International Journal of Engineering & Technology IJET-IJENS Vol: 11 No: 06 92

Optimization of doubling at draw frame for

quality of carded ring yarn
A. Subrata Kumar Saha, B. Jamal Hossen
Lecturer, Department of Textile Engineering
Ahsanullah University of Science and Technology
141-142, Love Road, Tejgaon I/A, Dhaka-1208, Bangladesh

ABSTRACT

Sliver has a huge impact on yarn quality parameter like evenness, imperfection index, Cvm%, U% of yarn.
In general doubling means the increase in weight per unit length. Doubling is a process used in yarn
manufacturing by which a single product is produced from a several intermediate feed product. The study
was performed on 0.12 hank card sliver which was used to produce 24/1 Ne carded yarn. At first the
number of doubling in the breaker and finisher drawing was 6, 7, and 8 respectively. The paper is to find
out whether the change of number of doubling has any effect on yarn quality or to find out the suitable
number of sliver doubling in passage 1 and passage 2.

Key words: Doubling, Draft, Hairiness, count, unevenness, imperfection index.

I. INTRODUCTION

In processing in the spinning mill, the unevenness of the product increases from stage to stage after the
draw frame. There are two reasons for this. Firstly the number of fibres in the section steadily
decreases. Uniform arrangement of fibres becomes more difficult because of their smaller number.
Secondly each drafting operation increases the unevenness. Each processing stage is a source of faults.
Drafting arrangements, in particular increase unevenness considerably. In order, finally, to achieve a
stable yarn the process must include operations that give an equalizing effect. These can be doubling,
leveling, and drawing [1]. In general doubling means the increase in weight per unit length [1].
Doubling is a process used in yarn manufacturing by which a single product is produced from a several
intermediate feed product. For example, sliver doubling where 4 to 8 slivers are fed to draw frame and
1 sliver is delivered. On the other hand, draft is to reduce the linear density of a fibrous assembly by
drawing. This process is called drafting and drafting operation increases the unevenness [4]. The
function of draw frame is to provide doubling and drawing at the same time. The paper is to find out
whether the change of number of doubling has any effect on yarn quality or to find out the suitable
number of sliver doubling in passage 1 and passage 2.The entire question leads us to this experiment.

II. DOUBLING

Doubling is very important for equalizing. This means well distribution of different fibres with their
same or different properties all along the length of the delivery sliver. The main purpose of doubling is
blending and elimination of mass variation of the delivery sliver [1]. Mass variation is reduced if there
are a few thick places and some amount of thin places in the same zone. If this kind of set up does not
arise the task of elimination of mass variation completely depends on the auto leveler [3]. Blending
also improved by doubling because cans from different carding machines are fed to a breaker draw
frame and cans of different breaker draw frame are fed to different finisher draw frame [5]. Thus a very
good blending of fibre can be achieved. When doubling and drawing are combined, the input
materials are doubled to reduce the long-term errors; however, new errors of shorter wavelengths
are added as a result of the process of elongation. There is an exchange of relatively long-term for
short-term error [6].

III. MATERIAL AND METHOD

In modern installation, the raw material is supplied via ducting pipe into the feed chute of the carding
machine. The carding machine produces card sliver. Then the card sliver cans are fed to the breaker
draw frame. The breaker draw frame sliver cans are then fed to the finisher draw frame. In breaker and
finisher draw frame different numbers of doublings was used and for each sample roving in simplex
machine were made and finally yarn was made in ring frame. After producing yarn we test the quality
of yarn.

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IV. EXPERIMENTAL PROCEDURE

In this work card sliver was collected from carding machine. The card cans were then fed to the breaker
draw frame, once for 6 doubling, once for 7 doubling and once for 8 doubling. 8 cans for each set of
doubling were prepared. Then those slivers were fed to the finisher draw frame. The target is to get
finisher sliver made from 6 doubling, 7 doubling and 8 doubling. Those above mentioned sliver from
each set of breaker draw frame sliver were prepared. Finally 90 cans finisher drawn sliver of 9 different
doubling were achieved. Then one simplex were selected for roving making. There are 9 samples each
having 10 cans. Spindle no 111 to 120 of simplex machine were used for sample 1. For every sample
those same spindles of same simplex machine we used. In one particular ring frame, from spindle no-
601 to 610 the roving for each samples were fed. Finally 90 ring bobbins in 9 different samples each
sample has 10 bobbins were made. Than tested those samples with the help of Uster tester-5. Different
colour of can, belt, and sliver band, bobbin for separate different doubling can, roving and ring yarn
were used.

V. DATA ANALYSIS

Table 1: Process summary:

Number of Number of
Number of Number of
sliver Number of sliver Number of
roving yarn
doubling in breaker cans doubling in finisher cans
produced produced
breaker produced finisher draw produced
(bobbins) (cops)
draw frame frame
6 10 10 10
6 8 7 10 10 10
8 10 10 10
6 10 10 10
7 8 7 10 10 10
8 10 10 10
6 10 10 10
8 8 7 10 10 10
8 10 10 10

Table 2: Uster tester result for breaker draw frame sliver:

Number sliver doubling in

U% Cvm%
breaker draw frame
6 3.20 4.02
7 3.62 4.68
8 3.85 4.71

Table 3: Uster tester result for finisher draw frame sliver:

Number of Number of
sliver doubling sliver doubling Cvm%
Sample Number U%
in breaker draw in finisher draw
frame frame
1 6 2.45 3.09
2 6 7 2.44 3.04
3 8 2.43 3.03
4 6 2.53 3.17
5 7 7 2.46 3.11
6 8 2.43 3.08
7 6 2.55 3.26
8 8 7 2.53 3.16
9 8 2.52 3.13

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Table 4: Uster tester result for roving:

Number of sliver Number of sliver

Sample doubling in doubling in Cvm%
U%
Number breaker draw finisher draw
frame frame
1 6 4.36 5.46
2 6 7 4.31 5.39
3 8 4.16 5.24
4 6 4.31 5.45
5 7 7 4.32 5.59
6 8 4.23 5.44
7 6 4.39 5.55
8 8 7 4.39 5.53
9 8 4.35 5.40

Table 5: Uster tester result for 24/1 Ne carded ring yarn:

Number of Number of
sliver sliver
Sample Cvm Thin Thick Neps
doubling doubling Hair
Numbe U% (- (+50% (+200 IPI
in breaker in finisher % iness
r 50%) ) %)
draw draw
frame frame
1 6 11.44 14.58 7.9 166.3 96.6 270.8 6.18
2 6 7 11.36 14.48 3.5 155.4 90.2 249.1 6.12
3 8 11.30 14.30 3.2 147.2 80.5 230.9 6.02
4 6 11.56 14.58 4.2 159.3 90.4 253.9 6.32
5 7 7 11.22 14.27 3.9 145.4 85.2 234.5 6.30
6 8 11.21 14.32 4.2 150.8 87.4 242.8 6.24
7 6 11.52 14.67 5.7 160.3 98.4 264.4 6.34
8 8 7 11.36 14.47 2.5 165.4 92.3 260.2 6.32
9 8 11.22 14.30 2.9 152.6 95.5 251.0 6.42

VI. RESULT AND DISCUSSION

4
3.8
U%

3.6
3.4
3.2 U%
3
6 7 8
Number of doubling in breaker draw frame

Figure 1: U% of carded sliver Vs different number of doubling in breaker draw frame

4.8
4.6
Cvm%

4.4
4.2
4 Cv%
6 7 8
Number of doubling in breaker draw frame

Figure 2: Cvm% of carded sliver Vs different number of doubling in breaker draw frame

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From Figure 1 & 2, it is observed that U% & Cvm% of card sliver shows an increasing trend when the
number of doubling increase. The main reason of this increasing trend is when number of doubling
were increased the feed material weight increases but delivery material weight is needed to remain
same. So breaker draw frame draft is increased and that increases the U% and Cvm% of sliver.

2.56
2.54
2.52
2.5
U%

2.48
2.46 U%
2.44
2.42
1 2 3 4 5 6 7 8 9
Sample Number

Figure 3: U% of carded sliver Vs different number of doubling combination sample in finisher draw
frame

3.3
3.25
3.2
Cvm%

3.15
3.1
Cvm%
3.05
3
1 2 3 4 5 6 7 8 9
Sample Number

Figure 4: Cvm% of carded sliver Vs different number of doubling combination sample in finisher draw
frame

From Figure 3 & 4, it is observed that U% & Cvm% of card sliver in finisher draw frame shows a
decreasing trend when the number of doubling in finisher draw frame increases (sample no 1 to3, 4 to
6, 7 to 9 ). The main reason of this decreasing trend is finisher draw frame has auto leveller. It reduces
the unevenness of sliver with the increment of number of doubling.

4.42
4.37
4.32
U%

4.27
4.22
U%
4.17
4.12
1 2 3 4 5 6 7 8 9
Sample Number

Figure 5: U% of carded roving Vs different number of doubling combination sample in simplex

machine

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5.7
5.6

Cvm%
5.5
5.4
5.3 Cvm%

5.2
1 2 3 4 5 6 7 8 9
Sample Number

Figure 6: Cvm% of carded roving Vs different number of doubling combination sample in simplex
machine

From Figure 5 & 6, it is observed that U% & Cvm% of card roving in roving frame shows a decreasing
trend when the number of doubling in finisher draw frame increases (sample no 1 to3, 4 to 6, and 7 to
9). Sample 3 shows the best result.

11.6

11.5
U%

11.4

11.3 U%
11.2
1 2 3 4 5 6 7 8 9
Sample Number

Figure 7: U% of carded yarn Vs different number of doubling combination sample in ring frame

From Figure 7 it is observed that U% of carded yarn at ring frame shows a decreasing trend when the
number of doubling in finisher draw frame increases (sample no 1 to3, 4 to 6, and 7 to 9). Sample 6
shows the best result.

14.7
14.6
Cvm%

14.5
14.4
14.3 Cvm%

14.2
1 2 3 4 5 6 7 8 9
Sample Number

Figure 8: Cvm% of carded yarn Vs different number of doubling combination sample in ring frame

From Figure 8, it is observed that Cvm% of carded yarn shows a decreasing trend when the number of
doubling in finisher draw frame increases (sample no 1 to3, 4 to 6, and 7 to 9). Sample 5 shows the best
result.

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275
265

IPI%
255
245
235 IPI%

225
1 2 3 4 5 6 7 8 9
Sample Number

Figure 9: Yarn imperfection index (IPI) of carded yarn Vs different number of doubling combination
sample in ring frame

From Figure 9, it is observed that imperfection index (IPI) of carded yarn shows a decreasing trend
when the number of doubling in finisher draw frame increases (sample no 1 to3, 7 to 9). Sample 3
shows the best result.

6.5
6.4
Hairiness%

6.3
6.2
6.1 Hairiness%
6
1 2 3 4 5 6 7 8 9
Sample Number

Figure 10: Hairiness of carded yarn Vs different number of doubling combination sample in ring frame

From Figure 10, it is observed that hairiness of carded ring yarn shows a decreasing trend when the
number of doubling in finisher draw frame increases (sample no 1 to3, 4 to 6). Sample 3 shows the best
result.

VII. CONCLUSION

This experiment shows that sample no-3 means six doubling in breaker and eight doubling in finisher
draw frame is a good combination of doubling in carded ring yarn production. Considering U% and
Cvm% sample-3 does not show the best result. The U% and Cvm% value of other sample are very
close to sample-3 value. In case of yarn quality main parameter is yarn imperfection index (IPI). In 6-8
doubling combination yarn imperfection index (IPI) is lower. In the yarn test result considering IPI and
hairiness it is clearly seen that 6-8 doubling combination is the best. A spinning mill which is looking
for very good quality yarn should try this setup.

REFERENCES:

[1]. Klein W., Manual of Textile Technology, The Textile Institute. ISBN 0 900739 91 6
[2]. Pattabhiram T. K., Essential Elements of Practical Cotton Spinning, Somaiya Publications Pvt. Ltd. Mumbai, New Delhi.
[3]. Lawrence, Ph.D. Carl A. Fundamentals of Spun Yarn Technology. Library of Congress Cataloging-in-Publication Data,
ISBN 1-56676-821-7 (alk. paper)
[4]. Mohammed Rubaiyat Chowdhury, “Effect of doubling numbers on sliver and yarn quality,” The AUST Journal of Science
and Technology, vol.-1, Issue-2, July, 2009, pp. 117–126
[5]. Akshay Kumar, S M Ishtiaque, “Impact of different stages of spinning process on fibre orientation and properties of ring,
rotor and air-jet yarns,” Indian Journal of Fibre & Textile Research, vol.-33, December. 2008, pp. 451–467
[6]. Peter R. Lord, Handbook of yarn production, The Textile Institute. ISBN 1 85573 696 9

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