Instructions for students following TTX3255 Woven Fabric Technology I

This level 3 course in woven fabric technology replace the course TTX3233, which had been offered until the academic year 2009/10. The new course had been developed from scratch and it has a completely new set of lesson material. Broad aims and objectives After completing this course, one must be able to employ the processes of yarn preparation and weaving for economical production of quality woven fabrics as well as to manage such work. He/She must be able to select most suitable machines to produce different woven fabrics once all the fabric parameters are known. Broad teaching strategies Credit Rating Total Study Hours Breakdown of study Hours Component Printed materials Tutor Marked Assignments Lab classes + Report Writing Day Schools On-line activities Continuous Assessment Tests Final examination Total Continuous Assessment Tutor Marked Assignments = Continuous Assessment Tests = Lab tests and lab reports (course work) No. of units 38* 03 06 03 05 Time per unit (in hours) 02 08 04 03 03 Total time in hours (No. of units X time per unit) 76 24 24 09 15 6 150

02

1.25

02.5

01

03

03 153.5

* Numbers of sessions in printed material 03 02

Eligibility Criteria Final CA marks = {(0.3 x Best CAT) + 0.3 x [(0.4 x Best TMA /Second Best CAT) + (0.35 x Best TMA /Second Best TMA / Second Best CAT) + (0.25 x Second Best TMA / Third Best TMA / Second Best CAT)] + (0.4 x LAB Average)} 40% LAB Average = (0.5 x Average marks of of 3 lab tests) + 0.5 x Average marks of 06 lab reports) Final Examination Essay Type and Short Answer Type Three Hour Question Paper

Assignments TTX3255 Woven Fabric Technology I -

2012/2013

Assignment I This assignment is based on the course content of the first three units of the lesson material of TTX3255 Woven Fabric Technology I. These three units deal with weaving preparation, which includes warp and weft preparation. You must study all three units before attempting to answer questions of the assignment. Date of submission of the assignment: 03rd August 2012 Send your assignment to the following address: Course coordinator TTX3255 Woven Fabric Technology I Department of Textile and Apparel Technology Open University of Sri Lanka Nawal, Nugegoda The Objectives of this assignment Improve your ability to distinguish different fabrics and identify their properties. Discuss the influence of properties/characteristics on end-uses. You must be able to explain the process of weaving and know all the important parts of a weaving machine. You must be able to explain the basic structural parameters of a woven fabric and identify different basic weaves. You must learn the importance Winding and Warping and different methods of Winding and Warping. You must learn to calculate yarn crimp and warp and weft yarn requirements for a known fabric and explain the importance of warp sizing and why only warp yarns usually sized. Question 1: Collect the following samples of planar structures: A woven fabric used as umbrella cloth A woven fabric used to make ladies blouse A shoe lace A knitted fabric used for vests A polyethylene sheet used to parcel food (lunch sheet)

Compare these five types of planar structures with respect to following properties: -Mass per unit area -Fabric hand (How you feel when you touch them) -Stretchability -Elasticity -Air permeability -Water absorption -Fabric structure a) Tabulate these properties and discuss the suitability of these fabrics for intended end uses. You must submit your fabric samples along with the assignment. b) Analyse the umbrella cloth and try to identify the following: -Warp density and weft density -Nature and type of warp and weft yarns -Structure of the fabric c) What are the most significant differences between the shoe lace and other woven /knitted fabrics? d) Which of the above materials can be considered as textiles? Elaborate your answer. Question 2: Visit a place where fabrics are produced using hand looms. Sketch the hand loom and describe how hand loom weaving is carried out (You must also explain how warp and weft yarns are prepared). Question 3: a) Define the Following terms Crimp, Weave, Plain weave, Twill Weavel b) Warp and weft yarns have been removed from a fabric piece having 10 cm x 10 cm dimensions. The de-crimped lengths of the warp and weft yarns were measured as 111 mm and 114 mm respectively. Calculate the fractional and percentage crimps as well as the crimp factors of the warp and weft yarns. Question 4: a) Why do we carry out winding operation? b) Sketch three yarn packages suitable (i) to be used as weft package in conventional shuttle weaving (ii) to be used as weft package in shuttle-less weaving (iii) to be used as warp package for weaving Name the three packages you have sketched, and explain how package stability is ensured in each of the above cases. Question 5: a) Explain the two warping methods, beam warping and sectional warping. b) What is the function of creels? Describe three different types of creels and compare their advantages and disadvantages.

c) An order for 80,000 m of the following loom-state fabric has been received by a fabric manufacturer. Polyester/Cotton 15 tex X Polyester/Cotton 20 tex X 1.20 m 32 1/cm X 26 1/cm Warp Crimp, C1 = 8%, Weft Crimp, C2 = 8%, Warp and weft waste = each 2.5% A beam warping machine with a creel of capacity of 600 is available. Calculate, i) The number of back beams to be prepared and the width of the beams. ii) Total requirement of warp and weft yarns. iii) Number of yarn packages required for warping and the weight of yarn to be wound on to each package. Question 6: a) Is it necessary to size all types of warp yarns used for different fabrics? b) Why dont we require pirn winding machines for modern shuttle-less weaving? c) What are the properties we expect from sized warp yarns?, Why?

Assignment II
This assignment is based on the course content of the units IV to VI of the lesson material of TTX3255 Woven Fabric Technology I. These three units deal with basics of weaving and indetail studies on shedding and picking. You must study all three units before attempting to answer the questions of the assignment. Date of submission of the assignment: 19th October 2012 Send your assignment to the following address: Course coordinator TTX3255 Woven Fabric Technology I Department of Textile and Apparel Technology Open University of Sri Lanka Nawal, Nugegoda The Objectives of this assignment You must be able to explain the process of weaving by defining all the important motions such as primary, secondary and auxiliary motions. You must be able to explain the importance of a timing diagram of a weaving machine and how a timing diagram is drawn. You must be able to calculate the weft insertion rate of a loom. You must be able describe different methods of shedding such as eccentric, crank, cam and dobby and compare them with respect to advantages and disadvantages. You must be able to compare the methods of air-jet picking and water-jet picking. You should be able to explain the advantages of projectile picking over conventional shuttle picking.

Question 1: a) Motion / mechanisms of the weaving machines are usually categorized in to three groups. What are these three groups? Categorize all the motions known to you into these three groups. b) What is the timing diagram of a weaving machine? Distinguish between circular timing diagrams and linear timing diagrams. Question 2: a) A shuttle loom has a nominal reed width of 150 cm and it is processing a 100% Nylon plain weave fabric of 135 cm reed-in-width at a speed of 150 PPM. Calculate the nominal and the working weft insertion rates of the machine. Nominal weft insertion rate = ----------------------------------------------Working weft insertion rate = ---------------------------------------------b) If the weft has a crimp of 4%, what would be the loom-state width of the fabric produced. c) What is the most cheapest and reliable method of shedding which can be used to weave this fabric. Explain this method briefly. Question 3: a) Distinguish between crank, eccentric and cam shedding. b) What are the advantages of dobby shedding over cam shedding? c) You want to weave a 1/3 twill weave fabric. Sketch the profile of the cams you would select to weave such a fabric. What is the minimum number of cams and heald shafts required to weave this fabric? What should be the speed ratio between the cam shaft and the main shaft of the loom when you employ the cam you have sketched on a loom to weave 1/3 twill fabric? Question 4: a) What are the the disadvantages of conntional shuttle picking? b) Compare conventional shuttle picking with projectile picking with respect to productivity, stresses applied on yarns during weaving, quality of the woven fabrics etc.. Question 5: a) Compare the methods of weft insertion by rigid rapiers and flexible rapiers with respect to advantages and disadvantages of the two methods? b) Compare the method of weft insertion by water-jet with weft insertion by air-jet. With respect to cost, environmental aspects and fibre materials, which can be processed . Assignment III This assignment is based on the course content of the units VII and VIII of the lesson material of TTX3255 Woven Fabric Technology I. These two units deal with beat-up mechanisms, auxiliary motions as well as with loom monitoring and automation. You must study both the units before attempting to answer the questions of this assignment. Date of submission of the assignment: 18th December 2012 5

Send your assignment to the following address: Course coordinator TTX3255 Woven Fabric Technology I Department of Textile and Apparel Technology Open University of Sri Lanka Nawal, Nugegoda The Objectives of this assignment You must be able to explain the functions of a sley and how sleys are designed for different types of looms. You must be able to distinguish between different types of sley mechanisms. You must be able to distinguish between negative and positive let-off mechanisms and compare main advantages and disadvantages of different mechanisms.. Describe the operational principles of weft stop and warp stop motions. Describe how different coloured fabrics can be woven and operational principles of multi-colour shuttle looms as well as to compare them with shuttle-less looms Question 1: a) What are the functions of a sley mechanism?. b) State the differences between the sley designs used for conventional shuttle weaving and air-jet weaving? c) Distinguish between linkage and cam operated sley mechanisms. Question 2: a) Distinguish between negative and positive let-off mechanisms. b) Describe the main disadvantage of a manually operated negative let-off?

Question 3: a) Distinguish between negative and positive take-up mechanisms. b) What do you understand by positive intermittent and positive continuous take-up mechanisms? c) Distinguish between cloth take-up mechanisms and cloth winding mechanisms. Question 4: a) Compare centre fork mechanism with side fork mechanism with respect to the operational principles and advantages as well as disadvantages. b) Describe the operational principle of a castellated bar type warp stop motion. Question 5: a) What are the different methods of producing coloured woven fabrics? b) What is a 4X4 Loom? c) Weft colour changing in shuttle-less looms is easier than in the case of shuttle looms. Discuss this statement.