Investigation and Optimization of Roving Making Machine

[INTERNATIONAL JOURNAL FOR RESEARCH & Volume-3,Issue-2, Feb 2015 DEVELOPMENT IN TECHNOLOGY] ISSN (O) :- 2349-3585

Investigation and Optimization of Roving Making Machine Prof.A.B.Tupkar 1, Bhushan Dhande 2, Ankur Bhute 3 , Siddhant Jadhao 4 ,Suchit Surkar 5,Prayag Roy Choudhury 6 1 2 3 4 5 6 Department of Mechanical Engineering Bapurao Deshmukh College of Engineering, Sewagram & MGIRI Wardha. Wardha (Maharashtra), India.

Abstract— Textile is one of the biggest manufacturing at the same time. A number of developments during the industries in India. Investigation is related to textile industry eighteenth century further mechanized the spinning process. In especially to Khadi Yarn manufacturing process in rural 1733, the flying shuttle was invented by John Kay, followed by areas. Presently spinning mills are operating on very large Hargreaves' spinning jenny in 1766. The jenny featured a series scale and not able to fulfill the demand of hank for of spindles set in a row, enabling one operator to produce large manufacturing Khadi yarn needed for hand weavers. The quantities of yarn. Several years later Richard Arkwright main aim of this paper is to make design of roving making patented the spinning frame, a machine that used a series of which will be efficient in cost and production, easily rotating rollers to draw out the fibre. The ring frame was understandable to rural workers and will be effortless. This invented in 1828 by the American John Thorp and is still paper embraces on design of the miniature model of speed widely used today. This system involves hundreds of spindles frame to produce @ 60 Kg of roving in 8 Hours. Analysis mounted vertically inside a metal ring. Many natural fibres are and optimization of process parameters of roving making now spun by the open-end system, where the fibre are drawn machine for production of best quality yarn is also included. by air into a rapidly rotating cup and pulled out on the other This will result in increase income and standard of living of side as a finished yarn. rural textile worker. 3. BRIEF INTRODUCTION OF DIFFERENT YARN Index Terms: Khadi, Optimization, Roving, Textile, Yarn. MANUFACTURING PROCESS I. INTRODUCTION This paper is related to textile industry especially to Roving In under the yarn manufacturing process, there are mainly frame process, which is a yarn manufacturing process. In this seven processes: paper identifies the different problems occurring during 3.1 Blow Room Process: Blow room is the initial stage in manufacturing of yarn in roving process, it also highlights the spinning process. The name blow room is given because of the- critical success factors which are most important in quality air flow and all process is done in blow room because of air point of view. It also describes the preventive action against flow. In blow room the tuft size of cotton becomes smaller and any failure. This paper also describes different problems in smaller. Mixing of cotton is done separately as well as in blow quality perspective and identifies the reason for these problems room. Compressed layer of bale is also open in blow room with due to carelessness of employees during manufacturing of yarn the help of machine. in roving process. 3.2 Carding Process: Carding process is very important since it 2. HISTORY helps us both way to open the tuft into a single fibre and to Until about 1300, yarn was spun on the spindle and whorl. A remove the impurities and neps. Card feeding is done by two major improvement was the spinning wheel, invented in India ways. One is manually and other is through chute feed system. between 500 and 1000 A.D. and first used in Europe during the Approximately 90% cleaning efficiency is achieved with the middle Ages. A horizontally mounted spindle is connected to a help of carding machine. large, hand-driven wheel by a circular band. The distaff is 3.3 Drawing Frame Process: This process, in spinning mounted at one end of the spinning wheel and the fibre is fed regarding to quality point of view plays very important role for by hand to the spindle, which turns as the wheel turns. A the quality of yarn. It effects on quality especially on evenness component called the flyer twists the thread just before it is of sliver. Drafting arrangement is provided in draw frame wound on a bobbin. The spindle and bobbin are attached to the which should be simple, stable design, should have ability to wheel by separate parts, so that the bobbin turns more slowly produce high quality product. It should have high fibre control. than does the spindle. Thus, thread can be twisted and wound www.ijrdt.org | copyright © 2014, All Rights Reserved. 7

Volume-3,Issue-2, Feb 2015 Paper Title:- Investigation and Optimization of Roving Making Machine ISSN (O) :- 2349-3585

Auto leveller is also used to adjust and to improve the linear is popularly carried out using an apron drafting system and density of the sliver. then inserting low level of twist into the roving in order to 3.4 Combing Process: For getting high quality of yarn, one impart sufficient cohesion and condensing to the roving to extra process is introduced which is called combing process. facilitate uniform and controlled drafting during ring spinning, Combing is an operation in which dirt and short fibres are particularly pre-drafting stage. Simple roller drafting was used removed from sliver lap by following ways: in some system up to 50 years ago but due to its relatively poor  In specially designed jaws, a narrow lap of fibre is fiber control, it was replaced by apron drafting system which firmly gripped across its width provides far better fiber control, due to aprons exerting a very  Closely spaced needles are passed through the fibre light pressure on the fibers, until they reach nip of front rollers. projecting from jaws Draft range between 3 and 16, with roving linear density Because of straightened condition of fibre combing makes typically between 300 and 600tex, the drafted twisted strand is possible spinning smoother and more lustrous yarn. In combing wound on to the bobbin using flyer and bobbin arrangement, process length of fibre are strong so it need less twist produced one turn of twist being inserted with each rotation of flyer. then carded yarn. Flyer speed of over 1500 rpm is possible. 3.5 Roving process: It is an intermediate processes in which 4.1 Analysis of Roving Making Machine: fibres are converted into low twist lea called roving. The sliver 4.1.1 Drafting system: which is taken from draw frame is thicker so it is not suitable for manufacturing of yarn. Its purpose is to prepare input Draft:-The amount of attenuation of textile material at different package for next process. This package is to prepare on a small stages of spinning and roving process, for example. 1 m of compact package called bobbins. Roving machine is input material when delivered as 5 m is said to have undergone complicated, liable to fault, causes defect adds to the a draft of 5.In other words reducing the linear density of textile production costs and deliver the product. In this winding material with respect to time by passing the material through operation that makes us roving frame complex. There are two successive pair of roller’s rotating at higher peripheral speeds. main basic reasons for using roving frame: Various formulas used in textile industry to calculate the draft  The roving sliver is thick and untwisted. Because of it as follows: hairiness and fly is created. So draft is needed to reduce the linear density of sliver. The ring drafting arrangement is not capable that it may process the roving sliver to make the yarn.  Draw frame can represent the worst conceivable mode of transport and presentation of feed material to the ring spinning frame. 3.6 Ring Spinning Process: Ring Spinning machine is used in Drafting:-It is a process of reducing the bulk and weight per textile industry to twist the staple fibre into a yarn and wind on unit length of a semi processed textile material such as rove or a bobbin for storage and also input for the winding section for sliver and simultaneously parallelizing its fibrous components, more precise the yarn to minimize the defects of end yarn. as it passes through the various machines used in making yarn. 3.7 Winding Section: It is the last section of yarn manufacturing process where auto cone machines are installed 4.1.2 Roller drafting system (High speed drafting): and take an input material from ring spinning section as a yarn Commercially, there are various methods to draft the textile bobbin and give a yarn on paper cone after passing detecting fibrous material like roller drafting system applied at ring instrument as an output. In winding section, there are lot of spinning, speed frame and draw frames etc, aero dynamic heads in auto cone machines use to wound the yarn from ring drafting functional at rotor spinning, electro mechanical bobbin yarn to paper cone yarn. After making the yarn in ring drafting, frictional drafting etc. Out of these techniques, roller process, auto cone section made it more even yarn by passing drafting system is the most commercially successful one due to through the optical sensor which is installed in different heads its high versatility, simple design and construction, high of machine. The yarn which is obtained from winding section reliability and can handle variety of fibres and a wide spectrum is able to sell the customers. of count range can be spun. Increasing the delivery speed or productivity of a spinning machine but maintaining the same hank or feed material linear density will proportionately 4. ROVING MACHINE increase the speed of drafting but draft ratio remains constant. Roving production on machine termed a roving machine or By using only roller drafting high speed drafting can be speed frame machine, is a final process prior to ring spinning, it achieved. www.ijrdt.org | copyright © 2014, All Rights Reserved. (8)

Volume-3,Issue-2, Feb 2015 Paper Title:- Investigation and Optimization of Roving Making Machine ISSN (O) :- 2349-3585

From table 1 we can find the roving speed is little bit less in the case of apron drafting system in comparison with roller drafting system but it is giving more draft in comparison with roller drafting system.

4.2 The Flyer Earlier flyers were invariably made of steel, but they are now mostly made of light alloy (Fig.3). At the high speeds currently considered normal steel flyers would spread at the legs Fig 1:- Rollers drafting system considerably; this is detrimental to the operation of the machine, and even more so to the winding operation. The 4.1.3 3/3 Double apron drafting system (High speed drafting amount of spreading depends upon the rotation speed. When with high draft ratio):3/3 system with double apron is quite this varies, e.g. during starting and stopping, the presser arm commonly used in roving frame. In the double apron drafting (5) adopts a continually varying inclination, which causes system the fibre guidance unit consists of two aprons rotating continual shifting of the winding point of the bobbin. It with the middle rollers. The top apron must be pressed against becomes impossible to ensure a controlled build over the the bottom apron with controlled force in order to provide complete package. In addition, light alloy flyers have lower guidance. For this purpose there must be a gap between the two weight. Flyers can have varying sizes, which are specified in aprons at the apron delivery end (tensor gap) that is precisely inches. The stated sizes are actually winding dimensions, i.e. adjusted to the fibre volume. This gap can be adjusted by using the maximum height (first number) and the maximum diameter different spacer plates, shoes, etc. The top aprons, which are (second number) of a wound package of material. Roving often plastic aprons, are always short. However, the bottom frames are supplied in the following size: aprons can be as short as the top aprons or quite a bit longer and guided accordingly around deflecting elements (Fig. 1). 12˝ x 5 1/2˝ ; 12˝ x 6˝ ; 14˝ x 6˝ The advantage of long bottom aprons over short aprons is that 14˝ x 6 1/2˝ ; 16˝ x 6˝, 16˝ x 7˝ they are easy to replace in the event of damage. They are also less inclined to become clogged with fibre fly.Increasing the As well as imparting the roving twist, the flyer has to guide the delivery speed or productivity of a spinning machine and the very sensitive strand from the flyer top to the package without same time reducing the feed hank from finer side to courser introducing false drafts – not exactly an easy task. For one side will proportionately increase both the speed of drafting thing, the strand has only protective twist and is very liable to and also draft ratio. It can be achieved by using 3/3 double break. For another, the flyer is rotating, along with the roving, apron system. at a speed of up to 1 500 rpm. The fibre strand must therefore be protected against strong air currents. For this purpose, in most roving frames to date, one of the two flyer legs (4) has usually been hollow, i.e. with a deep guide groove that is open in a direction opposite to the direction of rotation. The strand is drawn through this groove. The second, solid flyer leg serves to balance the grooved leg. Newer designs no longer feature this easily accessible, „service-friendly“groove. Instead, they have Fig:2 3/3 Double apron drafting system a very smooth guide tube set into one flyer leg. In this case, the TABLE1. COMPARISON OF ROLLER AND APRON strand is completely protected against air flows and the roving DRAFTING is no longer pressed with considerable force against the metal Parameters High speed High speed drafting drafting(Roller with high draft ratio of the leg, as it is in the previous designs. Frictional resistance drafting) (Apron drafting) is significantly reduced, so that the strand can be pulled Input (feed hank) 2 meters 2 meters through with much less force. This reduces false drafts and Output(delivered 7.5 meters 10 meters strand breaks while allowing high production speeds. However, Roving) Time required 1.2 minutes 1.5 minutes Roving speed 1.66 1.33 minutes meters/min

Volume-3,Issue-2, Feb 2015 Paper Title:- Investigation and Optimization of Roving Making Machine ISSN (O) :- 2349-3585

piecing of strand breaks is somewhat more difficult. 4.2.2 The presser arm A steel yoke, the so-called presser arm, is attached to the lower end of the hollow flyer leg. The arm has to guide the roving from the exit of the flyer leg to the package. The roving is wrapped two (A) or three (B) times around the yoke. The number of turns determines the roving tension. If this is high, then a hard, compact package is obtained. If it is too high, false drafts or roving breaks can be caused. The number of wraps depends upon the material and twist level. Fig:-3 Flyer 4.2.1 Various designs of flyers: Limits on the performance of the roving frame are determined by both the delivery speed and the rotation speed of the flyer. The influence of the flyer depends upon its form and drive. Using these criteria as a basis, the following distinctions can be drawn between three flyer types:  spindle-mounted flyers (Fig.4 a); Fig:-5 Guidance of the roving by the pressure arm  closed flyers (Fig. 4, b);  Top-mounted flyers (Fig.4 , c). The standard form has in the past been the spindle-mounted flyer (Fig. 4, a). This is simple as far as design and drive are concerned, but not from the service point of view or for 4.3 Winding of the bobbin: automation purposes. In this design, the spindle is simply a Roving bobbin is a cylindrical body with tapered ends (Fig.6). support and drive element for the flyer, without any ancillary It is created by building layer upon layer of parallel coils of function. It is a long steel shaft, mounted at its lower end in a roving on wooden or plastic bobbin tubes acting as package bearing and supported in the middle by the vertically cores. To form the tapered ends, the height of the lift must be reciprocating shaft of the package tube acting as a neck reduced after each layer has been completed. The roving bearing. Rotation is caused very directly and over a short bobbin is the ideal package form for supplying material to the transmission distance from the main shaft by way of a gear ring spinning frame; when full, the bobbin carries a relatively train and a longitudinal shaft that extends past all spindles and large quantity of material, owing to its compactness; when is fitted with bevel gears driving bevels on the spindles empty, it occupies a relatively small volume, convenient for themselves. The spindle tip is conical and provided with a slot. transport and storage. The angle of taper of the ends is When the flyer is set on the spindle cone, a pin on the flyer normally between 80° and 95°, and depends upon the projects into the slot so that the flyer and spindle are converted adherence of the material. The angle is made as large as into a unit for drive purposes. The closed flyer (Fig. 4, b), possible, so that as much roving as possible is wound onto the supported both above and below, has been used only by Platt package. However, the angle must be small enough to ensure Saco Lowell in the “Rovematic” machine. It has the advantage that the layers do not slide apart. of reduced spreading of the legs at high operating speeds.

Today, the standard design is the top-mounted flyer (Fig. 4, c).

Among other things, this form facilitates automation of the

doffing operation. The flyer is supported by ball bearings at the

neck and is driven by gear wheels or toothed belts from above.

Fig:-4 Various designs of flyers Fig:-6 The bobbin form

Volume-3,Issue-2, Feb 2015 Paper Title:- Investigation and Optimization of Roving Making Machine ISSN (O) :- 2349-3585

5. OPTIMIZATION OF PROCESS PARAMETERS OF ROVING MAKING MACHINE: TABLE 3. EXPERIMENTAL VALUES ARE POSTULATED AS 5.1 Optimization of top rollers pressure: In the experiment conducted for optimization of top rollers pressure, top roller pressure is varied from 1.2 to 3 kgf/cm2 and roving breakage rate is calculated for this. Observations are tabulated in table 2. Roving breakage rate =No of breakages/100spindle in 1 hour.

TABLE 2. EXPERIMENTAL VALUES ARE POSTULATED AS Top rollers Roving Top rollers Roving pressure breakage pressure breakage (kgf/cm2) rate (kgf/cm2) rate 1.2 7.45 2.2 3.04 1.4 6.32 2.4 4.2 GRAPH 2. EXPERIMENTAL VALUES PLOTTED ON 1.6 6.06 2.6 4.58 GRAPH 1.8 5.76 2.8 6.2

2.0 4.28 3 6.8 From graph (2) and table (3) it is seen that breakage rate of

roving decreases with increase in flyer speed up to 1040 Rpm

and then again increases. Hence 1040 Rpm is optimum flyer speed for roving making machine.

6. CONCLUSIONS Above we studied the different processes in yarn making specially the roving making process. Studies and optimizations with results are as follows:  3/3 system with double apron is quite commonly used in roving frame. It is because it has high drafting speed as GRAPH 1.EXPERIMENTAL VALUES PLOTTED ON well as high draft ratio. GRAPH  Top mounted flyers should be used as it provides greater lift of spindle for winding of bobbin. From table (2) and graph (1) it is seen that as the top roller  The roving is wrapped two or three times around the pressure increases roving breakage rate initially decreases up to yoke. The number of turns determines the roving 2.2 kgf/cm2 and then again increases. Hence 2.2 kgf/cm2 is an tension. If this is high, then a hard, compact package is optimum top rollers pressure. obtained.  Top roller pressure increases roving breakage rate initially decreases up to 2.2 kgf/cm2 and then again 5.1 Optimization of flyer speed: increases. For the optimization of flyer speed lengthy and time  Breakage rate of roving decreases with increase in flyer consuming experiment is conducted. In this experiment flyer speed up to 1040 Rpm and then again increases. speed and breakage rate of roving is compared. Breakage rate  The optimum values of different variables are: flyer is calculated at each flyer speed starting from 500 rpm to1500 speed, 1040 Rpm and top rollers pressure 2.2 kgf/cm2. rpm. During this experiment top roller pressure is kept constant at 2.2 kgf/cm2. REFERENCES Roving breakage rate =No of breakages/100spindle in 1 hour. 1. Neha Gupta, Department of Mechanical Engineering, Integral University, Lucknow, India, “Analysis on the Defects in Yarn Manufacturing Process & its Prevention in Textile

Volume-3,Issue-2, Feb 2015 Paper Title:- Investigation and Optimization of Roving Making Machine ISSN (O) :- 2349-3585

Industry”, International Journal of Engineering Inventions, Volume 2, Issue 7 (May 2013) PP: 45-67 2. S.M Ishtiaque, R.S Rengasamy and A Ghosh, Department of Textile Technology, New Delhi 110 016, India. “Optimization of speed frame process parameters for better yarn quality and production”. Indian Journal of Fibre and Textile Research, Vol 29, March 2004, PP 39-43. 3. J.B.PRICE, EUSDA ARS Southern Regional Research Center, 1100 Robert E. Lee Boulevard, New Orleans, Louisiana, 70124 “History and Experiences with Small-Scale Sample Evaluations of Cotton and Potential for Improvement”, the Journal of Cotton Science (2008). 4. A. D. Desai, “Improving Customer Delivery Commitments the Six Sigma way: Case Study of an Indian Small Scale Industry”, International Journal of Six Sigma and Competitive Advantage, 2006, 2(1), pp. 23-47. 5. W.Klein,“Technology of Short Staple Spinning”, The Textile Institute, Manual of Textile Technology, All volumes. Eric Oxtoby, “Spun Yarn Technology”, Butterworths, 1987. 6. Grosberg P and Iype C, “Yarn Production-Theoretical Aspects” 7. B.Sujai,manager application technology, Inarco Ltd, “High speed drafting of textile material with high draft ratio and its impact on cots and aprons in ring spinning machines”.