BUSITEMA UNIVERSITY

FACULTY OF ENGINEERING

DEPARTMENT OF TEXTILE AND GINNING ENGINEERING

DESIGN OF COlLER MECHANISM FOR THE CARDING MACHINE IN

THE TEXTILE LABORATORY OF BUSITEMA UNIVERSITY

NAKIYlNGI MOURENE

BU/UG12009/80

[email protected]

SUPERVISORS
1. ;\'Ir. Ssernbatya Martin
2. Dr. Nibikora lldepbonse

This project submitted to the Department of Textile and Ginning Engineering

as a requirement for of the award of a degree in Bachelor of Science in Textile
Engineering

MAY, 2013
 ACKNOWLEDGEMENT

I thank. the Almighty for the gift of life together with the wisdom, 'strengtlt mid courage he
blessed me w j th in my four years of study aug most of a.J1in seeing me through this project.

Special thanks go to mydear supervisors Dr. Nibikora Ildephonse .and Nir: Ssembatya Martin
together with my other lecturers who offered. nie guidance for accomplishing my project. Your
gujdanec added ..a. great <leal o f value to iny work. Thank you indeed,

NtH forgetting my deal' parents Mr and Mrs Ssekadde Sserunkuma Mathias and my elder sister
N,ib1JOSH Irene who are always there for me no matter the situations. Thankyou so much for you r
financial-and moral suP.P9Tt.

I ;l!SO thank all my friends who supported .me materially, morally ami socially espec:.il!lIy
rhroughour all my life in Busitema.Uuiversiry specifically; Frank, Henry, Anita, blISh, Diana,
Shafik phis iill1llY coursemates-androommates. You made life ill Busitema comfortable.
 DEDICATION
.. :'

This project is dedicated to my deaf parents plus my elder sister for their selfless Jove and
support they alway? 'offer me.

..,
11
 DECLARATION

1 'J\K1YI GI MOURENE BU/UG/2009/80 hereby declare that this is my own and original
project. It has never been done or submitted in by any other person in Busitema University or
any other university or institution of higher learning.

Signed: ~.· .

Date: ~.)JC?S.1.l.{j.B..: .

I :( I C If- 1'2.

III
 APPROVAL

I hereby declare that this project of the title 'DESIGN OF COlLER MECIIA us 'I FOR THE
CARDfNG MACHINE TN THE TEXTILE LABORATORY OF BUSlTEMJ\ U\IVERSI rv
has been executed under my supervision and is ready for examination.

Approved by:

I. DR. NIBIKORA ILDEPHONSE

Signature: Date: .

2. VIR. SSEMBATYA MARTIN

Si~nature~ .Datc.Qq(crct~~.~ .

IV
 TABLE.OF CONTENTS

.ACKN.O\VT..F,.D(ir-::'MENT :.. : : : , , ; i; :;.:: i

..DEprC'A T1Q"N:~ , ; : :.: : ,.: · : li

rJEcLAJ~<\Tl(JN ;... :: , , , ; , : , jj'j

,\'PPR{)·V}\.L ,..,-,, c.: : .•..._. iv

i\BSrR/\(:r ,~ : :..:.: ,. : ;.: ; : , 7

.I,JST ()V tA.BIJ~S :..; "..; : , , : .' , " <)

LIST (}F FJellJI{fS , , ;, : , :..,..,' ". , , ro

·1. I:;\iTRC)l)UCTI()N ':.'.; ; : : : , '.' ,..'.; ,,, ; " ..: '" ':': ,. 12'

Ll Background ,..,., , ·.., ~ :..':..; , :."" ,.. 12

1..2 Problem staternent., ~ , \ -, " ' < , ~' " : 1.3

1.3 Objectives ofthe study ,:., ; ; : :;': , : , ,,, e 14

"1.3.i Overallobjective : _.:: ,., ,. ~ '., :..~..: : 14

1.3:2 Specific objectives · , ,;.: :: " 14

1A Justification' :· : :., : , , ; ; :.;..: 14

1.5 Scope nf ihe.stndy ; ,.,.;.; ,'~ "'''':C' ; :" ; 14

1. L.lTERAH.!RE REV lEW , , " , ,; ,.•, ; i5

2.'1 .CarcIing machine , :: : .' :, ;. , ,.. J 5

 2. I. I Technologieal pcints.of the card ..: :, '.' r r : •••••••• , , ,; ••••••••• 15

2.1.:z.. Coiling mechanism forthe card ." : 1.5

2.1.3. Coiling patterns ;·..· , , , : : IG

2.}.4. Workingofa coiler mechanism ,.:, ; : ; _ , '.' ,." ..-... 16

2. L). EffeCts of sliver faults ., : " · 11" " .. 1 , ; 11

2.2., tVlilchjlll'! design .., : -..~; : : ; : ~ r ••• : v •••• , .. ·,.. 18·

-,I_.' 1 ..().
;_.. .'
, VC1:VICW Q 1" I'
"Hlac.uue ..d estgn
. : · ,.~ , .. i , ;.~ :1 0'.

2.2 . .i.. Classification of machine design _ ;.: : IS

"-._._.
"I??'" (Jenera l C.011SI iderati 'M'I"D"
eratrons 111 at nne . esign ; , ; : :: ,., 1"S

2.2.3. General Procedure inMachiueDesigu " , : :..:., : 19

2 ..~. Mechanical drlves. : -: :,· :.:.., : , :.. 19

,
~ 'J; I • (·}I;'i·'I·\I·,'·""
,'~ "'... o 1.. gear dri yes
I~ "~I .' ~ ~~ ••.•.• : '.:.' ••. ~~ •.••• ,.~ •••• t ~ •••••••• :.: ,•••••••• : •••• .., •• " : ,
1(\ ,'./

2::}'2.. TGl'l11s: used in Gears: " Ji.· , .. :.:: •. : ,; ; 20

2.,3.3. Advantages and Disadvantages of GearDrlves , ,.; 23

2.3A. 'Gear Materials ..·., · , :.· :.:.: :., :, ,., : , 23

2.3.5 .. Design Considerations for a Gear Drive : , : :.: , 24

1,;\.6. Bt.v~l gears , : :..· ; :..· :..::.., : ,: :.., , : 24

2.4. Sha Ils .. : : , _ _ " , ..; e •.•. , .' ';'" ••••.• : '; '.":'" 3'0

.'2.4.1 Overview of shafts .,.., : , : ': ..; : r " " .. , .' ~O

2
 .2.4.2. TYI?eS of Shafts ; ",,',,; ..'.' .": V"""" .: .. t ".""'" .••_., ~,. ;. " ,.; .. II

2,4,3, Standard Sie:9S of Transmission Shafts " .." "" ,.." ..""'; .;, " .., .3.1

2.4·.4. Stresses in Shafts :, .., " · ; :..: : , 31

'2.4.S. Maximum Permissible Working Stresses for Transmission Shafts " ,31

2.4..6: Design of.Shafts : _ n< ; " :: : .. :. 31

2;5: Rollingcontact bearings , ; : ,' : ..: , , , ,., , ·..:.33

25.1 Overview oftolling ..contact bearings < ; ;: .. ; ••• " < :.".: " ~3

2.5.2 Types ofRolling Contact Bearings , , - " , ; i ; 33

2.6. Springs '; , ,; , e •• , ,,, , •••• , :', •.••• ,. " .•• , 41

2.6, J Overview of springs , , " ;." " ,:.~.;" qJ

.2.6.1 TYlidS of Spr;llg$ «; ; ; ; · , " " <" " .. " : 41

2..6.3 Ma·l~ri~tlfor Helical Springs , , , , ; ,,, , 42

3. rvIE~rll()r)()LOCj'Y ..,., , , :: ; ,,: , 45

3..1 Over view.. .' " ;.,' ": ..: ,:..,, : , : 45

.\ 1J Design Considerations _ ;: ; " : .'".,( , .45

3,1.2 Design Tools and Resources " ;.., : : .,..,._" ,.4:>

J) Detenuiuarion ofthe doffel' speed ..,..., : , " r , 45

3.3 Deiernuuation of the web draft, ; ;.,' : 46

J..{Dctcrminf}ti()l1 ofthe driving mechanism : ;; 47

.....
.)
 3.4.1. Overview , , ;.: , , r: :» , 47

3A.2 Gear specifications ,.., ,:, ,.,.:., : ,..,. , ,.. : , .,., ' ,.: , 47

Calculations lor spur gear dimensions .. , , ,', , , , :.." ,~ 47

JA,J Design of the.transmission sbaft , , ,.:..: ,.., ,': : ,_.. 49

Selection of'bearings f .. ,;., ; ••.•,'.,.,-,': .. ,', •••• , .•••••• ~ ,' : ;. , ....•••.••• .:.. : ,.: :, .. , 50

35 Designing. of the other components of the coiler .mechanism ":.".." ~"..,: ". 50

.:U.l The definition of problem , ,..,..,: :,..,' , , ,::.., , ,'· " 50

1 - ? S·
0")'-' ificati
ipecificauons . a '101:
e.onSl·d·ere· "'1 rpart
.t':. eac .:.' d ..
. esign eel ': " 50

1.5.3. Synthesis (mechanism) , : , , > ••• ; ".: , , ,. 5I

'3.0 (\)::;t estimaiicn.x., , -: ,..: .' : , t ,' ••••• , , , '.' .•• '''., ; " ":''' .• ,, ;).J

4. RESULTS AND DISC(JSSIONS ; "., · ", ,.; , 52

4.1. Parts modified : : , .'..: , ,' , ,' ·..; ;,: : , , 52

4.2. Driving mechanisms ,; : .v , ••• , ,: .. , ••••.•••• ,'' , 53

4~2.1. Layout ofthe gearing system: AutoCA1) drawing .:.." , " 53

4.2.2. Explanation ,.." " ..;,.· , L :~· ,', ...''''" ,' i." 53

4:3, GG~ii' specifiearions.. " " , ,..,.., ,..,., ;.."" /." :..; :..: , _ ,54

4.3.1. Gear Material ,', ,; :.: , ,..,-., 'w ;,.~,,';,; '54

4.3.3 Calculations for gear diameters ..,' -;.., " " l'," •.•, ",: " ,.55

Dimensions- ofth« bevel gears measured at the largesttooth section., , ·" · 55

4
 4.4, Transmission shafts specifications.i..... ..", .." ", · ,., ·,." :..56

4..4.2 Ti1l'ee dimensional drawing for the shaft with itsforces. ; ;;.. ;> , : ,.. 56

-4..4.3. Bending moment diagrams .., : ;.: ; ,'" : , , ' 57

-4.4A Checking forthe critical speed :of the shaft ".; 5.9

4.4.5, Shall keyway 'design ,; ''';_''~:''-''''''''_'''':'''''''' ,. '.' s. 60

4..4.(L Selection of'bearings ,'v- ,', " : :" ••••• '."' .. , "t. " ,.,.~.,. 00

4.4.7 ..Lubrication. ~ , , ,: ,..; , y. ".'" '_. " ••••'." __ : , .•.••. , :.,'•• 62

4.5·, Speci fications ofother components of the. coiler mechanism ~' , ,,' 62

4,5.1. Trumpet design :.., " ,.., , " " ; ,., ,:" ,,,"",' ,..61

!J·.5.2. Turntable design , " ": : ,,.,' " ; :, ;., " ()3

4.5.3. Fted plate :, ,.." ,., , : ; =:'>:': , , , •., ()~

.4.5.4. Calendar rollers ' ;;,." , ,.; ,,,..,..,.,.:' , ,' : ",.," : (i4

4.::,.), .(~ojler phi.tc ,:..", ..:." '.','."" , , ', "..: ,,'..;..: -.' ,. , ,.,'.., (14

4;5..6, ..Coller. tube " ,',, ,, : , ', ;..· ,.1 .•.• , : : 65

4.:5'.7,Can size ;,",' , ,..,: , :.., , , :" ..:, " 65

4.5,8 .. Can spring ; , , :..:., , , , , , " , ,.., ;, ; ,.. 67'

4.7.•Synthesis (mechanism) and machine assembly : : , , " 67

5. 'C(;)~t <lS tinmtion ,,; ,,,..,., : ; _...:. , ,',.~ ' " , "".: ,:." .:.: ,.. 7Ci

(i. Challenges, cQl1cI.USiQ)1S and Recommendations : , , ,., " TJ.

5
 6.1 Challenges ..; , , ,..: , , : , : : v- , , ,;,.,' 72

6")...; ~. one 1llSton~._

. ...'.. : : · ; :.,.: ) : , 72.

6.3: Recommendations , ;
.v- : , : .. : •• ~ •• : • 0 • • ;.· : ••• 72

References , " " t , •••• , : ::." , •••• "':" ., , •••••• 73

Append ices : '.','.''::::..; ': , _ : ,..'74

;.

6.
 ABSTRACT
During fabric prod uction , subsequent processes namely; spinning, weaving 01' knitting, wet
processing and garmenting' are followed. 'Spinning process has the blow, carding, draw frame,
combing (oprional], .speed frame and finally ring frame for formatinn of yam , Cai'(liilg is kl10\\,11

to be the heart of spinning since a fault in the carding process affects yarn quality. TJ1C purpose
of .cardiug is tCi; individualize fibres, eliminate impurities, reduce neps, eliminate ()J' 'dust, and
short fibres, blend fibres, orientate fibres-and finally sliver formation.

On 17ilt J,hi(firrv, 20 13; Busitema University

• .' , .' '.,J
textile laboratorv received various machines from
• J" '"

W/\GTEC'H, UK under the MSI Textile Engineering Project. Among these machines is a mini
card (code 337A). This mini cajding machine 'does not perform an the, functions of carding; it is
limited to web formation thus misses 'out on the formation .of card sliver, The slivel' is tim;::
manually formed from the 'web -by the machine. operator using handsby folding. This makes t11C

sliver fcrmation process; time coasuming and exposes the sliver to numerous 11\111la11 errors
related re foreign rnatrer or imperfections f91111e,<;! during folding. This.project therefore provided

a solution to the above problems by introducing' 'n coiler mechanism to 1)le machine which
continuously fOl'l11S' carded sliver.

Tbe -drum originally used to collect the web' became irrelevant 'hecause the web was to he
condensed by the coiler mechanism into sliver thus no more need for weh colleetiou. Therefore,
the drum was thus ~o beunscrewed off the machine together with its drive, The components of
the coiler mechanism were designed (basically size, shape and material select ion), 'i'he:
components considered ill this 'case 'included; "gears formoriorr transfer, shafts, bearings, tb,i;;d
'plate, trumpet, calendar rollcrs.icoiler tube, coiler plate, card can, tum (able and coiler post plus
machine frame, The wholecoiler mechanism was drawn and assembled using solid edge and 3-D
AutQC'AD 2007 as-the design tools,

However; the .project was too 'big because the mechanism had so many CO 11:1ponents. Also,
literature on specific design of so many textile machinery parts is rareherrce basic mechanical
engineering design-considerations were made.

7
Despite the challenges, the: toiler' mechanism for specifically the. mini carging machine in the
textile laboratory of Busitema University was successfully .desigued and with an the parts-as
ll'icnlli'il1cd earlier. The-drive was picked from the doffer then given to the calendar rollers, coiler
plate .antl turn table throu gh gear drives with help ·of transmi ssion shafts.

Recommendations have also been made. Hi both the. university and. Textile engineers in.Uganda.
For the university to take lip this project for implementation because of its advantages discussed
in the. report and for textile engineers to work J)~r~dill hand with mechanical engineers to start 1I1)

textile machinery manufacture-in Uganda so asto enable acquisition textile machineryat reduced
costs since importation.costs will 'Qedogged.

8
 LlST O:FTABLES

'fahle 1.1: Mechanical propenies ofsteels used tor shafts :..: :_,; ,,, , , : 30

Table 2.2: The principle dimensions for radial ball bearings/source; R.S Khurmi and ..l. K.C,hlpta.
·2006.) ,.: ., , ,.:.:..: , , , : " _. 37

'J"ab:li2.3: Values of Xp.aild Yo for-radial bearings (source: RS Khurmiand ~U(_GPf)l8•.1006). 3.8

Table 2.4: The life of bearing's for various types of machines (source: R.S Khuirni an~l
J.I(.O·upta, 20()6.} ~ ; .'.' :..; : , ; , 39

Table 2.5; Values of X and Y for dynamically loaded bearings (source: R.S Khurmi and
J.l('.Cilipta, 2.006) .., : " !., ; : .-: ,., , :.. -40

Table 2.6: V,~hISs of allowable rnodulus of elasticity and ruodulus of rigidity (or various spring
I1Hl1.Cri-aI.$ , " , , ,. ,.: ; '"', : ,.:. ,: : _ ,.: , _.. 43'

Table -2.7: Standard' wire guage (SW.G)nun1bel:an~ coriespondingspringdiameter 43

T.able 3J.:.TabJc showingparameters of the web formed 011 the drum : ~ , ·.:40·

Table 4.1: Spur gear proportions as pet calculations. (based on proportions of standard involute
.teeth (Y. R Bhandari, 2007). , : , ,; : : ;, : ) 55

'1'.n) I ._:·a~ e
I Ie 4 ') '1"bl. t:
1.01' en Iell 1ate d sp~r' gears' "soecifl '.
sp.eci icauons : : "., ..,., --
).)

T~lbJe-4.3: Table for bevel g~ar dimensions ; :,.., ~ :, 5p

·l'rthk'4.4: Table! for calculated -transmitted torque and force ..components for bevel gears SCi
 LIS.T O~FFIGURES

Figure 2.0.1.; General.idea ofhow a coiler.works , ;., , -: i6

Figure 2.2: shows. the terms used in gears (soure: R,:S.Kfmrmi and JK.Gupl~o:.l.·200.6)., ; 20

Figure 2.3: Terms used' ii1 bevel gears: Source: (R.·S·. Khurmi and J.K.Gllj)ta,.2()(j(j), is
-,

Figlil'e 2.4: Development of-a back conef source RS Khurmi and J.K..G.uPla, 20(6) ...... ,....;.... :.28

F·Igure "'::).:.,
') - F'on;:.es acting
..... on a 1"'1
)eye gear ,.., , ;.., ;, : :., :', ?<)
-c,

Figure :2:6: ball ami roller bearingstsource: RS .K1111rnli and ,J.,K,Gupta, iOQ6.} _ _ 34

Figure 2.7: Thrust and ball bearings (source: R.Sot(huhnl and lK.Gupta, 2006) ,'., 34

Figure 2.8: Types ofradial ball bearings (souro:e: R.S Khurrni and lKeJupta, 2(06) , 35

Figure 2.9: Standard designation of'ballbearings (source': R.S.Khl111111 and lK.OuJ}la. 2006 ).: 36

fil'!urc 2.1 I); Hd ical springs (source: R.S· Khurmi arid J ,K.Gupla, 2qO(i) , "'" " ." _ , 4·}

Figlll:e 3.1: Drive to the rlofter ::..": , "' ~ :.:..,,; :..,, 4(\

Figure 4.1: Drll111 initially used for web collection.. ..:;, : ..".,,, , : :.. ".' 52

I'"
'lgl1!'.e 4?
.._: (",.,
};Jca}'J.ng· d'tagram
.. t'or t hee desi
(eslgll , r » » : ••••• : ·.; , : ,,, :
<; '\
•••••

Figure 4.3:"3 -D drawing for slraf; forces :c., . : " , : , , , 5.7

)tlgt!!,0'4.4: force diagram, X-Y plane "' : ,: :, , ": , ,..5.7

FigurcA:5:' Bending J11~)mel.lt diagram, x-y plane : ; , , " ,., ..58

I",
'lgLlJ'I:!' 4 ·..0 '1"
r::··:Ii.l:ce diJa.~r<.lm·lor
r. Z·
..~·Y I'
plane .....,......... " ... ,,,........ ,.....·,,.,.......... ,.::..·........ , ...... ,,_ ....... , -» " .. co
:)C).

Fygllr~'-4.7:: Bending momentdiagram , " , , , , ; 59'

']0
Figure 4.8: Isometric drawing :.: ; ;.." _ ~.,., _.68

Figure 4'.9: The whole rrtaohineafter assembly , , , c :, 68

Figure 4.1(}: Front' view ·of the assembled drawing , .: , ; ;.. 69

1J
 1. JNTRODUcriON
1.1 Background
In textile manufacturing industries for fabric production, the: following processes are generally
subsequently followed namely; spinning, weaving Dr knitting, 'wet processing and garmenting.
Spinning process 11'.. s the blow 1:PQm for opening and Cleaning of fibres, carding fer
individualization- of' fibres and formation of cardsliver, drawframe for alignment of fibres and
removal. of hooks from carding; combing (optional) tor further alignment and blending, speed
frame For formation 'of roving and finally ring frame.for formatiorr of yarn,

Carding is' known to he the Matt of spinning.since a faul(in the carding' process affects yarn
quality. The purpose of carding is to'; open tile, flecks into individual fibres, 'clean OT eliminate
impurities, reduction of neps, elimination of dust, elimination of shorr fibres. fibre blending, fibre
onentation or.alignment und sliver formation.

The main _parts and important regions 'Of the carding machine are; feed plate which feeds the
fibre 131)to the. feed roller, This thenfeeds the fibres to the licker-in. The. licker-in has an under
, , '

casing, which carries out eliminationofimpurities before transfer of.fibres to the cylinder. Above
[he cylinder are flats and between the cylinder and flats the' following tale place: ()penillg or
flocks to individual fibres, elimination of remaining. impuritiestttash particles). elimination of
short fibres, (neps also removed with short fibres), untangling the neps, dust removal !,m,d
longitudinal orientation of the fibres, Th~ main work of-the card is.individualizarion of fibres.and
it is done between the main cylinder and the tints only. By moans of this fibre separation, it is
possible to eliminate the fine dirt panicles. and dust After the, mai 11 carding action, the fibres OJ)

tho cylinder wire points are, carried around to, the nearest point between the cylinder and tho:
.doffer hence. web Iormation. The web then goes through the calendar rollers which rhen Iced it
to the coiler mechanism for sliver formation (Prof. A. R" Khare, '1999),

.Ugunda has some few textile mauufacturing industries among which are; southern rangc.Nyanz»
textiles ill Jinja and Phoenix logistics in Kampala. These industries carry out all the above
mentioned processes. There are no textile machinery manufacturing .industries LJt!ancja mainly
because of the high technology required for the textile manufacturing processes and the high

12
 REFERENCES

1. Prof. A.R. Khare, 1999. Elements of carding and drawing. Textile Manufacturers
departments, V.J.T.l, Mumbai-400019.
2. R.S Khurmi and J.K Gupta, 2006. A textbook of machine design (S.I Units) by Eurasia
Publising House (PVT) Ltd, Ram Nagar, New Delhi- 110055.
3. Budynas-Nisbett, (2006). Shigley's Mechanical Engineering Design, eighth edition, by
McGraw-Hill Primis.
4. http://textilelibrary.wordpress.com. (4/08/2011, 1:42:08). Card construction, setting and
clothing
5. v.B. Bhandari (2007). Design of machine elements, second edition, ISBN-0-07-061141-
6,976-0-07-061141-2, published by NcGraw-Hill Company.
6. R. L. Norton, (1997). Machine Design; An Integrated Approach. (Einstein College of
Engineering, Sir.C.V.Raman Nagar, Tirunelveli-12)
7. V.Tamilarasi (2004). Strength of Materials. (Lecture notes Prepared by Department of
Civil Engineering).
8. E. J. HEARN(2000). Mechanics of Materials I; An Introduction to the Mechanics of
Elastic and Plastic Deformation of Solids and Structural Materials. Third edition.
9. Joseph E. Shigley and Charles R. Mischke, (1996). Standard Handbook Of Machine
Design, Second Edition.
10. J.D. Booker, M. Raines and K. G Swift, (2001). Designing capable and reliable products.
11. Micheal. F. Ashby, (1999). Material selection in Mechanical design, Second edition.
12. hllp: textilelihrarprordpress.com,28/02/2013
13. http://asiancotton.comlftles
14. http://www.freepatentsonline.com

73