Fibre Transfer Mechanism in a revolving flat carding machine

This paper presents a rigorous theoretical and statistical framework for analysing fiber transfer dynamics in carding machines. Fiber transfer between the Lickerin, cylinder, and doffer surfaces is governed by aerodynamic forces, fiber tension, and material properties. Through dimensional analysis, empirical modelling, and parametric sensitivity studies, this work characterises the drag force, Reynolds number, bending moment, and transfer efficiency as functions of cylinder speed, fiber diameter, aspect ratio, and Young's modulus. Results confirm that aerodynamic drag — not centrifugal force — is the primary mechanism driving fiber transfer, with strong transfer (Lickerin→Cylinder) achieving near-unity efficiency and weak transfer (Cylinder→Doffer) being constrained by doffer hook geometry. Regression analyses demonstrate linear drag-diameter and quadratic drag-speed relationships (R² > 0.9). Sensitivity analysis reveals cylinder speed as the dominant parameter, contributing up to ±44% variation in drag force for a ±20% speed change. These insights directly inform machine design optimisation for improved yarn quality.