1. 1. Presented by:Md. Nazmul Hassan RayhanDepartment of Textile EngineeringDaffodil International University
2. 2. WARPING:Warping:The parallel winding of warp ends from many winding packages (cone or cheese) on to a commonpackage (warp beam) is called warping.Types of warping:1. Beam warping direct warping.2. Patterns band or drum warping Sectioned warping,(Indirect warping)3. Ball warping
3. 3. TYPES OF WARPINGBeam WarpingA weavers beam may have up to 10,000 ends and if this were to be produced directly itwould be necessary to have up to 10,000 creel packages. Such an arrangement wouldbe very difficult to accommodate and manage ;consequently it is normal practice toproduce wrappers beams which may contain up to about 1000 ends and these arecombined at the slashing stage. Because of the difficulties involved in combining theends ,patterned warped beams are seldom produced on the direct system and anypattern that is produced is achieved by combining beams of various colors at the laterstage of slashing.This imposes limitations which can only overcome by changing to pattern weaving.Sectional Warping ProcessIn sectional warping sections are made sequentially and because of this the process israther slow ;it is the practice therefore to produce no more than is required to fill a singleweavers beam. The result is that the sectional warping is used mainly for short runs orfor complex color patterns.
4. 4. QUALITY OF A GOOD WARPThe essential features of a good warp are as follows:1. Sufficiently and uniformly strong.2. Uniform in cross section.3. Uniform warp tension.4. Uniformly sized.5. Less hairy and clean.6. Minimum no. of knots .7. Proper or standard size and types of knots.8. Free from naps, slobs and loose fibers.9. Parallel arrangement of warp yarn in the weavers beam.
5. 5. IMPORTANCE OF WARPINGImportance of warping:1. Constructions of beam warp yarn.2. Constructions of a parallel yarn sheet.3. Modifying the faults of yarn like thick & thin places, large knotsetc.4. Winding the predetermined length of yarn.5. Combination of small packages.6. Finding long length of warp yarn.7. Accelerating the next process.
6. 6. OBJECTS OF WARPINGObjects of warping:The object of warping is to convert a predetermined number of single end packages,such as cones or cheeses into a sheet of yarn of specified length & width. Theindividuals ends in the warp are uniformly spaced across its full width. The warp yarnscomprise one of the systems of yarns required to produce a woven fabric & also forwarp knitting. The objective at warping, as erroneously considered by many is not at allto remove yarn faults, the breaks due to these being only incidental.
7. 7. WARPING ELEMENTS & MOTIONEach warping m/c has the following warping elements & motion:1. Warping creel for accommodation the bobbin.2. A builder motion.3. A guide reed. Uniformly spreading the yarn over the warp width.4. A measuring motion registering the warping length.5. An automatic knocking off motion to stop the m/c up on achieving the required length ofwarping in case of yarn breakage.6. A drive7. A starting & stopping motion.8. Warping m/c is furnished with package doffers signal devices, blowers. Fluff -exhaustsystem.
8. 8. WARPING PROCESS INVOLVES
9. 9. CHECK LIST BEFORE PRODUCTIONCheck List Before Production:With the production before data control operator will call-up the following forrecording:1. Warp length shift.2. Down time.3. Efficiency.4. No. of thread breaks.5. No. of warp beam doffed.6. Time for thread repair.7. Time for beam change.8. Operator must check yarn quality in term of count, material, and colorwith customer demand.9. Operator must check yarn quality in term of strength and record yarnbreak rate. Standard for good quality yarn 10 breaks/10,00,000 meter.
10. 10. COMPONENTS OF WARPING MACHINEHEAD STOCK:1. Guide Reed : Uniformly spread the yarn over the warp width.2. Adjustable V-Reed : Guides the yarn to follow the fixed path.3. Speed Controller : control the speed, crawl speed or full speed.4. Pressure Roller : Exert required pressure to the warp yarn.5. Measuring Device : Measures the length of the yarn.6. Beam Bracket : Holds the warp beam.7. Emergency Stop Device: For emergency stop.8. Automatic Knock Off : Stop m/c at achieving required length of beamor in case of9. Yarn breaks.10. Electrical Panel Board : To give the automatic controlledfunction.
11. 11. Hi-speed warpingMd.Monirul IslamId:- 133-23-3651Section AB.Sc. In TE
12. 12. High speeded warpingIn this process, the threads are being directlywinding on a beam while unwinding the yarnfrom creel
13. 13. HI-SPEED WARPING MACHINE
14. 14. YARN PATH DIAGRAM OF MACHINEMain Parts:1. Yarn cone or Chase2. Balloon Breaker3. Yarn tensioner4. Yarn guide5. Ceramic guide6. Auto stopper7. V-reed8. Lease rod9. Roller10.Pressure Roller11.Pre-beam
15. 15. Major components of Warping Machine:Warping machine has three major components:1. Creel2. Head Stock3. Pressure roller4. Control DeviceCreel:Parallel creel with travelling packageCreel capacity of SIM fabric directwarping m/c:oNo. of warping m/c: 2oM/c no 1: Both side: 756
16. 16. Symmetric diagram OF DIRECTWARPING MACHINE
17. 17. DIRECT I HI-SPEED WARPING MACHINE
18. 18. HI-SPEED WARPING MACHINEDispoYarn from storeCreelingWarping
19. 19. Working principle of H.S. Warping At the beginning so many beams are preparedas the following equationNumber of beams = In which way threads are assembled showsthe number of beams
20. 20. DIRECT I HI-SPEED WARPING MACHINE
21. 21. COMPONENTS OF WARPING MACHINECREEL:1. Cone Holder : Hold the cone or arrange the cone in the creel.2. Yarn Guide : To guide the yarn.3. Tension Rod : Maintain yarn tension by upper & lower disctensioner.4. Ceramic Guide Disc : To guide the yarn from creel to warping m/c.5. Auto Stop Sensor : To sense the breakage yarn.6. Creel Panel Board : Display where the yarn break
22. 22. Creel:
23. 23. FUNCTION OF COMPONENTS OF CREELFunction of components of creel:1. Cone or cheese spindle for high speed warping.2. Thread guide: To pass through the yarn in the reqd way.3. Tensioner: To keep the yarn always in a uniform tension.4. Yarn cleaner: To remove various faults of yarn like slubs, neps etc.5. Suction fan or blower: To remove the dirt & dust from the yarn.6. Breakage indicator: To indicate breakage in package.7. Stop device: To stop the m/c when yarn will be broken.
24. 24. Control device:Similar to winding, warp yarns are threaded through tension devices , stopmotions, leasing rods and the reed. The stop motion electrically links each warpend to the warper braking system; when a warp end breaks, the warper stops. Alight indicates the location of the broken end. The warping process is generallyirreversible, unwinding, of the beam would cause yarn entanglement. The stopmotion device which can be mechanical or electronic for quick response, is usuallylocated near the creel.Fans are used to prevent lint accumulation when warpingstaple yarns.
25. 25. High Speed Warping m/c Setting:
26. 26. Use of High-Speed Warping Machine Producing one color fabric like gray fabric For producing one/single color fabric For the same count of yarn Example: Shirt , Pant , Polo Shirt etc.
27. 27. Sectional Warping m/c.
28. 28. Sectional warping is a process of preparing warp beam over two stages.First, yarns are wound in narrow tapes on a large drum.Second, the rewinding of the warp onto a beam is performed.Sectional warping machineMain parts :CreelDrum or dresserWarping combWarping carriageLeasing and splitting devices for sizingBeam carrying chuckGuideLevelling roller
29. 29. Features of sectional warping To produce fancy fabric of different colors. Hand weaving used in sectional warping. To produce weavers beam from small amount of warp yarn. To produce weavers beam from twisted yarn. To produce weavers beam from which do not required any sizing material tobe applied before weaving. Weavers beam can be formed immediately after. Production is less, so it is costly process. Yarn tension can not be kept uniform. A tapered beam or drum is used.
30. 30. Process Flow Chart Sectional Warping MachineProcess Flow: DispoYarn from storeCreeling(According to warp plan)Machine setupSection wise warpingBeamingWarp width:Total Ends Warp WidthBelow 7200 1800 mm7200 2000 mmAbove 7200 2100 mm
31. 31. SCHEMATIC DIAGRAM OF DIRECT WARPING MACHINE
32. 32. HEAD STOCK OF SECTIONAL WARPING MACHINE:
33. 33. HEAD STOCK OF SECTIONAL WARPING MACHINE:
34. 34. CREEL DIAGRAM
35. 35. Requirement of warping
36. 36. REQUIREMENT OF WARPINGShould meet the following requirement:1. The tension of all wound ends must be uniform and possibly constant during all thetime of withdrawal from supply packages, otherwise the rate of breakage will beincreased & the structure of the ready cloth will be impaired.2. Warping should not impair the physical & mechanical properties of yarn. The tensionshould moderate to allow the yarn to completely retain its elastic properties & strength.The yarn should not be subjected to sharp abrasive action.3. The surface of warping package must be cylindrical. Therefore, the spreading of yarn(density) throughout the whole width of warping must be as uniform as possible.4. A pre determined length of warping should be observed.5. The production rate of warping should be as high as possible.
37. 37. REQUIREMENT OF WARPING1. The yarns in the sheet should be in uniform spacing.2. The yarns in the sheet should be in uniform tension.3. The yarns in the sheet should be of a predetermined length.4. The sheet should be containing a predetermined number of ends.5. There should be no broken ends in the beam.
38. 38. Faults & Remedies of Warping:Warp off centre of the beam:Due to not carefully placing of creel wraith and flanged beam.Remedy: Beam and wraith placed properly.Ridgy or uneven warp beam:This effect due toWinding of small no of ends on larger beam.When the dents are bent or the spacing between dents is uneven.Mixed count.Remedy: Higher no of ends be used.Crossed ends:Due toFaulty knotting after yarn breakage.Tying of broken ends.Loose warp.Remedy: Knotting and tension controlled.
39. 39. Faults & Remedies of Warping:Snarl formation in the warp:Due toOver tension.Improper twist.Position of guide.Remedy: By proper tension and twist.Missing ends:Due toFaulty stop device.Exhausted cone or bobbin.Absence of cone or bobbin on creel.Remedy: By correct stop device is usedHard beam:Due to high tension.Remedy: Tension and pressure maintained.
40. 40. Faults & Remedies of Warping:Unequal length :Due to faulty measuring device.Remedy: correct measuring device.Broken ends:Remedy: To be joined carefully the yarn.Warp ends round the creel peg.Unequal length of warp.Unequal size or weight of cone or cheese in the creel.Lapped ends.Piecing.Soft end on the warping beam.Warp ends round the creel peg(spindle) and results broke.
41. 41. Causes of yarn breakage in warping:Causes of yarn breakage in warping:1. Weak yarn.2. Sloughing off.3. Over lapping.4. Knots/ bad splice.5. Slubs.6. Loose yarn.7. Pig tail.8. Cut yarn.9. Bad tip cone.10. Short cone