It is a commonly known fact that fabrics are constructed through two major techniquesapart from other minor techniques. In these processes, two distinct sets of yarns called the interlaced with each other to form a fabric. 'Warp' is the set of yarns that are laid out first 'Weft' is the yarn that is woven under and over the warp yarns that are already stretched warp is the continuous row of yarns and the wefts are the yarns that are woven in from side definitions, it is clear that textile warping is the processing of creating the base yarn that woven cloth. weaving and knitting warp and the weft are on a loom or frame and onto the loom. Thus to side. If we go by these runs top to bottom on
Yarn Preparation
Yarn preparation in warp knitting combines methods used in weaving and knitting. In some cases, the ends of yarn can be fed directly off cones into the knitting machine but the number of cones needed restricts this working method. The large floor space required for a creel is justified only when it is technologically essential- for example, with Jacquard and curtain machines. In all the other cases, the yarn ends are fed off warp beams. Yarn preparation can be reduced to a simple winding of yarn ends on to the warp beams in a knitting machine since artificial yarn is mainly used along with moderate tensions applied to the knitting yarn. As such, smooth operation can be ensured without sizing the yarn. The quality of warp beam is crucial for determining the quality of the knitted fabric. Variations in yarn thickness, tension, twist and other factors too might result in a defective fabric. In most of the cases, warping mistakes are not easy rather impossible to correct during the knitting process.
Methods of Warping
The yarn manufacturers, these days, can supply prepared warps but most of the knitting firms prefer to prepare their own warping equipment and warp beams independently. Mostly, they select the standard types of yarns and warp effect yarns in the plant. There are two basic methods of warping that can be used to prepare the warps for the knitting machines- Indirect Warping and Direct Warping
Indirect Warping: The yarns from the yarn packages are wound onto an intermediate cylinder (mill) in many parallel groups with a specified
density, and then they are back wound onto the warp beam.
Direct Warping: The ends of the yarn are wrapped in one operation, from the yarn packages onto the warp beam.
However, there are certain requirements that have to be kept in mind while using both the methods, information about which has been given in the table below.
Requirements for Direct and Indirect Warping Requirement Yarn ends per section Number of revolutions Warp length Number of sections Yarn ends per section R - Required; O - Optional; NA - Not Applicable Yarn ends density R R R NA NA Direct Warping R R R R o
Warping Defects
There are certain major warping defects on beam warpers that can be identified as given below.
Lapped Ends :
The broken end of yarn is not tied to the end on the warp beam and overlaps the adjoining yarn. The beam is not properly braked and the signal hook fails to operate.
Bulges : Yarn ends are drawn from the middle and the broken end is not correctly pieced up to the adjoining yarn. Broken ends on the beam : It occurs due to reasons mentioned in the above point. A group of ends is broken and tied
It happens due to any on of these reasons- improper threading of the yarn into the tension devices, ejection of yarn from under the disc of the yarn tensioning device, or yarn tension devices of poor quality.
Frequent yarn breakages at the beam edges :
It results due to burrs and nicks on the surface of the warp beam flanges.
Improper length of warping :
It is due to malfunction of the counter, and the brakes of the measuring device & warp beams.
Coarse Knots :
It happens when the pressure roller is lightly pressed against the warp roller.
Fluff, oily ends and yarn of different density :
It is due to Irregular laying of yarn ends in the reed, missing a dent and placing two ends in the adjoining yarn.