Modelling of the carding process for spunlace nonwovens with particular regard to selected mechanical parameters in a double-drum card. Part 1: modelling of the fibre deck forming process

The production of nonwoven fabric dedicated to the hygiene sector of industry is a dynamically developing market segment. Competition among manufacturers forces high performance in the economic production of nonwoven fabric with appropriate physical–mechanical parameters. One of the most important processes which guarantees that such characteristics may be obtained in the production of nonwoven fabrics, is the carding process. The article presents the modelling of the carding process on a modern, double-drum carder. The dynamics of the formation of nonwoven slivers was analysed, taking into account the homogeneity of the density of the fleece formed. In the description of carding dynamics, the mass balance of fibres was taken into account. Numerical simulations concerning the gradual increase in fibre accumulation, over time – and in relation to the fibre collection factor and the number of rollers in the worker–stripper systems – are presented.