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lap & comb (1)
lap & comb (1)
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Cont…
Piecing is an operation that allows the two strip-one combed in previous cycle and
the other freshly combed to superimpose on each other partially. 3
Lap Former
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Sliver and Ribbon lap machines
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Sliver and Ribbon lap machines
In the first case, a number of slivers are doubled and drafted together to form laps in
sliver lap machine.
These laps are then again doubled by unrolling them one over the other and then
drafted to form the final lap in the ribbon lap machine.
The side by side blending of slivers in the first process and overlapping in the
second ensure adequate uniformity in the final lap.
However, in the ribbon lap machine, whenever a lap is exhausted, a new one is
joined to feed the same number of laps resulting in a piecing defect.
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Super lap machine (Sliver blending)
Here, both the operations of side by side blending and overlap blending are carried
out in the same machine.
Therefore a large number of slivers (28 or even more) are used and more draft is
provided in a single operation.
Any piecing required during breakage of slivers or exhausting a sliver does not result
in fault as big as lap piecing.
Since the number of processes between the card and the comber should be of even
number and more parallel fiber in lap is desired, a draw frame passage is required
before feeding the carded sliver into a super lap machine.
In modern combing rooms, lap preparation is invariably carried by the super lap
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machine.
Operating principle of super lap machine
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Operating principle of super lap machine
Creel Zone:
Used as feeding zone.
16 to 32 draw frame slivers passed through guide
roller, guide bars and fed to drafting zone.
Guide Roller:
It guides the passage of feeding slivers.
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Calendar rollers & Lap formation:
The slivers are fed side by side, passing through rollers and stop motion.
The slivers enter the drafting section and then calendar section to produce
a compact lap.
Finally, the lap is wound on to spool.
Doffing of Lap:
The Lap former doffs automatically once the desired length of Lap wound on
the spools.
During doffing empty spools are taken by the machine itself from the reserve
holder and next round of winding starts.
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Chapter Six
Combing Machine
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Introduction
Combing is a process by which the quantity of short fibers and remnant fragments
of impurities present in a carded or drawn sliver are minimized to give a clean sliver,
Having more of a rectangular staple diagram, with the vast majority of the
constituent fibers in a straightened and parallel state.
Combing, therefore, makes possible the spinning of yarns of fine counts with low
irregularities and a cleaner appearance.
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Tasks of combing machine
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Negative Effects Of Combing
I. Piecing defects:
This will be discussed later and as will be seen, that with proper measures, it can
be minimized.
II. Reduces the inter fibre cohesion:
The high degree of parallelization of fibres in the combed sliver may reduce the
inter fibre cohesion
It may lead to breakages in creels or false drafts in subsequent processes.
So, combed sliver should be carefully handled in subsequent operations.
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Amount of Noil in Combing
Noil is the material removed by comber, which includes fibres, trash and neps.
The amount of noil can be expressed in two different ways:
% Noil =
Tear ratio = : 1
Tear ratio =
The tear ratio is mostly used in the worsted sector, whereas % noil is used in cotton
spinning process.
The amount in combing noil depends on the type of yarn to be spun and also on the
quality of fibre.
In cotton industry the range is 5-30%.
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Classification of combing mills
Combing mills can be divided in to the following groups based on the type of
combing:
I. Long staple combing factories:-
These factories produce fine to superfine yarn and also use high grade
fibre having long staple and low trash.
Percentage noil in combing is kept high.
Production in combing is low.
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Cont…
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Cont…
Raw material used here is the same as that for the production of carded yarn.
Yarn count range is medium and sometimes, low to medium .
Percentage noil is kept low (6-14%).
Production in combing is high.
Light combing is also introduced to a greater extent owing to the impairments in
cotton quality influenced by mechanical harvesting.
Even when minimum noil is removed, there is a noticeable improvement in the
fibre parallisation in sliver;
Smoothness and shining of the yarn is improved.
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Combing efficiency
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Types Of Comber
Short-staple spinning mills use only the rectilinear comber with swinging nippers
and stationary detaching rollers.
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Sequence of operations in a Rectilinear comber
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Cont…
(d) The nippers open again and move toward detaching rollers (A)
(nippers forward)
(e) Detaching rollers (A) have returned part of previously draw-off
stock (web V) by means of a (partial) reverse rotation,
So that the web protrudes from the back of the detaching
devices(web return).
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Cont…
(f) In the case of the forward movement of the nippers the projecting fiber fringe
(B) is placed on the returned web (V) (piecing).
(g) The detaching rollers being to rotate in the forward direction again and draw
the clamped fibers out of web (W) held fast by feed rollers( S) (inside the nippers)
(detaching).
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Cont…
(h) Before the start of the detaching operation, top comb (F) has thrust its single row
teeth into the fiber fringe.
As the fibers are pulled through the teeth of the top comb during detaching, the
trailing part of the fringe is combed, thus making up for the inability of the circular
combs to reach this part of the fringe (passive combing by the top comb)
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Cont…
(i) As the nipper assembly is retracted, the nippers open for the next feeding step.
The top comb is withdraw a new combing cycle begins.
(k) Contrary to the movements of the other parts, the combing cylinder rotates
continuously.
During this rotation and at a certain instant the combing segment is brought into the
vicinity of a rapidly revolving brush (K) mounted blow the combing cylinder.
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Cont…
This brush removes the imperfections from the combing segment, and ejects them
into an extractor that carries the noil away to a collecting filter system.
All these mechanically very demanding processing steps are carried out on 8
combing heads simultaneously at speeds of up to 500 mm times per minute. 27
Parameters influencing the combing operation
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Cont…
2. Material preparation:
Parallelization of the fibers in the sheet (batt); Batt evenness;
Batt thickness; Orientation of the hooks.
3. Machine settings:
Feed distance;
Type of feed; Depth of penetration of the top c
Detachment setting; omb
Point density of the combs; Draft;
Circular comb clothing (angles of teeth, density Drafting arrangement settings.
of teeth, etc);
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Cont…
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Influence of the feed stock on combing
1) Parallelization of the fibers in the batt
Lack of longitudinal orientation, i.e. noticeable fiber disorder, leads to elimination
of longer fibers together with the noil.
Loss of good fibers owing to fiber disorder is reinforced to the extent that the
circular combs are overloaded during passage through a disordered batt, so that
they pluck and tear at the stock, thereby carrying away bunches of fibers.
The same happens with a excessively thick batt.
With contrast machine settings, the quantity of noil decreases linearly with
increased parallelization of the fibers and with a decrease in batt thickness
(below the optimum). 31
Cont…
2) Batt thickness (weight)
This effect arises from the retaining power of the fibers relative to impurities,
which depends not only on the disorder of the fibers but also on their quantity.
A thick batt always exerts greater retaining power than a thin one.
At least up to a certain level, the clamping effect of the nippers is also better
with a higher batt volume.
Adversely, a thick batt always exerts a heavy load on the comb and this can
lead to uncontrolled combing.
In this case, the fiber farthest from the circular combs (upper side of the
nipped web) may escape the combing operation,
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Cont…
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The influence of machine components and settings on combing
2) Type of feed
Feeding can take place when the nippers move backwards to the detaching
rollers (known as backward feed or counter-feed), and
Is used when better quality of product is required at the loss of more noil (12-
25%).
Feeding can take place when the nippers move forward to the detaching rollers
(known as forward feed or concurrent feed) during a combing cycle.
Is preferred when higher production rate with less noil desired (5-12%).
Forward feed is mostly used over all staple ranges for achieving noil levels from
8 to 18%. 36
Cont…
One main reason is better “self cleaning” effect during detaching and top combing
action by generating higher retaining forces.
Fiber rear ends and the hooks are more extended.
Disturbing impurities (husk particles, dust and trash, leaf, fiber neps and seed coat
fragments) and short (floating) fibers are hold back by the top comb during
detaching and are combed out by the next circular combing cycle.
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Cont…
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Cont…
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Cont…
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Elements of rectilinear combing machine
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Elements of rectilinear combing machine
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Cont…
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Cont…
Two spiring (8), one each to right and left of the nipper
assembly, generate the required contact pressure for the
nipper closing.
The so-called bite.
The nose (n) is designed to press the fringe downward during
clamping,
So that the fringe cannot escape the action of the circular
combs.
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Cont…
The circular comb:
A cylinder drive shaft (R) extends through the
whole machine, and carries one combing cylinder (D) per
combing head.
The combing cylinder in turn supports a combing segment
(half-lap) (S), which is bolted to the cylinder and is fitted with Fig: Circular comb with metallic
clothing (teeth)
metallic clothing(K).
Since metallic clothing are more robust, they are not liable
to get damaged easily.
Such clothing's require less maintenance
Circumference with wire points are usually 750, 900, 1100 in
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different machines.
Cont…
The Top comb
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The End!!!
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