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TFM Lecture 12

The document discusses the five basic mechanisms of the weaving process: warp let-off, shedding, filling insertion, beat-up, and fabric take-up. It focuses on explaining the warp let-off and shedding mechanisms in detail.

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Muhammad Danish Habib
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18 views

TFM Lecture 12

The document discusses the five basic mechanisms of the weaving process: warp let-off, shedding, filling insertion, beat-up, and fabric take-up. It focuses on explaining the warp let-off and shedding mechanisms in detail.

Uploaded by

Muhammad Danish Habib
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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FABRIC

MANUFACTURING
PROCESSES
“Weaving Process”

Dr. Ali Hasan Mahmood


Weaving Machine
Weaving Process

There are five basic mechanisms that are essential for


continuous weaving process.

 Warp let-off
 Shedding
 Filling insertion (picking)
 Beat-up
 Fabric take-up
Weaving Process
Weaving Process Cont…
Warp let-off
 It releases the warp yarn from the warp beam for weaving
purpose.
 The let-off mechanism applies tension to the warp yarns by
controlling the rate of flow of warp yarns as uniform tension
is necessary for weaving.
 Let-off mechanisms can be classified as positive and negative.
 In negative let-off mechanism, the tension on the warp
yarns provides the driving force against friction forces in the
let-off motion. It is mainly used for non-automatic weaving.
 In positive let-off mechanism, the warp beam is turned at a
rate which depends on the yarn length between the warp
beam and cloth fell.
Weaving Process Cont…
 The let-off mechanisms can also be classified as mechanical or
electronic.
 The modern machines having electronic let-off provides a positive
and controlled release of warp yarn from full to empty beam which
results in a consistent warp tension. It is good for preventing fabric
defects such as pick density variation and stop marks.
 Weaving tensions should be maintained at minimum levels for best
weaving performance.
 Electronic let off system have the capability to release the yarn
tension at the stop of the weaving machine and recover it at the
starting of the machine and in this way the overstretching of the
yarn which is the major cause of defects is prevented.
 The system can follow any movement of the machine such as
forward slow motion (jogging) and pick finding motion.
Weaving Process Cont…
Weaving Process Cont…

Warp Shedding
 Shedding is the movement of some warp yarns up and some down to
make an angled opening for the filling yarn to be inserted through.
 The opening is called “shed”.
 Before the insertion of the next filling yarn, the warp sheet has to re-
arrange according to the fabric design pattern so that the required
fabric structure is produced.
Shed Geometry
 The requirements for the shed opening are determined by the filling
insertion and beating motions. According to the figure the
maximum shed opening is given by:
 H = B tan α
 Where H = shed opening, B = the distance between the heddle eye
and cloth fell and α = angle between the warp yarns and fabric plane.
Weaving Process Cont…
 It is desirable to have a small H in order to reduce the lift of the
harnesses and therefore to reduce the stress on the warp however,
the magnitude of H is mostly determined by the size of the filling
insertion device.
 The tension in the upper and lower warp yarns at the shed opening
must be kept uniform to ensure high quality fabric.
 Warp yarns controlled by lifting devices closest to the back of the
machine receive more stresses because they have to rise and
lowered a greater distance to form a clear shed.
 An unclear shed would have the danger of the filling yarns being
caught by the warp yarns or breaking of the warp yarns by the
insertion device.
 Each warp yarn is drawn through the eye of a heddle which is a
metallic bar. Heddles that guide the warp yarns with identical
patterns are attached to the same harness.
Weaving Process Cont…
 When the harness moves up or down, all the warp yarns attached to
that harness moved up and down together.
 The figure shows the plain weave arrangement which requires only
two different set of warp yarns such that during insertion of filling
yarn, one set is up and the other set is down.
 For the next filling, the set of warp yarns swaps their position to
allow interlacing of warp and filling yarns.
 First warp end is drawn through harness 1, the second through
harness 2, the third through harness 1, the fourth through harness 2
and so on.
 The Changing in order of entering and/or order of lifting results in
different weave patterns.
Weaving Process

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