Some lessons of Weaving

Woven fabric is produced by interlacing the threads running down the fabric (warp yarns) with those lying across it (weft yarns). The major reasons for the variations in the appearance of Woven fabric are the yarn structure and the fabric structure The aspects of yarn structure that are most likely to affect The final appearance and properties of the fabric include the degree of hairiness of the yarn Its smoothness and lustre Its extensibility and twist Strength, which is critical in ensuring satisfactory performance during use

Woven fabric parameters There are four basic parameters that are essential for every woven fabric: Thread Count/ Fabric density (Sett) Yarn Diameter (Linear density) Yarn Bending (Crimp) and The order of yarn interlacement (Weaving)

Thread count: Fabric density or compactness is one of the most significant Factors when considering the durability of the fabric. It is determined by the closeness of the yarns after the fabric is being woven A garment made from such a fabric shrinks less in washing, slips less at the seems and keeps its shape. A fabric of compact construction has a high thread count. Thread count, also known as fabric count or cloth count is determined by counting no. of warp yarns and weft yarns in a square inch of fabric.

The warp yarns and weft yarns are commonly referred to as end and picks, so the terms commonly used are EPI = ends per inch and PPI = picks per inch To ascertain the thread count, one may use a pick glass or fabric counting glass, which is a “magnifying glass mounted on a small stand with a 1 inch square opening through which the no. of warp and weft are counted”. Another and faster means of determining thread count is with a transparent plastic plate of line gratings having a sequence of parallel lines set with mathematical precision at decreasing distances from each other.

When the line grating scale is placed on the fabric, light passing through produces a wave pattern (moire effect) that is interrupted by a harmonic image of a oval form. The center of which, where the waves converge into a straight line, the thread count can be noted along the edge of the plate. Thread count: measures the no. of warp and weft in 1inch square Yarn count: measures the degree of fineness in the yarns Low thread count: 20 /inch –tobacco cloth High thread count: 350/inch – typewriter ribbon 74 x 66 ; first no. indicates the warp and the second, filling. which is sometimes described as 140.

Balanced construction: A fabric is said to be balnced if the number of warp yarns are almost equal to the number of weft yarns. Ex: 64 x 60, 28 x 24 Fabric count and yarn count are interdependent. A high count fabric even with poor balance will give better wear than a low count fabric with good balance.

Linear Density or yarn count: fineness of yarn (measured in ratio of length to weight or weight per length) The popular yarn count systems that have been used for many years include the cotton count, worsted, metric and denier. Crimp: Crimp refers to the amount of bending that is done by a thread as it interlaces with the threads that are lying in the opposite direction of the fabric. It is the difference between the length of yarn (Ly) taken from a length of fabric (Lf) (Ly –Lf) (Ly –Lf) Crimp (c) = ----------- Crimp% (c%)= ----------- x 100 Lf Lf

Weave: Weave refers to the order of interlacing of the warp ends and the weft picks A weave repeat is commonly illustrated in the square or grid paper design. A weave repeat is the smallest number of threads required to show all of the interlacings in the pattern. It is usually considered sufficient to show one repeat only.

Fabric Weight: Fabric weight (Wc) is the weight of yarn per square meter in a woven fabric, which is the sum of the weight of warp (W1) and the weight of the weft(W2). Expressed in GSM; Grams per Square Meter Wc = total length of yarn in 1square meter x mass per unit length of yarn. Total weight per square m = W1+W2 gm -2 and Weight per piece =(W1+W2)x piece length x piece width g.

Cover factor: Cover factor (k) is defined as the area covered by yarn when compared with the total area covered by the fabric. Warp cover (k1)= n1√n1 (k2)= n2√n2 10 10 Total Cover factor kc =k1+k2

WEAVING: Weaving is a process of interlacing of the warp ends and the weft picks Major method of fabric construction The technique became known even before spinning Spinning developed when people discovered that the raw material could be improved before they were woven.

WARP: The length wise yarns which run from the back to the front of the loom, which forms the basic structure of the fabric and are called the warp. Warp yarns are yarns that are parallel to the selvedge which run through the length of the fabric WEFT: Crosswise yarns that run across the loom are called the weft / woof / filling yarns. Weft yarns are yarns that are perpendicular to the selvedge which run through the width of the fabric

Preparation for weaving: In the weaving operation, the filling yarns undergo less strain when compared to the warp yarns. Weft yarns are prepared by spinning them in to desired size and give them the amount of twist required for the type of fabric for which they will be used. Warp yarns must pass through such operations as Spooling Warping and Slashing

Spooling: In spooling the yarn is wound on larger spools or cones which are placed on a rack called creel. From this creel, the yarns are wound on a warp beam Warping: In warping the yarns are taken from the spools placed on the creel and are wound around the warp beam or roll as per the calculated width of the fabric. An uninterrupted length of hundreds of warp yarns results, all lying parallel to one another. Slashing: The yarns are unwound from the warp beam and put through the Slashing or sizing bath containing either starch based or synthetic based starches (PVA) depending upon the fibre content of warp yarns. The sized yarns are again wound on a final warp beam which can be readily used in the loom.

Essential weaving operations: In any type of weaving, four operations are fundamental. They are performed in sequence and are constantly repeated. Shedding: Raising specific warp yarns by means of the harness or heddle frame or heald shafts Picking: Inserting filling yarns through the shed Beating Up: Pushing filling yarns firmly in place by means of the reed Taking up and Letting off: winding the finished fabric on the cloth beam and releasing more of the warp from the warp beam

Shedding: The raising of the alternate warp yarns formed an inverted V opening or shed, through which the filling yarn was inserted. on the modern looms, shedding operations are performed automatically by the harness. Harness: it is a rectangular frame, to which a series of wires called heddles are attached. As each warp yarn comes from the warp beam, it must pass through an opening like “ eye of a needle” in the middle of the heddle. The operation of drawing each warp yarn through appropriate heddle eye is known as “ drawing in ”.

Picking: As the harnesses raise the heddles which in turn raise the warp yarns, the filling yarn is inserted through the shed by a carrier device. A single crossing of the filling from one side of the loom to the other is called a pick. Beating up (Battening): All warp yarns pass through heddles eyes and through openings in another frame that resembles a comb and is called a reed. With each picking operation, the reed automatically beats each filling yarn against the portion of the fabric that has already been formed. It gives the fabric a firm and compact construction

Shuttle looms: The conventional loom utilises a shuttle that contains a bobbin of filling yarn which emerges through a hole in the side. Shuttle loom is the oldest kind of loom but versatile and effective. Disadvantages: shuttles causes abrasion on the warp yarns and sometimes causes warp breaks. Function slowly (110 to 225 picks per minute) Shuttle looms are noisy.

Shuttle less looms: Shuttle less looms uses a different method of picking, which provides specific characteristics and applications. Missile or Projectile looms: The picking action is accomplished By a series of small bullet like projectiles which grip the filling Yarn and carry it through the shed and return empty. All the filling inserted from one side of the loom and A special tucking device is used to hold the filling in place at the edges of cloth to form selvedge. Speed: upto 300ppm and less noisy than shuttle looms.

Rapier looms: These looms are competetors to the missile looms. There are two types of rapier looms. Long and single rapier that carries the weft across the width from one side of the loom to another Double rapier that is one on each side of the loom. One rapier feeds the filling yarn halfway through the shed of warp yarns to the arm on the other side, which reaches in and takes it across the rest of the way. Speed: 200 to260ppm at the same noise level of projectile loom

Water jet looms: A pre measured length of filling yarn is carried across the loom by a jet of water. Can produce superior quality of fabrics. Suitable for non absorbent fibres like synthetic fibres. Speed: 600ppm, at noise levels lower than missile and rapier Air jet looms: These looms use a jet of air to propel the filling yarn through the shed. Require uniform filling yarns. They are suitable for use with medium weight yarns than very light and very heavy yarns. Speed: 600ppm, at noise levels lower than missile and rapier

Selvages (Selvedges): As the shuttle moves back and forth across the width of the shed, it weaves a self edge called a selvedge on each side of the fabric. The selvedge prevent the fabric from raveling It is usually made more compact and stronger than the rest of the fabric by using more or heavier warp yarns or by using a stronger weave. The kind of selvedge depends upon the economy of production and the expected use of the fabric.

Plain selvages: simple plain weave, same size yarns, threads more compactly packed. Fairly durable and firm. Tape selvages: basket weave for flatter edges, made of heavier yarns or ply yarns for greater strength Split selvages: made by weaving narrow width fabrics twice its ordinary width with two selvages in the center

Fused selvages: for fabrics of thermoplastic fibers. The fabric is fused to seal at the edges. This technique is sometimes used to split wider fabrics in to narrow width fabrics. Leno selvage: used on shuttle less looms. Uses a narrow leno weave at the edges which locks the cut ends along the edges Tucked selvage: used on shuttle less looms. A special device is used to tuck and hold the cut ends in to the fabric weave.

Classification of weaves Weaves fall in to three main categories: Basic weaves (Plain, Twill, Satin and their derivatives) Fancy weaves Compound structures

Plain weave: It is the simplest weave having the most basic interlacing. Each weft goes over a warp and then under a warp yarn. It gives a firm and flat structure and is ideal for finishes like printing. The fabric looks alike from the face and the back and is therefore reversible. Checks and stripes can be created by using different coloured yarns in warp or weft.

The two main variations of plain weave are: Basket weave: two or more yarns are taken as one set and are Interlaced in plain weave pattern. Such weave creates interesting textures, but are not very stable. Rib Weave: A rib effect is produced by using several yarns as one or a thick yarn in either warp or weft direction which create ridge like effect

Twill weave: A twill weave is characterized by diagonal lines on the face or the back of the fabric. For ex: Denim This weave requires a minimum of three harnesses for manufacturing. Twill weave is characterised by high strength and compact weaving. These fabrics have good abrasion resistance and are durable. The direction of the twill can be varied to create interesting effects such as broken twill, pointed twill, herringbone etc.

Satin weave: Satin weave is characterised by a smooth, shiny and

Distinguishing warp and weft: Direction of the fabric determines the way in which the fabric should be cut when a garment is made from it. It is easy to identify the direction of warp and weft - If the fabric is new – warp along the length of the fabric If the fabric has selvedge – warp parallel to the selvedge Fabric with no selvedges can be identified by observing the weave of the fabric.

In plain weave- greater no. of yarns in one direction indicates the direction of warp In twill weaves, filling yarns run in the direction of the diagonal. In satin weaves, the direction of the floating yarns is warp. The direction of the coloured stripes indicates warp More stretch along the weft when compared to warp Finer yarns in the warp direction Filament yarns in warp and spun yarns in weft in mixture fabrics

Direction of ribs mostly in warp direction but can vary according to variety of fabric. Stronger and stiff or starched yarns in the warp Ply yarns in the warp Fancy yarns in the weft Elastic yarns in the weft Yarns of varying sizes in warp Inferior quality of yarn in filling

Yarns with higher twist in the warp Marked evenness in one direction indicates warp Napped fabric-direction of nap in the warp as it is passed through napped rollers in warp direction The reed marks or bands along the weft More shrinkage along the warp More drape in the direction of warp In garment: warp parallel to side seems weft along the length of waist bands.

Identifying the right side of the fabric: It is necessary to identify the face or right side of the fabric for cutting and sewing purposes. When the cloth is on a bolt, usually the fabric is folded or rolled with right side of the fabric inside to keep it clean More lustrous and shinier side is right side Print more distinct on right side of the fabric Napped or fuzzier surface is face (textural effects on right side) Slub yarns tend to be more outstanding on the right side

Woven fabric defects: Yarn defects: Slubs caused by uneven spinning Broken or missing end or pick Mixed end or pick with variation in size, twist, number of plies or colour Weave defects: A slack yarn or tight end or pick due to insufficient tension Uneven space between ends due to miss draw Miss pick due to improper weaving Reed marks due to improper drawing of warp through the reed Filling bars due to the variation in battening Tight selvedge due to excess tension in the warp Streaks caused by loom start and stop motions

Some lessons of Weaving

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Some lessons of Weaving