Yarn breakage practically found in warping and its remedy

Analysis various yarn Fault in Warping process of weaving Remedies of these faults.. Analysis various yarn Fault in Warping process of weaving Remedies of these faults.. Warp breaks

Yarn breakage practically found in warping and its

remedy

Yarn breakage practically found in warping and its remedy

Yarn breakage practically found in warping and its remedy TOPIC

Prepared By : Mazadul Hasan sheshir ID: 2010000400008

SUBMITTED TO

MR MUZAHIDUR RAHMAN CHOWDHURY

LECTURER SOUTHEAST UNIVERSITY DEPARTMENT OF TEXTILE

MR MUZAHIDUR RAHMAN CHOWDHURY

LECTURER SOUTHEAST UNIVERSITY DEPARTMENT OF TEXTILE

SOUTHEAST UNIVERSITY

DEPARTMENT OF TEXTILE ENGINEERING

PROJECT OBJECTIVE

Research.

Analysis various yarn Fault in Warping process of weaving

Remedies of these faults

Selection of raw materials

Product testing.

Product Quality improvement

Reduce wastage

To improve warping efficiency

To improve yarn quality in spinning

Research.

Analysis various yarn Fault in Warping process of weaving

Remedies of these faults

Selection of raw materials

Product testing.

Product Quality improvement

Reduce wastage

To improve warping efficiency

To improve yarn quality in spinning

During processing, textile materials are subjected to various stresses not only during the machine operation but also during its stoppage If these stresses exceeded a given limits it will adversely affect the quality of the produced yarns, fabrics and the efficiency of the machines

In weaving process, the strains on warp ends can lead to thread breaks, loss of quality and shutdowns Warp breaks still represent major problem especially for today's high-speed weaving machines Generally, warp yarn break occurs due to excessive tension greater than the strength of the yarn

INTRODUCTION

YARN FAULTS FOR WARP YARN BREAKAGE

16 RIBBON WOUND CONE

21 RING SHAPED CONE

An abnormally thick place or lump in yarn showing less twist at that place.

RECTIFICATION

1 Machine surfaces to be maintained clean

2 Rotors are properly maintained

3 Better fiber individualization at cards to be achieved

4 Optimum top roller pressure &back zone

5 Setting at rotor to be maintained

EFFECT

1 More end breaks in warping process

2 Damaged fabric appearance

3 Shade variation in dyed fabrics

1 Machine surfaces to be maintained clean

2 Damaged rotor to be avoided and proper maintained

3 Better fiber individualization at cards to be achieved

EFFECT

1 Damaged fabric appearance

2 Shade variation in the dyed fabrics

3 An abnormally thick place or lump in yarn showing less twist at that

place is called slubs

Yarn with kinks (twisted onto itself) due to insufficient tension after twisting

RECTIFICATION

1 Optimum twist to be used for the type of cotton processed

2 Drafting parameters to minimize thin places in the yarn to be

adopted

3 Correct tension weights and slub catcher settings to be employed

at winding

EFFECT

1 Entanglement with adjacent ends causing a break

2 Damaged fabric appearance

3 Shade variation in dyed fabrics

4 Mixing of cottons varying widely in fiber lengths and use of

immature cottons

CAUSES

1 Higher than normal twist in the yarn

2 Presence of too many long thin places in the yarn

3

THICK AND THIN PLACES

Measurable by USTER Imperfection Indicator and observable on appearance

RECTIFICATION

1 Defective rotor to be avoided

2 Right the card setting

3 Wide variation in the properties of cottons used in the mixing to be

avoided

4 Better fiber individualization at cards to be achieved Correct

spacers to be utilized

EFFECT

1 Damaged fabric appearance

2 Shade variation in dyed fabrics

3 Mixing of cottons varying widely in fiber lengths and use of

3 Defect rotor surface

4 Mixing of cottons varying widely in fiber lengths and use of

immature cottons

4

SOFT YARN

Yarn which is weak indicating lesser twist

RECTIFICATION

1 Proper yarn clearing to be ensured

2 Periodic replacement of rotor to be effected

1 Improper feed in rotor

2 Less twist in the yarn

3 Bad rotor

5

OIL STAINED YARN

Yarn stained with oil

RECTIFICATION

1 Appropriate material handling procedures to be followed

2 Oilers to trained in proper method of lubrication

3 Clean containers to be utilized for material transportation

EFFECT

1 Damaged fabric appearance

2 Occurrence of black spot in fabric

CAUSES

1 Careless oil in the moving parts, over head pulleys etc

2 Piecing made with oily or dirty fingers

3 Careless material handlings

6

1 Feed roller to be maintained

2 Mixing of cottons varying widely in fiber length to be avoided

3 Use of optimum roller settings

4 Use of properly buffed rollers free from eccentricity to be ensured

EFFECT

1 More breaks in winding

2 More noticable in polyester and cotton blended yarns

1 CAUSES

2 Mixing of cottons of widely differing staple length

3 Closer roller settings

4 Eccentric top feed roller

5 Non optimum temperature and relative humidity in the spinning

shed

6 Over spinning of cottons

7

1 More end breaks in subsequent process

2 Increase in hard waste

CAUSES

1 Wrong method of piecing and over end piecing of robot

2 Twisting the ends instead of knotting

8

OILY SLUB

Slub in the yarn stained with oil

RECTIFICATION

1 Yarn contact surfaces to be kept clean

2 Proper segregation of oily waste from process waste

3 Oilers to be trained in correct procedures of lubrication

EFFECT

1 More end breaks in the warping process

2 Damaged fabric appearance

3 Shade variation in dyed fabrics

CAUSES

1 Accumulation of oily fluff on machinery parts

2 Poor methods of lubrication in preparatory processes

3 Negligence in segregating the oily waste from process waste

9

KITTY YARN

Presence of black specks of broken seeds, leaf bits and trash in yar

RECTIFICATION

1 Cleaning efficiency of blow room and cards to be improved

2 Optimum humidity in the departments to be ensured

EFFECT

1 Damaged fabric appearance

2 Production of specks during dyeing

3 Poor performance during winding

CAUSES

1 ineffective cleaning in Blow room and cards

2 Use of cottons with high trash and too many seed coat fragments

10

Protrusion of fiber ends from the main yarn structure

RECTIFICATION

1 Proper mixing or blending

2 Periodic maintenance of different parts

3 Roller settings to be maintained

4 Optimum relative humidity to be maintained in the spinning room

5 Wide variation in the properties of cottons used in the mixing to be

avoided

EFFECT

1 More breaks in winding and warping

2 Formation of holes and stains in cloth

CAUSES

1 Use of cottons differing widely in the properties in the same mixing

2 Improper mixing

3 Maintaining low relative humidity, closer roller settings and very

high spindle speeds

FOREIGN MATTERS

Metallic parts, jute flannel and other similar foreign matters spun along with yarn

RECTIFICATION

1 Improper setting of cleaning zone

2 Removal of foreign matters(such as jute fibres, colour cloth bits) to

be ensured during preparation of mixing

3 Installation of permanent magnets at proper Places in blow room

lines to be ensured

EFFECT

1 reaks during winding and warping

2 Formation of holes and stains in cloth

CAUSES

1 Damaged fabric appearance

2 Improper preparation of mixings

3 Improper setting of foreign material separator in blow room

12

SPUN IN FLY

Fly fluff either spun along with the yarn or loosely embedded on the yarn

RECTIFICATION

1 Malfunctioning of humidification plant

2 Machinery surfaces to be kept clean by using roller pickers

3 Fanning by workers to be avoided

4 Performance of over head cleaners and humidification plants to be

CORK SCREW YARN

It is a double yarn which one yarn is straight and other is coiled over it

RECTIFICATION

1 proper maintenance of robot

2 proper mixing

EFFECT

1 Breaks during winding and warping

2 Causes streaks in the fabric

STITCHING ON CONE

Ends not laid properly on the cone at reversal of yarn path

RECTIFICATION

1 Maintenance cone winders to be good

2 Cone holder settings and alignment of tension

3 Brackets with drum to be carried out as frequently as possible

EFFECT

1 More end breaks in the subsequent process

2 Excessive yarn waste

CAUSES

1 Vibrating and wrongly set cone holder

2 Yarn coils wrapped round the base of cone holder

3 Traverse restrictors fixed at incorrect position

4 Improper alignment of tension brackets with the drum

15

RIBBON WOUND CONE

Formation of ribbon like structure on the circumference of the cone

RECTIFICATION

1 Over hauling of cone winders to be periodically carried out

2 Anti ribboning mechanism to be checked at frequent interval

3 Free movement of the cone holders to be ensured by proper

lubrication

EFFECT

1 Overall density of package is lower

2 Soft packing either at the base or at the nose of cones

CAUSES

1 Winding spindle not revolving freely

2 Cone holders incorrectly set

3 Defective settings of cam switch

4 Improper traverse motion

5 Vibration of cone and traverse

16

SOFT BUILD CONES SOFT BUILD CONES

Unduly soft structure of cone

RECTIFICATION

1 Unwinding tension to be maintained at 6 to 8% of single yarn

strength

EFFECT

1 Overall density of package is lower

2 Soft packing either at the base or at the nose of cones

CAUSES

1 Improper alignment of cone holder and traverse

2 Insufficient unwinding tension

17

BELL SHAPED CONE

Cones which are tightly built at centre, presents a shape of bell

RECTIFICATION

1 Quality of cones to be checked at that time of procurement

2 Optimum unwinding tension to be maintained

EFFECT

1 Excessive breaks during warping and winding processes

CAUSES

1 High yarn tension during winding

2 Cone holders incorrectly set to the winding drum

3 Damages in paper cone centre

18

NOSE BULGING

Bulging of bunches of the yarn at the nose of the cones

RECTIFICATION

1 Periodical inspection of settings in winding machines

2 Tenters to be instructed to adopt correct work practices

3 Avoiding usage of damaged paper cones

EFFECT

1 Slough during warping/unwinding

2 Excessive yarn waste in next process

CAUSES

1 Improper setting of cone holders to the winding drum

2 Damaged nose of the paper cones

19

COLLAPSED CONE

Collapse of the structure of the cone(paper cone)itself

RECTIFICATION

1 Using of poor quality/damaged paper cones should be avoided

2 Winding tenters should be trained by proper work methods

3 Proper material handling devices such as cone transport trolleys to

be used

4 Cone inserts to be used for paper cones

EFFECT

1 Yarn breaks in warping process

2 Wastage increase in yarn preparation

CAUSES

1 Use of poor quality/damaged paper cones

2 Poor system of material handling

3 Maintaining non optimum unwinding tension

20

RING SHAPED CONE

Formation of ring shaped bulge across the cross section of the cone

RECTIFICATION

1 Due to replacement of defective drums and stop motion

wires to be ensured ,

2 Periodic inspection of cone holder settings and tension

assembly to be carried out ,

EFFECT

1 More end breaks in the subsequent processes

2 Slough off during unwinding

CAUSES

1 Incorrect setting of the cone holder

2 Wrong placement tensioners in the tensioning assembly

3 Traverse of yarn affected due to defects in the grooves of the

drum

21

SL # BEAM LENGTH WEAK YARN SLOUGHING OFF OVER LAPPING KNOTS/BAD

SL # BEAM LENGTH WEAK YARN SLOUGHING OFF OVER LAPPING KNOTS/BAD

From Table-1: Data for 20 Ne

From Table-2: Data for 10 Ne

Fig: Effect of different types of yarn faults

in warping for 10/1 count carded yarn

From Table-2: Data for 16 Ne

Fig: Effect of different types of yarn faults in warping

for 16/1 count carded yarn

WEAK YARN ; 39.19%

OVER LAPPING; 5.41% KNOTS/BAD SPLICE; 2.70%

1 Found different types of yarn and package faults from warping the main cases of warp yarn breakage is improper raw material mixing and cleaning in spinning because majority percentage of yarn faults is weak yarn

2 The number of breaks varied directly with the yarn count.

3 Improper maintenance of spinning.

1 Found different types of yarn and package faults from warping the main cases of warp yarn breakage is improper raw material mixing and cleaning in spinning because majority percentage of yarn faults is weak yarn

2 The number of breaks varied directly with the yarn count.

3 Improper maintenance of spinning.

KEY FINDINGS

1 We had a very limited time In spite of my willing to study more details it was not possible to do so.

2 This while process is not possible to bind such a small frame

as this report, hence our effort spent on summarizing them

3 We cannot manage data perfectly Some fault cannot recovery such as parallel winding which is occur from robotic miss action in rotor spinning ,mixing ratio is not perfectly, large amount of wastage uses as for the rate of beating action is high and create more amount of neps which neps carding cannot remove perfectly If Feed material is quality full then produce goods also be good.

LIMITATION

Considering the objective of the work, a systematic investigation on ‘Yarn Faults in warping and its Remedies’ were performed in the training period All the activities had been done maintaining in sequence of the machinery of the production From the thorough investigation it is seen that the following faults are yarn faults, yarn package faults, mechanical faults in spinning Reducing warp breaks on warping machines

uplift the efficiency of this process and the efficiency of weaving machines, and finally enhances the quality of yarns and produced fabrics

Yarn faults tend to not fulfill the target of production of a industry As a result the production capacity of these industries falls significantly These are the common faults which I have tried to find out the causes & their Remedies against them.

CONCLUSION

1 Yarn Manufacturing Technology