % efficiency when speed is 120 nips per min and feed rate

is 0.3 inches per nip.


Copy, pencil, tool box and chalk, Hartford comber installed in spinning lab

Procedure:



Check the change points of comber


Close the covers.

Questionnaire:

What is the range of production in latest comber?

What is range of draft in latest comber?

Conclusion:


Semester: 8th


PRACTICAL # 8

Study of draft and twist gearing mechanism of simplex for making the given roving

Objectives:

1. To understand how to make required gearing.

2. To understand the mechanism of draft and twist gearing including control points.

3. To prepare the frame for given roving count and TM.

4. To calculate the followings.

(i) Rotary speed of Flyer.

(ii) Rotary and linear speeds of bottom drafting rollers.

(iii) Inter drafts of all drafting zones.

(iv) Total mechanical draft

(v) Draft constant.

(vi) Range of total mechanical draft.

(vii) Actual draft from given feeding and delivery materials.

(viii) Size of D.C.P for making required roving count.

(ix) Delivery rate of front drafting roller.

(x) T.P.I, T.P.C and T.P.M.

(xi) Twist constant.

(xii) Range of T.P.I.

(xiii) Size of required T.C.P for given roving T.M.


Feeding sliver and delivered roving, Roving Frame along with change gears, Empty bobbins of Roving

Frame, Feeding Sliver Fan, Wrapping drum, Weighing balance Calculator

Procedure:

Stop the machine.

Remove the feeding and delivered materials.

Open the machine covers.

Study the draft and twist gearing including various control points.

Make sketch of draft and twist gearing showing all change points.

Get size of belts, pulleys and gears and drafting rollers.

Decide about the required roving count along with its T.M.

Calculate the draft and twist constant.

Make required calculation including size of various change gears such as D.C.P and T.C.P.

Replace the old change gears with new gears.

Close the covers.

Run the machine and make required roving count.

Make testing required roving counts.

Verify the results.

Compare the given gearing with the gearing of old Roving Frame.

Questionnaire:

Why and when the draft is changed?

Why and when twist is changed?

Why and when T.M of roving is changed?

Semester: 8th


Define Draft and Twist Constant.

What are the uses of Draft and Twist Constants?

Conclusion:

Briefly describe your findings

Semester: 8th


PRACTICAL # 9

Study of lifter and tension gearing mechanisms of simplex for making given roving

Objectives:

1. To know how to make required gearing.

2. To under stand the lifter and tension control mechanisms.


(i) Rate of delivery in inches/mint.

(ii) Coils per min for 1st layer for the given bobbin dia.

(iii) Rotary speed of lifter shaft.

(iv) Linear speed of bobbin rail in inches/min.

(v) Coil per inch for given C.M.

(vi) Lifter constant.

(vii) Range of C.P.I.

(viii) Size of lifter wheel (L.C on F.L 16) for given value of C.M.

(ix) Rate of winding in inches/min at initial (1st layer) as well as at mid cone drum dia.

(x) Value of Roving tension.

(xi) Value of Kp (co-efficient) for given variables on F.L 16 Roving Frame.

(xii) Value of n (Increased layers per inch) for given Hank Roving.

(xiii) Size of Ratchet or Patent wheel for given Hank Roving.

Equipment, Tools and Material:

Given sliver for feeding, Bobbin of given Roving Frame, Roving Frame (F.L-16) along with change

gears, Empty roving bobbins, Warping Drum, Weighing Balance, Calculator

Procedure:


Study the lifter gearing.

Study the gearing for controlling winding rate and hence winding tension.

Make sketch of lifter gearing and the gearing giving drive to bobbin showing all change points.

Get all observations.

Decide about the value of CM and CPI for given roving material and count.

Calculate the size of lifter wheel.

Calculate the value of n (No. of increased layers)

Calculate the value of Kp and Rachet or Patent Wheels.

Replace the old gears with new gears.

Close the covers.

Run the machine and check actual CPI.

Check roving tension throughout the whole package building.

Verify the results.

Compare the gearing with the gearing of old roving frame.

Questionnaire:

What is lay and how it is denoted?

Why and when CPI is changed?

When and why roving tension is changed?

Semester: 8th


What are minor and major control points of Roving tension?

What are the variables for the value of Kp on F.L 16?

Conclusion:


Semester: 8th


Experiment # 10

Study of Draft and Twist Gearing for making the given yarn on the given Ring Frame-I

Objectives:



3. To understand the role of these gearings.

4. To get data for draft and twist calculations.

5. To prepare the frame for given yarn count and TM.


(i) RPM of Spindle.

(ii) Rotary and surface speeds of bottom drafting rollers.

(iii) Inter drafts of all drafting zones.

(iv) Total mechanical draft

(v) Draft constant.

(vi) Range of total mechanical draft.

(vii) Actual draft from given feeding and delivery materials.

(viii) Size of D.C.P for making required yarn count.

(ix) Delivery rate of front drafting roller.

(x) T.P.I, T.P.C and T.P.M.

(xi) Twist constant.

(xii) Range of T.P.I.

(xiii) Size of required T.C.P for given yarn T.M.


Feeding roving and delivered yarn, Ring Frame along with change gears, Empty bobbins of

Ring Frame, Feeding roving bobbins, Wrapping drum, Weighing balance, Calculator.

Procedure:

Stop the machine.






Decide about the required yarn count along with its T.M.

Calculate the draft and twist constant.

Make required calculation including size of various change gears such as D.C.P and T.C.P.

Replace the old change gears with new gears.

Close the covers.

Run the machine and make required yarn count.

Make testing required yarn counts.

Verify the results.

Questionnaire:


Semester: 8th


How the draft is changed?

How twist is denoted?


How TPI is changed?

Why and when T.M of yarn is changed?

How the T.M of yarn is changed?


What are the uses of Draft and Twist Constants?

What are the total changes due to change of D.C.P?

What are the total change due to change of T.C.P?

Conclusion:


Semester: 8th


Experiment # 11

Study of lifter and tension gearings on the given Ring Frame

Objectives:


2. To under stand the lifter and tension control mechanisms.

3. To get the required data from the given gearing.



(ii) Coils per minute.

(iii) Linear speed of ring rail in inches/mint.

(iv) Coil per inch for given C.M.

(v) Lifter constant.

(vi) Range of C.P.I.

(vii) Size of lifter wheel for given value of C.M.

(viii) Rate of winding in inches/minute.

Equipment, Tools and Material:

Given roving for feeding, Bobbin of given Ring Frame, Ring Frame along with change gears, Empty

ring bobbins, Warping Drum, Weighing Balance, Calculator.

Procedure:


Study the lifter gearing.

Study the gearing for controlling winding rate and hence winding tension.

Make sketch of lifter gearing and the gearing giving drive to bobbin showing all change points.

Get all observations.

Decide about the value of CM and CPI for given yarn count.

Calculate the size of lifter wheel.

Replace the old gears with new gears.

Close the covers.

Run the machine and check actual CPI.

Check yarn tension throughout the whole package building.

Verify the results.

Questionnaire:

What is lay?

How lay is denoted?

Why and when CPI is changed?

How CPI is changed?

What is the use of lifter constant?

How yarn tension is changed?

What are minor and major control points of yarn tension?

Conclusion:


Semester: 8th


PRACTICAL # 12

Study of gearing on doubling frame

Objectives:


2. To get the required data from the given gearing.



(ii) Coils per minute.

(iii) Linear speed of ring rail in inches/mint.

(iv) TPI

Equipment, Tools, and Materials:

Doubling frame, Spanners, Inch measuring tape, Empty bobbins of doubling frame, Yarn count testing

arrangement

Procedure:

Draw the twist gearing, gearing of drives of ring rail and of lappet rail.

Measure the diameters of pulleys and also the thicknesses of belts.

Calculate the spindle speed.

Measure the diameters of delivery rollers.

Determine the throw of the building cam and chase length of package were also determined.

Calculate the number of teeth of the gears.

Determine the yarn count, its TPI, twist direction and strength of a given single yarn in the

testing lab.

Calculate linear speed of ring rail and coils per inch.

Also calculate the value of doubling twist in opposite direction to produce a balanced yarn

from the given single yarn by using the formula:

Doubling twist = (spinning twist * N) / (N+1)

Where N are number of yarns to be plied

Calculate the size of new twist wheel as under:

TCP = T.C / T.P.I

Replace the old twist wheel with the new one.

Run the machine and get the required balanced doubled yarn.

Then stop the machine and calculate the again the testing parameters of this yarn with the

new twist wheel.

Calculate the production per spindle in kg/day

Safety measures:

Operate with the machine carefully and in its OFF condition.

Draw the correct gearing of the machine.

The old twist wheel must be replaced with new one to make the required doubled yarn.

Questionnaire:

How to change TPI?

How yarn tension is changed?

What are minor and major control points of yarn tension?

Conclusion:


Semester: 8th


PRACTICAL # 13

Study of driving mechanisms on Mach-Coner winding machine

Objectives:

1. To become familiar with the driving mechanisms

2. To study Retie, splicer / knotter, and magazine cam functions

3. To make driving mechanisms and calculate the followings:

(i) Drum speeds

(ii) Speed of cam shaft

(iii) Speed of tensor disc and wax roll

(iv) Speed of vacuum fan


Tool box, copy, pencil, and chalk, Murata Mach-coner installed in spinning lab

Procedure:


Dismantle one winding unit from machine

Make the sketch of driving mechanisms.

Observe the function of each cam

Count the teeth of gears, measure the diameter of pulleys, and belt thickness

Reassemble the winding unit on the machine

Close the covers.

Questionnaire:

How ring bobbin is changed after winding complete yarn of bobbin?

What is the function of yellow button?

How drum is stopped after completion of cone length or diameter?

Conclusion:


Semester: 8th


EXPERIMENT # 14

Study of Draft and Twist Gearing for making the given yarn on the Autocoro Frame

Objectives:



3. To understand the role of these gearings.

4. To get data for draft and twist calculations.

5. To prepare the frame for given yarn count and TM.


(i) RPM of Rotor.

(ii) Total mechanical draft

(iii) Draft constant.

(iv) Range of total mechanical draft.

(v) T.P.I, T.P.C and T.P.M.

(vi) Range of T.P.I.

Equipment Tools and Materials:

Feeding sliver and delivered yarn, Autocoro along with change gears, Empty bobbins of Autocoro,

Feeding sliver cans, Wrapping drum, Weighing balance, Calculator.

Procedure:

Stop the machine.






Decide about the required yarn count along with its T.M.

Make required calculation.

Close the covers.

Run the machine and make required yarn count.

Make testing required yarn counts.

Verify the results.

Questionnaire:


How the draft is changed?

How twist is denoted?


How TPI is changed?

Why and when T.M of yarn is changed?

How the T.M of yarn is changed?


Conclusion:


Documents

Ym Lab Manual