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Knitting:: Differences in Warp and Weft Knitting
Knitting:: Differences in Warp and Weft Knitting
Knitting is the name of the craft that involves two needles and yarn or thread. Loops
in the yarn are manipulated with the needles to make a knitted fabric.
The physical and mechanical properties of knitted fabric can be changed due to use
of various count of yarn, type of yarn (ring, rotor, and compact), quality of yarn,
stitch length / loop length, structural geometry, fiber composition of yarn etc. This
study focused on the various stitch length effect of grey single jersey. With an
increase in stitch length, the dimensional properties like CPI, WPI, GSM, thickness
& tightness factor will be decreased for all the structures; while comfort properties
like air permeability & water absorbency will be increased.
Different yarns and knitting needles may be used to achieve different end products by
giving the final piece a different color, texture, weight, and/or integrity. Using
needles of varying shape and thickness as well as different varieties of yarn can also
change the effect.
Knitted fabric has certain special characteristics that make it suitable for creating a
wide range of garments and accessories like tights, gloves, underwear and other
close-fitting garments. The structure of the loop of knitted fabric stretches and molds
to fit body shapes. The air trapped by the interlocking loops keeps the wearer warm.
Classification of Knitting:
1. Warp Knitting.
2. Weft Knitting.
1. In weft knitting only one set of yarn is used that form courses along the weft
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wise direction of the fabric, while in warp knitting many sets of yarns is used
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Knitting machines are mainly two types; they are circular knitting machine and
flat bed knitting machine. This two types are hugely use in knitting machine. A
knitting machine is composed of lots of parts. Every parts of a machine are important
for run the machine smoothly. Every part has a specific function during operation.
Different knitting machine parts and their functions are given below:
Creel: Creel is called the holder of cone. Cone is placed in a creel for feeding
the yarn to the feeder.
Feeder: Yarn is feed through the feeder. No of feeder is depends on the design
of the fabric.
VDQ Pulley: G.S.M of the knit fabric is controlled by VDQ pulley. VDQ
pulley is used for controlling the stitch length of the fabric.
Guide: Guide is called the supporting element. Guide is used to guide the
yarn.
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Sensor: Sensor is an automatic controlling system. When a yarn pass through
this sensor than if any yarn break down or any problem occur than it
automatically stop by this sensoring system.
Spreader: Spreader is used to spread the knitted fabric before take up roller.
Knit fabrics may be tube or open type. Spreader is adjusted as need.
Fixation Feeder: This type of feeder is used in electrical auto striper knitting
machine to feed the yarn at specific finger.
Different well known companies are manufacturing such types of knitting machine.
Day by day they are trying to add some advance technology two facilities best
opportunity. In this sense we can consider auto stripe, which gives more opportunity
two produce multi-color long stripe knit fabrics. Different zigzag design also can be
produced by an auto stripe machine. It is note that, faulty knitting machine parts
create knitting faults. To increase the knitting production we should use latest
knitting machine.
So, before buying a knitting machine we have to consider these above points.
Photo: Creel.
VDQ Pulley: It is a very important part of the machine. It controls the quality of the
product. Altering the position of the tension pulley changes the G.S.M. of the fabric.
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If pulley moves towards the positive directive then the G.S.M. is decrease. And in the
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Photo: Brush.
Tension Disk:
It confronts the tension of the supply yarn.
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Photo: Tension Disk.
Inlet and Outlet Stop Motion:
It is an important part of the machine. It stops the machine instantly when a
yarn is break.
Yarn Guide:
Its help the yarn to feed in the feeder.
Photo: MPF.
Feeder Ring:
It is a ring. Where all feeders are pleased together.
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Feeder:
Feeder is help yarn to feed in to the machine.
Photo: Feeder.
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Needle Track:
Where all Needles is placed together in a decent design .
Photo: Sinker.
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Sinker Ring:
Sinker ring is a ring, where all sinkers are pleased together.
Cam Box:
Where the cam are set horizontally. In cam box, practically 4 cams is set.
Cam: Cam is device s which converts the rotary machine drive in to a suitable
reciprocating action for the needles and other elements. 10
Photo: Cam.
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Lycra Attachment Device:
Lycra is placed hear and feeding to the machine.
Cylinder:
Needle track are situated hear.
Photo: Cylinder.
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Cylinder Balancer:
This part removes lint, hairy fibre from yarn and others. To clean the dust by
air flow.
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Photo: Expander.
Needle Detector: This part detect the any type of faults of needles.
Knit fabrics are the fashion of new age. Various designed fabrics are produced in
knitting machine. Knitting flow chart should follow during operation. During
production processes following machine parameters are considered.
Machine diameter
Machine rpm (revolution per minute)
No. of feeder in use
Machine gauge
Count of yarn
Required time
Machine running efficiency
Generally knit fabric production runs according to the order of buyer. When a buyer
orders for fabric, they mention some points related to production and end product
quality. Before production of knitted fabrics, these factors are needed to consider.
Those are as follow:
Knitted fabrics are various in designs. When a buyer order for a product they give a
sample or give the specification of the end product. Different designed fabrics are
produced by changing the cam setting, needle setting and size of loop shape.
Finished G.S.M:
It is technical term that indicates the weight of the fabric per square meter. In knitting
section grey fabrics are produced but the programmer should make his program for
getting the finished G.S.M after dyeing. Some points are considered while setting
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grey G.S.M; they are enzyme level, color and shaded or none shaded. G.S.M of the
fabric is controlled by the following way:
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→Major controlled by VDQ pulley.
→By altering the position of tension pulley, G.S.M of the fabric can be changed. If
pulley moves towards the positive directive then the G.S.M is decrease and in the
reverse direction G.S.M will increase. This also depends on the machine type.
Yarn Count: Yarn count differ on the finished G.S.M. Higher the yarn count higher
the G.S.M of the fabric. Sometimes spandex or lycra is used with the cotton in that’s
case yarn count of cotton select with the combination of lycra.
Type of yarn:
Different types of yarn are used for knit production. Cotton yarns may be combed or
carded. Also synthetic fiber like lycra(spandex) is used with cotton for some special
case. All depends on the buyer requirement.
Diameter of the fabric is another factor. Fabric may be open diameter or tube
diameter. Any how grey dia. will be selected with response of finished dia. of the
fabric.
Color depth:
If the depth of color of the fabric is high then loop length should be higher because in
case of fabric with higher loop length is less compact. In dark shade dye take up% is
high so G.S.M is adjusted then. Similarly in case of light shade loop length should be
relatively smaller.
Stitch length
The fundamental unit of a knitted fabric is the loop. Any circular knitted fabric is
composed of row after row of interloping or interlacing of loops. Different types of
fabric are made of different method. The gross dimension of knitted fabric is simply
a reflection of any shape & size of individual loops. There are several key variables
in the production which affect the average shape & size of the loops. After knitting
the grey fabric is dyed to required shade & finished to required weight & width.
Stitch lengths vary depending on yarn count and shade of the fabric. If stitch length is
not fixed with respond to finished G.S.M then knitting faults appear.
Fabric GSM:
The GSM of fabric is one kind of specification of fabric which is very important for a
textile engineer for understanding and production of fabric. ‘GSM’ means ‘Gram per
square meter’ that is the weight of fabric in gram per one square meter. By this we
can compare the fabrics in unit area which is heavier and which is lighter. 16
GSM cutter
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The weight of a fabric can be expressed in two ways, either as the ‘weight per unit
area’ or the ‘weight per unit length’; the former is self explanatory but the latter
requires a little explanation because the weight of a unit length of fabric will
obviously be affected by its width. In woven fabric, the weight per unit length is
usually referred to as the ‘weight per running yard’. It is necessary therefore to know
the agreed standard width upon which the weight per running yard is based. Usually
this width depends upon the width of loom. Before coming the term ‘GSM’ there
was another term called ‘lb/100 yards’. This expression is used by British Standard.
For measuring this there are a template and a quadrant balance. The template area is
1/100 square yards of which each arm is 1/10 yards in length. For measuring GSM, a
GSM cutter is used to cut the fabric and weight is taken in balance. Both of these
measurement and method is equally used for both woven and knitted fabrics.
Apparatus:
1.GSM cutter
2.Electric balance.
GSM or weight per unit area of fabric is an important property that is again related to
a host of their properties. The weight is determined by two factors that interact the
loop size and the yarn size. The effect of loop size is simple express. If the sizes of
the yarn remain constant, then increase the loop size produce a decrease of weight
per unit area.
We can control GSM by controlling stitch length (SL) which is controlled by VDQ
pulley diameter.
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If we increase diameter of VDQ pulley then increase yarn feed, stitch length and
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Data Collection:
Table-01:
3.0 Blanco
3.1 Plomo Or
Table-02:
2.90 White
Table-03:
2.70 Red
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2.90 White
Table-04:
Result Analysis:
Above the chart we can say that when stitch length of knitted fabric increase
this time fabric GSM will be decrease. In other hand, when stitch length of knitted
fabric will be decrease this time fabric GSM will be increase.
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Shade%
Above the chart we can say that finished GSM of knitted fabric can not
depends only stitch length. It is also depends on the color shade of the fabric. If the
shade % increase then the fabric GSM will be increase.
Relation among Yarn Count, Finished GSM, Grey GSM and Stitch Length.
200
Fabric
150
GSM
100
50
0
20 22 23 25 27 29 31 33 35 37 39
Yarn Count
Above the chart I show the relation among yarh count, Finished GSM & Grey
GSM.we can say that finished GSM of knitted fabric always 1.3 times higher than
grey GSM.We can make the single jersey fabric in different GSM by using different
yarn count with approx. same stitch length.
Conclusion:
For this lab report I have visited in the JK Knit composite Ltd. Knitting department
are performing to produce different types of weft knitted fabric. The Knitting
capacity of JK knit per day 14 tones. There are 62 knitting machines; 11
Rib/interlock machine, 3 Engineering stripe (jacquard), 6 three thread fleeces, 22
single jersey and 8 flat knit collar machine. A process of fabric manufacturing by
converting yarn into loop form and then these loops interlock together, which forms a
structure, is called knitting. Stitch/Loop length is the fundamental unit which controls
all the properties of weft knitted fabrics. Mainly stitch length & knit structure affects
all the dimensional, comfort, handle & other properties. I worked on different parts
of knitting machine and also parameters of knitted fabric with structure also. But
feeding is very important to control stitch length, stitch length also plays a great roll
on other structures also. From the analysis, I can get idea about Knits are most
commonly known for their natural softness, bulk, stretch, recovery and
conformability. However, knit fabrics also offer excellent engineering opportunities
because of the knitting process’s inherent ability to manipulate, control and secure
individual yarn placement. Weft knits are formed by a yarn or multiple yarns fed as
one to all selected needles. On weft-knitting machines, the yarn is directed to the
needles across the machine’s flow direction. For this reason, weft-knit stripes
generally run across the width of the fabric. Also understand the weft knitted fabric
quality, cost & profit of the industry depends upon the good production planning
with proper maintenance.
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