Practical 03

Roving Frame
Machine

Name : Arachchi S.S.K

Index : 211006U
Module : Principles of Yarn Manufacture
Date of Performance : 14/10/2023
Date of Submission : 27/10/2023
Instructed by :- Mr.Charuka Karunarathne
1|Page
INTRODUCTION
The roving frame machine is an essential part of the textile spinning process. It is
used to convert the drawn sliver from the draw frame machine into a finer, more
compact strand of fibers called roving. Roving is then fed into the ring frame
machine to produce yarn.
The roving frame machine has three main objectives:
1. Drafting:
Drafting is the process by which the linear density of the draw frame sliver is
reduced to a suitable level for input into the ring frame. In the roving frame,
this reduction is achieved using four top rollers and four bottom rollers in the
drafting zone. Typically, a draft of 5-20 is applied in the roving frame. To
facilitate efficient drafting, the top rollers are covered with synthetic rubber to
prevent static charges and reduce slippage when drafting occurs. Adequate
pressure, typically in the range of 100-250N, is applied to the top and bottom
rollers, striking a balance between transmitting motion to the fibers and
preventing excessive pressure.
2. Twisting:
Roving, the product of drafting, has relatively low strength and cohesion. To
address this, a small amount of twist, typically ranging from 0.7 to 2 TPI
(Twists Per Inch), is imparted to the roving. This twist can be controlled by
adjusting the speed of the flyer. Striking the right balance is crucial, as
excessive twist can reduce production rates and cause issues during drafting
on the ring frame, while too little twist can result in fragile roving that is
unsuitable for winding. The introduction of false twist enhances the strength
of the roving over its length, reducing the spinning triangle and improving
yarn quality.
3. Winding:
Winding represents the final stage of the roving frame, where the drafted and
twisted roving is properly wound into a suitable package using a package
building mechanism. Typically, the yarn is wound onto a tapered bobbin for
easy transportation. Two winding systems are possible: bobbin leading and
flyer leading. Modern roving frames predominantly employ the bobbin
leading system, where the bobbin rotates at a higher surface speed than the

2|Page
 flyer. The flyer leading system, where the flyer rotates faster, has limitations,
and is no longer widely used in roving frames.
The roving frame machine is a critical component of the textile spinning process. By
producing high-quality roving, it helps to ensure the efficient and effective
production of yarn.

OBSERVATIONS

Material path of Roving frame machine

3|Page
CALCULATIONS
➢ Material Draft
• Input material – Draw frame sliver.
• Output material – Roving.
Material Draft = Linear density of input material / Linear density of output material
= 4.89 gm-1 /0.5897 gm-1
= 8.2924
➢ Mechanical Draft
• Speed of the second bottom roller -129rpm
• Speed of the third bottom roller -22rpm
• Speed of the fourth bottom roller -16rpm
• Speed of the first bottom roller -135rpm
• Diameter of a bottom roller -2.83cm
Since diameter of the four rollers are same therefore diameter is not dependent on
surface speed.
Tension draft = Speed of the first bottom roller/Speed of the second bottom roller
= 135 rpm /129 rpm
= 1.047

Break Draft = Speed of the third bottom roller/Speed of the fourth bottom roller
= 22 rpm / 16 rpm
= 1.375

Main Draft = Speed of the second bottom roller/Speed of the third bottom roller
= 129 rpm/ 22 rpm
= 5.864

4|Page
Total Draft = Tension Draft × Main Draft × Break Draft
= 1.047 × 5.864 × 1.375
= 8.442

➢ Twist
• Rotational speed of flyer -848 rpm
• Delivery speed in rpm – 135 rpm
• Diameter of delivery roller -2.83cm
Delivery speed (m/min) = (2×π × radius × delivery speed in rpm) = 0.09m/min
Twist = Rotational speed of flyer(rpm) / delivery speed(m/min)
= 848 rpm /(12.0025m/min)
= 70.6519 turns per meter

DISCUSSION
Roving frame machine is an optional machine in the staple spinning process. It is
used to produce a finer, more compact strand of fibers called roving, which is then
fed into the ring frame machine to produce yarn. However, it is not essential to
produce yarn, and some mills may choose to omit it from their process.
There are several reasons why mills may choose to omit the roving frame machine:
• Cost: Roving frame machines are expensive to purchase and maintain.
• Space: Roving frame machines are large machines that require a lot of space.
• Maintenance: Roving frame machines require regular maintenance to keep
them running smoothly.
• Quality: While the roving frame machine can improve the quality of the final
yarn, it is not essential for producing high-quality yarn.

5|Page
Why the flyers in the machine in a Zig zag pattern
There are three main reasons why the flyers in the speed frame machine are arranged
in a zig-zag pattern:
• Space efficiency: The zig-zag pattern allows more flyers to be fitted into the
machine, which increases production capacity.
• Balance: The zig-zag pattern helps to balance the machine, which reduces
vibration.
• Safety: The zig-zag pattern helps to prevent the flyers from colliding with
each other, which could cause damage to the machine and injuries to
personnel.
Disadvantages caused by zig zag pattern to the spinning process.
The zig-zag pattern of the flyers can cause the following disadvantages to the
spinning process:
• Tension variation: The zig-zag pattern can cause the tension in the yarn to vary
as it travels through the machine. This can lead to yarn breaks and reduce the
quality of the final yarn.
• Maintenance difficulty: The zig-zag pattern can make it difficult to maintain
the flyers properly. This can lead to increased wear and tear on the flyer
parts, which can reduce the life of the machine.
• Noise: The zig-zag pattern can increase the noise level of the machine. This
can be a problem for workers who are exposed to the machine for long periods
of time.
What is the action taken in modern Roving machine to overcome those
problems?
Modern roving machines have taken several actions to overcome the disadvantages
caused by the zig-zag pattern of the flyers:
• Tension control: Modern roving machines use electronic tension control
systems to maintain a constant tension in the yarn throughout the spinning
process. This helps to reduce yarn breaks and improve the quality of the final
yarn.

6|Page
 • Easy maintenance: Modern roving machines are designed with easy access to
the flyers for maintenance. This helps to reduce the cost and downtime
associated with maintenance.
• Noise reduction: Modern roving machines use various noise reduction
techniques, such as acoustic enclosures and vibration dampeners, to reduce
the noise level of the machine.
Additionally, some modern roving machines use a different flyer arrangement
altogether, such as a circular arrangement or a straight arrangement. These
arrangements can help to reduce the disadvantages caused by the zig-zag pattern, but
they may also have their own disadvantages.
Overall, the roving frame machine is an optional machine in the staple spinning
process. It offers some advantages, such as increased production capacity and
improved yarn quality. However, it also has some disadvantages, such as high cost,
high maintenance requirements, and the potential for tension variation and noise.
Modern roving machines have taken several actions to overcome these
disadvantages, but they may still not be the best solution for all mills.

REFERENCES

➢ Kiron, M.I. and Mazharul Islam Kiron Founder & Editor of Textile
Learner. He is Textile Consultant (2021) Roving Frame or simplex
machine: Description and material passage, Textile Learner. Available
at: https://textilelearner.net/roving-frame-description-and-material-
passage/ (Accessed: 27 October 2023).

7|Page