Assignment on

Simplex machine
Course Code – TE-301

Course Title – Yarn Manufacturing -2 With Lab

SUBMITTED TO
Md. Robiul Islam
Lecturer
Dept. of TE
Daffodil International University

SUBMITTED BY
Jahangir alam
ID- 082-23-874
Section-B
Department of Textile Engineering
Daffodil International University

Date of Submission:
 Study on a Simplex Machine
The Simplex is an intermediate machine between draw frame and ring frame
the main objective of this machine is to convert sliver in to roving for the
convenience of subsequent processes. The sliver we obtain from draw frame
is still thicker sliver which is not good for yarn manufacture. So that the
sliver thickness or the yarn count is reduced by this machine to the required
level. But in this operation main draw back is that the reduction is some
what so high and cannot be obtained from roller drafting mechanisms. The
solution for this is to reduce the yarn count in to a low level but not to the
level required to the yarn manufacture which means the production of
intermediate sliver which is called roving sliver.

There are basic two reason which forces to the use of roving frame.

1. Sliver is thick, untwisted strand that tends to be hairy and to create fly.
The draft needed to convert this is around 300 to 500. Drafting arrangements
of ring frames are not capable of processing this strand in a single drafting
operation to create a yarn that meets all the normal demands on such yarns.

2. Draw frame cans represent the worst conceivable mode of transport and
presentation of feed material to the ring spinning frame.
The objectives of Simplex:

1. Drafting the sliver in to a roving

2. Insert a twist in to the roving

3. Wind the roving in a bobbin

Drafting

The drafting system used in this machine is four over four. This system
improves the drafting and higher draft can be achieved. In this machine the
drafting is very high than any of other machine. So that precautions are
made to improve the draft. In the machine we can observe three drafting
zones. Somehow after the drafting zone both material mechanical draft is
required.

1. Break draft

In here the main objective of the break draft is to improve the fiber
orientation instead of drafting itself in main draft the drafting operation take
place. But for a optimum draft the fiber orientation is very important factor.
For achieve good draft fibers has to be straighten and parallel, this is done by
break draft.

2. Main draft

Main draft is the drafting zone the real drafting is taken place. In here a draft
in high magnitude is taken place. For good fiber control many methods are
used such as aprons pressure bars.

3. Tension draft

The main objective of the tension draft is to maintain better and adequate
tension to the sliver. In this zone actually the finer count for the roving frame
is already achieved but after freeing from front roller nip twist has to be
inserted for this it's important to keep good evenness throughout the sliver.
In drafting we normally keep the front roller surface speed at a constant level
because during the winding process keeping that at a constant level
improves the yarn quality and it helps to good control over roving sliver.

In Simplex draft level often has its over and upper levels of drafting the
drafting is done in between this limits if not each of the case tends to transfer
high masses through the nips. So that the drafting resistance is high and
difficult to get controlled draft. Always the break draft kept in low level
because it only improves the evenness of the sliver.

In this machine two condensers are used in the drafting arrangement. The
purpose of these condensers is to bring the fiber strands together. It is
difficult to control, Spread fiber masses in the drafting zone and they cause
unevenness. In Addison, a widely spread strand leaving the drafting
arrangement leads to high fly levels and to high hairiness in the roving. The
size of condensers should be selected according to the volume of the fiber
sliver.

In main drafting zone aprons are used for further control of the drawing
sliver. In the zone the number of fibers is less and they are given draft so that
any floating fiber content would occur fabric defects and it has to be
avoided.

Further pressure is implemented on main drafting roller to improve the nip

contact and higher nip. Since a high drafting is taken place the possibility to
make slippages is somewhat high this is avoided and prevented to avoid long
term variations in subsequent processes.

Cleaning is one another important aspect of drafting zone since high draft is
given to the sliver short fibers can immune from the main flow of fibers and
then may wind on rollers itself. If this process keep happening the drafting
capability of the rollers are effected through how contact area and lose grip.
So that tow aprons are used to clean reach and every roller during drafting.
In this machine two top and bottom cleaners are used.

TORAL DRAFT = FRONT ROLLER SURFACE SPEED (RPM)/

BACK ROLLLER SURFACE SPEED (RPM)

TOTAL DRAFT= INPUT MATERAL DENSITY/

 OUT PUT MATERIAL DENSITY

TOTAL DRAFT= 40 g/10m

=4 gm/m

TWISTING

Flyer inserts the twist to the sliver. The twist level is depended upon two
factors they are
flyer speed
delivery speed
The relationships between the twist and above factors are given below.

TWIST = FLYER SPEED (RPM) /

DLEIVERY SPEED (meters per min)

The insertion of the twist is done by the flyer when flyer rotates the twist in
sliver is put. Next end of the sliver is connected to the pressure finger and
therefore next end of the yarn which is through fault twister has no choice
than twisting around. Bobbin and flyer are driven separately, so that winding
of the twisted strand is carried out by running the bobbin at a higher
peripheral speed than the flyer.

The level of twist is somewhat very important is subsequent processes. The

requirement of the twist in this level is that the roving sliver is quite thin as it
cannot hold the fibers itself, this causes sliver breakages and small
deformations and elongations in roving sliver may cause long term
variations in ring frame. Therefore it's important that sliver has some
strength to withstand deformation forces and slacks during ring spinning.
Even the unwinding in ring spinning machine also insert some tension on
sliver the sliver tension must be adequate of withstand to this forces

But the excessive twist also influences the economics of the ring spinning
machine. The twist has to be completely removed before the roving is taken
to the main drafting zone of the ring fame. That means there should be a way
of inserting higher breaking draft which is not that much god for the control
of the system as well as the economics.
False twisters are used on the flyers to add false twist when the roving is
being twisted between the front roller and the flyer. Because of this
additional twist, the roving is strongly twisted and this reduces the breakage
rate. Spinning triangle is also reduced which will reduce the fiber fly and lap
formation on the front bottom roller. Because of the false twister, the roving
becomes compact which helps to increase the length wound on the bobbin.
This compactness helps to increase the flyer speed also.

BOBBIN WINDING

In winding process there are several aspects has to be achieved. The buildup
motion consists of several sub categories.

To shift the spindle rail according to the diameter increase

To reverse the trail motion direction at the top and bottom

To shorten the lift length after each layer from tapered ends.

The spindle diameter increases with the roving is being wound on the
package tube. The rotating speed of the spindle has to be adjusting
accordingly to reduce sliver breakages. Sliver breakages occur when the
centrifugal force is increasing with the package diameter. Since the diameter
of the packages increases with each layer, the length of the roving per coil
also will increase. Therefore the speed of movement of bobbin rail must be
reduced by a small amount after each completed layer since the delivery
speed is remaining as constant the only option is to speed down the spindle.
If we reduce the delivery speed instead the economy of the machine goes
down. This is undesirable and must be avoided. To differentiate the spindle
speed according to the diameter special deferential mechanism is used.

To form a package, the layer must be laid next to its neighbors. For that the
lay-on point must continually be moved. The shift of the winding point is
affected by moving the bobbin rail. This raising and lowering is done by
rails. Since the package diameter is steadily increasing, the lift speed must
be reduced by a small amount after each completed layer.
In bobbin winding three separate mechanisms are used to control the
motions and there by
achieve above objectives.

Cone drum mechanism

Reversing mechanism

Buildup mechanism

Simplex frames
For the supply of roving to the ring shed operating in accordance with the
above production program two types of roving hanks have been selected.
Roving hank of 0.80 for yarn counts of 10.20 Ne and 16.20 Ne. and roving
hank of 1.0 for yarn counts of 20.20 Ne and 30.20 Ne. The number of hanks
of roving is generally kept as small as possible. The objectives are to
facilitate balancing of production, implementation of colour scheme and
elimination of mixed yarn production. On the basis of the foregoing
assumptions, the number of Simplex frames required to supply roving to be
ring shed are calculated as follows:

Actual yarn count

20.2 &
Particulars 10.2 & 16.2 Remarks
30.2
Daily yarn production
11, 137.80 26,112.24
(LBS)
Production required
from simplex frames
11,471.93 26,895.61
with 3% waste in ring
spinning.
Hank of roving 0.8 1.0
Twist factor and turns
0.85/0.76 1.0/1.0
per inch
Flyer speed (RPM) 1,100 1,100
Delivery in inches per
1,447,37 1,100
minute
 100% production per
86,15 52.38
spindle per day (LBS)
Actual production Efficiency
73.23 44.52
/spindle/day = 85%
No. of simplex frames
156.66 604.12
spindles required
Simplex
frame with
No. of simplex frames
1.31 5.03 120
required
spindles
each.
Total number of Simplex frames = 6.34 or 7.0

DISCUSSION

The operation of the speed frame is somewhat can be removed in staple yarn
spinning process. We can understand this by looking at the objectives of the
machine. After draw frame the slivers generated is parallel and can be used
to process yarns. But the problem is that the drawing action to convert draw
frame sliver in to the yarn is difficult because high draft has to be inserted to
the sliver. In conventional type roller drafting does not meet this level of
success. Even though they can it's not economically viable. The basic
problem occurs when a incident of high draft is that slippage and the weak
control of the fibers. But using advance fiber controlling devices and using
multiple roller systems there is a possibility of achieving required higher
draft. In multiple roller systems the draft can be distributed among different
drafting zones in to a level of draft which is possible with roller drafting.

The material problems are another factor that influences the utilization of
speed frame. Some staple fibers such as cotton has large verity of variations
from one batch to batch specially matured fiber content and short fiber
content vary. If a sliver's made using this low quality raw materials many
problems will occur even though high level of drafting can be achieved.
Specially drafting waves will make long term variations. This effects can be
avoided using critical carding conditions and thereby
The draw frame sliver cans is a worst way to transform martial to other
places and machines. These hardships are solved by using roving sliver
packages which is small in size and other advantages. In industrial
environment the mobility of packages is very highly considered as a
important aspect, because it has very high influence in economy of the
factory. If draw frame sliver is wound on a package has convenience in
transporting the slivers still there is a opportunity to remove speed frame in
spinning machine line up.

----------------------------