Cairo University Faculty of Engineering Industrial Training MDE Department Year 4

Cairo University Industrial MDE Department
Faculty of training 4th year

Engineering
Report
Submitted By Omar Mohsen Submission Date:

Abd El Azim
Checked By Dr chahinaz
Dr.Ihab
1.2Acknowledgment:
Host: El Medani for spinning and weaving
Faculty supervisors: Dr.chahinaz Abdelrahman, Dr.Ehab Abdel Ati
Technicans: Ibrahim,Mohamed
Engineers:Abdelbaset,Abdelhadi
1.3 Executive Summary
This report is intended to show and discuss the efforts done by the
student: Omar Mohsen Abd EL Azim during the industrial training and
what is done in each department and what were the main targets of the
training
Introduction about spinning and weaving industry
2.1 definitions
The process of spinning: it is the process of twisting together fibers or

polyesters (polymer) to form a yarn spinning is one of the most
important processes in the textile industry as yarn is used later to form
textile.
On the other hand weaving is a method of textile production
In which two distinct yarns are interlaced at right angle to form cloth.
Types of yarn used in the textile manufacturing process
Vegetable fibers: ginning, fiber blend, carding, combing, spinning (that is,
ring and open end), and twisting ·
Animal fibers: scouring, fiber blend, carding, combing, spinning (ring),

and twisting · Two
Mineral fibers: spinning, twisting, and sizing · regenerated natural fibers:

carding, combing, spinning (ring), and twisting ·
Manmade fibers: carding, combing, spinning (ring or open end), and

twisting
There are processes that are important and will be mentioned in other
section such as: Mercerizing, Bleaching, Dyeing, Printing and Stentering
(Environmental, Health, and Safety Guidelines for, 2007)
2.2 histories about textile industry
The textile industry is one of the oldest industries worldwide as it has

deep roots in history. It began with Neanderthal man who realized the
necessity for something to cover and protect his body from the harsh
elements of nature. Egypt is considered a pioneer in the textile industry
as its history dates back thousands of years. Through the different
decades and with the support of different successive governments, the
textile industry has developed to become a major pillar for the Egyptian
development. (Matar, 2010)
3-Introduction about the place
3.1 information about the company:
Location: 10th of Ramadan
Telephone: 0554413120
Processes: spinning, weaving, Stentering and dyeing
Administrator: Samir el Medani
This place is certified by EOS (Egyptian organization for standardization

and quality)
4- problems and explanation
As I am a mechanical design student my role in the training was a junior

trainee in the mechanical maintenance in the workshop of factory it was
a good chance as most of the machines there was purely mechanical
(the power was by ac electric motors) and this chance gave me an
approach to apply what I have learned in the college but this doesn't
mean that all faults were mechanical only as I faced some electrical
issues as faults in the inverter of the motor also I faced some problems
in the control circuits of machine(relay,faulty wires,….etc.) and this was a
very important experience for a mechanical engineer to deal with
electric drives , electric installations and controllers(PLC) in the following
section more details will be given as it will be clear for each department
what I have learned and what are the technical issues of the factory.
5- Training details&learned information:
In this section particularly different departments will be determined as

what I have done in this department.
5.1 weaving
In this department I have spent most of the time of the training.
First machines of this department are going to be mentioned
1-Liba machine
2-Karl Mayer machine
General perspective of winding machine concept of working:
The winding process - winding and spool drive: (Bobbing winding

machine) the spinning thread is conveyed by the guide wheel
To the front end of the rotating arm. Before entering the winding, it
should be rotated by the rod
And perpendicular to the thread splint. The front end of the spun yarn
and the winding around the
Rod to make it in the next winding process spinning will not lose.
Winding machine winding
System The machine arm is wound around a spinning thread. After the
system is initialized, the
Swivel arm is waiting in the initial winding position and is rotated by the
rod to the winding position.)
The swivel arm is wound 10 turns slowly and stops and the scissors are
closed to cut the last
Wound coil. Rod rotation of a certain angle, the rotating arm quickly
winding thread spinning, after
A certain period of time to stop the rotation of the rotating arm
(repeated a number of turning and
Winding process), the coil after molding, the rotating arm to stop, this
time by the rod with the
Initial position of 90 (On the front of the line plate), the board on the
splint and scissors open, by
The top of the bar to move forward, top off the previous round around
the good line, sticker conveyor
Belt will be a piece of paper to the line under the plate; the splint is
pressed and moved by the bobbin
To be separated from the bobbin, and the thread splint is relaxed and
will be rotated by the rod to the
Initial winding position.
General perspective of knitting warping machine:

First let's mention the three important parts about knitting warp
machine.
1-warp yarn guide bar
2-needle bar
3-laying in bar
Motor drives the three bar through gearing &using link, cam
First when the motor drives the motor pulley, motor pulley drives the
main shaft through the intermediate pulley and from the main shaft
goes to three different bars one motion transfer to the needle bar
needle bar gets transverse motion through link another motion goes to
the warp yarn guide bar to give motion, warp yarn guide bar gets a
swinging motion from the link which is connected with needle bar finally
last motion goes to laying in bar, there is a pattern cylinder where
pattern link chain is mounted on it a follower is placed on the pattern
link chain which moves.
Figure 1 carl mayer wrapping knitting
5.2 spinning
The working
principle of
spinning
machine: The
roving
bobbins are
inserted in
holders on
the creel.
Guide bars
guide the
roving's into
the drafting
system ),
where they
are drawn to
their final
count. The drafting system is at an angle of 45-60° and is one of the most
important units on the machine, since it exerts a very considerable
influence on the uniformity of the yarn in particular.
After the resulting thin ribbon of fibers leaves the delivery roller, the
twist necessary for imparting strength is provided by spindle rotating at
high speed. In the process each rotation of the traveler on the spinning
ring produces a twist in the yarn. Ring traveler is also necessary for
taking up this yarn onto a tube mounted on the spindle. This traveler - a
remnant of the flyer on the roving frame - moves on a guide rail around
the spindle, the so-called ring .The ring traveler has no drive of its own,
and it is dragged with spindle via the yarn attached to it. The rotation of
the ring traveler lags somewhat behind that of the spindle due to the
relatively high friction of the ring traveler on the ring and the
atmospheric resistance of the traveler and the thread balloon between
yarn guide eyelet and traveler.
This difference in speed between the spindle and the traveler results in
the thread being wound onto the tube. In contrast to the roving frame,
the ring spinning machine spindle operates with at higher speed than
Figure 2 spinning process the traveller
.The yarn is
wound up into a cylindrical cop form by raising and lowering of the rings,
which are mounted on a continuous ring rail. The layer traverse of the
ring rail is also less than the full winding height of the tube. The ring rail
therefore has to be raised slightly (shift traverse) after each layer has
been wound. For a time, machines were also built featuring shift
traverse produced by lowering the spindle bearing plate rather than
raising the ring rail. These machines are no longer available today.
Figure 3 spinning machine
5.3 stenter
A Stenter is a fabric transport device for bringing dimensional stability to

the fabric. This machine grasps fabric at both selvages simultaneously
and continuously and carries it from one point to another. Two endless
chains equipped with either clips or pins grasp the selvages and move in
a proper way, carrying the fabric between them. The width between the
two chains can be automatically adjusted by means of motor
arrangements. A stenter is the best method of handling fabrics that
require precise width control.
Activities that are carried out in stenter machine

1. Application of finishing chemicals
2. Drying and stretching
3. Curing
4. Heat setting
5. Pigment dyeing
Mainly the stenter that was in the workshop is Bruckner the parts that
were included in the machine.
Inlet J-scray: This part is used to store the fabric during the batch change
and Inlet unit contains various parts like tension device, draw roll,
pressure roll and break roll.
Padding mangle: It contains chemical trough, guide rollers and squeezing

mangle. Fabric is dipped into the finish chemical then sent to squeezing
mangle. During this time finish chemicals are applied on the fabric and
squeezes out extra chemicals from the fabric.
Weft straightener: It has two bow and three skew rollers which correct
the skewness and bowing and make the weft yarns straight.
Over feed system: To give over feed or under feed of the fabric to
respective chain track.
Inlet chain track: To aid proper pinning or clipping of the fabric
Drying chambers: To dry the fabric or to fix the finishing chemicals by

hot air from the blowers. The blower sucks hot air from radiator and
blow it into the nozzles through which drying occurs. Inside the drying
chamber also contains width adjustment spindle and pin/clip chain track.
5.4 compressor room
The compressor type is screw compressor as it is a good compressor for

a high pressure of large volume of air application.
The company dealt with is Atlas Copco
The unit dealt with was GA160 maximum pressure 10bar
Input power 166kw
Rotational shaft speed 1488r/min
Single stage (copco, 2010)

6- Achievements
First of all it was very important to deal with machines by assembling

and disassembling machine parts maintaining them as the practical
issues are always missed in the university. Dealing with technicians,
engineers and labors also increased my experience in practical life and
knowing the industrial environment how to deal with risks and hazards.
Also being a part of environment to attend at a certain time and leave at
a certain time is also an important behavior, as at the end I was pleased
that my seniors were pleased with my performance and behavior during
the training.
7-How the IT complemented the academic study:
IT complemented the academic study as there is no real in depth

practical workshops nor direct dealing with machines in the university so
it was very good to see machine elements in real life application.
8-Conclusion
All in all the training was very crucial and I trained in maintenance
(mechanical&electrical) dealing with spare parts, assembling,
disassembling, analyzing and seeing drawings. Also analyzing the
environment is very important seeing its advantages and disadvantages
many thanks to the University for the Meaningful Courses that I took
and applied in the industrial field.
9-References
Bibliography
(2007). Environmental, Health, and Safety Guidelines for. international finance group.
copco, a. (2010). ga160 manual.
Matar, S. F. ( 2010). An exploratoration into job satisfaction and motivation.

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Cairo University Industrial MDE Department

Faculty of training 4th year

Submitted By Omar Mohsen Submission Date:

Host: El Medani for spinning and weaving

Faculty supervisors: Dr.chahinaz Abdelrahman, Dr.Ehab Abdel Ati

1.3 Executive Summary

The process of spinning: it is the process of twisting together fibers or

On the other hand weaving is a method of textile production

Types of yarn used in the textile manufacturing process

Animal fibers: scouring, fiber blend, carding, combing, spinning (ring),

Mineral fibers: spinning, twisting, and sizing · regenerated natural fibers:

Manmade fibers: carding, combing, spinning (ring or open end), and

2.2 histories about textile industry

The textile industry is one of the oldest industries worldwide as it has

3.1 information about the company:

Location: 10th of Ramadan

Processes: spinning, weaving, Stentering and dyeing

Administrator: Samir el Medani

This place is certified by EOS (Egyptian organization for standardization

4- problems and explanation

As I am a mechanical design student my role in the training was a junior

In this section particularly different departments will be determined as

In this department I have spent most of the time of the training.

First machines of this department are going to be mentioned

2-Karl Mayer machine

General perspective of winding machine concept of working:

The winding process - winding and spool drive: (Bobbing winding

General perspective of knitting warping machine:

Figure 1 carl mayer wrapping knitting

Figure 3 spinning machine

A Stenter is a fabric transport device for bringing dimensional stability to

Activities that are carried out in stenter machine

2. Drying and stretching

Padding mangle: It contains chemical trough, guide rollers and squeezing

Inlet chain track: To aid proper pinning or clipping of the fabric

Drying chambers: To dry the fabric or to fix the finishing chemicals by

The compressor type is screw compressor as it is a good compressor for

The company dealt with is Atlas Copco

The unit dealt with was GA160 maximum pressure 10bar

Input power 166kw

Rotational shaft speed 1488r/min

Single stage (copco, 2010)

First of all it was very important to deal with machines by assembling

7-How the IT complemented the academic study:

IT complemented the academic study as there is no real in depth

copco, a. (2010). ga160 manual.

Matar, S. F. ( 2010). An exploratoration into job satisfaction and motivation.

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