Optical fiber and its Applications


                                                                                Fiber Optics
An optical fiber is a flexible, transparent fiber made of glass (silica) or plastic, slightly thicker than a human hair. It functions as a waveguide, or “light pipe”, to transmit light between the two ends of the fiber. The field of applied science and engineering concerned with the design and application of optical fibers is known as fiber optics.

Principle
The principles on which optical fibers work are
·         Index Of Refraction
·         Total Internal Reflection

Index of Refraction
The index of refraction is a way of measuring the speed of light in a material. Light travels fastest in a vacuum, such as outer space. The speed of light in a vacuum is about 300,000 kilometers (186,000 miles) per second. Index of refraction is calculated by dividing the speed of light in a vacuum by the speed of light in some other medium. The index of refraction of a vacuum is therefore 1, by definition. The typical value for the cladding of an optical fiber is 1.52. The core value is typically 1.62. The larger the index of refraction, the slower light travels in that medium. From this information, a good rule of thumb is that signal using optical fiber for communication will travel at around 200,000 kilometers per second. Or to put it another way, to travel 1000 kilometers in fiber, the signal will take 5 milliseconds to propagate.

Total Internal Reflection
When light traveling in an optically dense medium hits a boundary at a steep angle (larger than the critical angle for the boundary), the light will be completely reflected. This is called total internal reflection. This effect is used in optical fibers to confine light in the core. Light travels through the fiber core, bouncing back and forth off the boundary between the core and cladding. Because the light must strike the boundary with an angle greater than the critical angle, only light that enters the fiber within a certain range of angles can travel down the fiber without leaking out. This range of angles is called the acceptance cone of the fiber. The size of this acceptance cone is a function of the refractive index difference between the fiber's core and cladding.
In simpler terms, there is a maximum angle from the fiber axis at which light may enter the fiber so that it will propagate, or travel, in the core of the fiber. The sine of this maximum angle is the numerical aperture (NA) of the fiber. Fiber with a larger NA requires less precision to splice and work with than fiber with a smaller NA. Single-mode fiber has a small NA.

                                                                               
Construction
Modern optical fibers are formed by two layers of glass. As shown in fig, the fiber core (8 μ m) is surrounded by a concentric core of lower index glass known as cladding (125 μ m).

The cladding is surrounded by a protective layer. The total internal reflection occurs as the core-cladding interface. In fibers designed for high-speed telecommunication, the core is only a few microns in diameter, not much larger than the wavelength of the light used. In such cases, the full electromagnetic wave picture must be describing the propagation of the light. However, when the highest data transmission rate are not required, fibers with a "large" core of perhaps a hundred micron or more used such fibers are known as multimode fibers. For multimode fibers, ray, picture is adequate to describe the behavior of the light.
                                                                              
Types of Optical Fiber
There are following types of Optical Fibers

Multimode Fiber

Multimode fiber, the first to be manufactured and commercialized, simply refers to the fact that numerous modes or light rays are carried simultaneously through the waveguide. Modes result from the fact that light will only propagate in the fiber core at discrete angles within the cone of acceptance. This fiber type has a much larger core diameter, compared to single-mode fiber, allowing for the larger number of modes, and multimode fiber is easier to couple than single-mode optical fiber. Multimode fiber may be categorized as step-index or graded-index fiber.

Single-mode Fiber

Single-mode fiber allows for a higher capacity to transmit information because it can retain the fidelity of each light pulse over longer distances, and it exhibits no dispersion caused by multiple modes. Single-mode fiber also enjoys lower fiber attenuation than multimode fiber. Thus, more information can be transmitted per unit of time. Like multimode fiber, early single-mode fiber was generally characterized as step-index fiber meaning the refractive index of the fiber core is a step above that of the cladding rather than graduated as it is in graded-index fiber. Modern single-mode fibers have evolved into more complex designs such as matched clad, depressed clad and other exotic structures.

Photonic fibres
In photonic fibres the transmission of light is guided by a number of cavities around the core. The core may be made in glass or even an air cavity! These are new fibres on the market and for the moment (2008) their performances are still under the requirements for astronomical applications.



Applications of Optical Fibers
·         Telecommunications specialty fiber applications in building EDFAs, dispersion compensation, and amplification—long haul applications in standard transmission and connectivity are served by our sister division
·         Medical grade fibers, cable and assemblies used in sensing, surgical procedures, and communications between devices and control and analysis equipment within sensitive environments such as MRI and radiation suites
·         General Industry factory environments and secure installations
·         Commercial Laser encompassing fiber laser and amplifier components for micro
and macro applications 
·         Government, Aerospace and Defense also encompasses navigation systems, payout applications and in-flight entertainment
·         Mass Transit and Transportation Hubs terminal-based and en route transportation applications, navigation, and RoHS, REACH, and Low Smoke Zero Halogen compliance
·         Windpower connections within and between towers and the central operations center
·         Solar specific fiber optic needs in solar voltaic farms
·         Oil & Gas down-hole well applications, Distributed Temperature Sensing (DTS)
·         Fiber Sensing all forms of detection with optical fiber, Fiber Bragg Grating-based solutions

SHEARING


SHEARING:

“Shearing” is a cutting process to remove protruding fibers on the surface of fabric.

SHEARING PROCESS STAGES


1.     Brushing of cloth.
2.     Cutting of projecting fibers.
3.     Suction of fiber removed by shearing.

SHEARING MACHINE PARTS & WORKING


1.     Outer casing which cover the machine assembly.
2.     A guide roller which just facilitates the movement of fabric.
3.     Two brushing rollers, first is in opposite to the direction is which the fabric move and second is in the same direction of the fabric. They are use to remove any type of hanging extra materials which can disturbance in process of shearing.
4.     Shearing Machine Parts & their function
5.     An adjustable bed- plate provides a base support for shearing action between the bed plate and cutting plate.
6.     A cutting roller with bladed mounted on it in spiral form which provide extra length of cutting blades from one end to the other  and make sure the contact between the blades and fabric in whole one revolution. Which increase the shearing rate projecting fibers as in a straight blade plate length is less then the spiral blade. Setting of blade require be accurate for a clear cut finish.
7.     A fan after cutting blades used for the removal of the removed projecting fibers.

MACHINE USED FOR SHEARING

            
Shearing machine is used for shearing.

AMOUNT OF SHEARING DEPENDS

1.     The amount of projecting fibers.
2.     Length of the projecting fibers.
3.     Speed of bladed roller. (40 meters/min)
4.     Setting between Blade roller to Bed.
5.     Sharpness of the bladed roller


De-sizing Process and its types

De-sizing Process
A process carried out to remove the sizing material (like starch) from the cloth. 

Objective of De-sizing

             1.     To eliminate the water repellent nature of sized cloth.             
             2.     To increase the absorbency.             
             3.     To reduce the consumption of chemicals in subsequent process.

Importance of De-sizing

                The importance of de-sizing is mainly because of water repellent nature of “Sizing materials”. So, it is important to remove the size material before conducting any  coloration or finishing process.

Enzymatic desizing


What are enzymes?

Name
·         Greek, meaning “In Yeast”

Nature
·         Bio-catalyst (proteins)

Structure
·         Usually large & complicated

Properties
·         Specific action
·         Thermo ability
·         Low energy of activation
·         Narrow working pH arrange

Classification
·         According to origin
·         According to action
·         According to structure
·         According to working temperature
Sources of Amylases
·         Malt
·         Bacteria
·         Pancreas

Requirements of desizing:
        • Desizing materials
        • Desizing methods
        • Desizing machine
Desizing processes
Desizing, irrespective of what the desizing agent is, involves impregnation of the fabric with the desizing agent, allowing the desizing agent to degrade or solubilise the size material, and finally to wash out the degradation products. The major desizing processes are:
  • Enzymatic desizing of starches on cotton fabrics
  • Oxidative desizing
  • Acid desizing
  • Removal of water-soluble size

Enzymatic desizing
Enzymatic desizing is the most widely used desizing process of degrading starch size on cotton fabrics using enzymes. Enzymes are complex organic, soluble bio-catalysts, formed by living organisms that catalyze chemical reaction in biological processes. Enzymes are quite specific in their action on a particular substance. A small quantity of enzyme is able to decompose a large quantity of the substance it acts upon..
Amylases is the enzyme that hydrolyses and reduce the molecular weight of amylose and amylopectin molecules in starch, making it water soluble enough to be washed off the fabric.
Effect of PH and Temperature on enzyme desizing
Effective enzymatic desizing require strict control of pH, temperature, water hardness and electrolyte addition Activity of enzymes increase with temperature; however, above a critical temperature, enzymes are deactivated. The effectiveness of enzymes exhibit a maximum at certain temperatures, usually 40 -75 0C. Bacterial enzymes are the most thermally stable and can be used up to 100 0C under special stabilizing conditions. Certain salts increase the activity of specific enzymes. Pancreatic amylase is ineffective without the addition of salt. A combination of sodium chloride
Exhaust Process
                           Enzyme                    4 g/l
                            NaCl                        4 g/l
                           Wetting Agent         1 g/l
            Continuous Process


1. Saturate fabric with a solution containing:

Bacterial Amylase 0.8 - 1.0 %
Wetting agent 0.1 - 0.2 %
Sodium Chloride 10 %

2. Hold:

Open-width Range: Steam 1 to 2 minutes at 200 to 212 0F.
Rope Range: Store in J Box for 20 to 30 minutes at 170 to 180 0F. or
over night at room temperature.
3. Thoroughly rinse with hot water, 175 0F or hotter.

           
Oxidative desizing
In oxidative desizing, the risk of damage to the cellulose fiber is very high, and its use for desizing is very rare. Oxidative desizing uses potassium or sodium persulfate or sodium bromite as an oxidizing agent.
Acid desizing
Cold solutions of dilute sulphuric or hydrochloric acids are used to hydrolyze the starch, however, this has the disadvantage of damaging  cellulose fiber in cotton fabrics.
Removal of water-soluble sizes
Fabrics containing water soluble sizes can be desized by washing using hot water, perhaps containing wetting agents (surfactants) and a mild alkali. The water replaces the size on the outer surface of the fiber, and absorbs within the fiber to remove any fabric residue.
Assessment of size removal:
A drop of iodine solution placed on a test specimen resulting in a characteristic blue color is the universal test for identifying starch. It can be used as a qualitatively test to show whether all the starch was removed. Absence of the blue color signifiesthat all the starch has been removed. The intensity of the color is some what related to how much is left. Usually, if the color is faintly perceptible, the remaining starch will come out in the scouring and bleaching steps that follow.




SINGEING and its types


SINGEING:
Singeing    
The process of removal of protuding fibers from the surface of gray fabric by burning is called singeing.
OBJECTIVES OF SINGEING
Objectives of Singeing of  Woven Fabrics
Ø  Surface hairs helps to entrap air in the fabric when immersed in water it takes longer for water to enter the fabric since it must first displace the air .Singeing therefore helps to increase fabric wet ability.
Ø  It create a smooth surface for printing. It may be possible to print fine details on the Hairy surface but once the hairs moves again after printing and fine details  becomes fuzzy.
Ø  To emphases the woven Structure of the fabric if that is considered desirable.
Ø  To prevent a frosty appearance after dyeing. The projecting Dyed Hairs give the Fabric Surface The appearance of being poor   then rest the body of the fabric
Ø  To prevent or minimize the tendency of blend of Fabrics to form Pills. Pills  are the little Bolls of the Fibre that arise on the surface of some fabrics as a result of abrasion that occur during Usage.

Machines for singeing:
  •   Rotary cylinder singeing machine
  •   Plate singeing machine
  •  Flame singeing    

PLATE SINGING MACHINES OPERATIONS


1.     In plate singeing the fabric is pass over one or two curved plates of cupper with size 1”-2” thickness.
2.     Guide rollers are used to ensure the enough contact of cloth with the plate surface so that the projecting fibers are removed without any damage.
3.     Two levers are used to move the plates up and down depends upon the life of the plate.

PARAMETRES OF SINGEING MAHINES


1.     The plates are heated up to 150 °C.
2.     Speed of the cloth is 135 to 225 meters per minute.

ROLLER SINGEINGE MACHINE OPERATIONS


1.     In roller singeing machine fabric is passed over a hallow cylinder of cupper or cast iron cylinder which is heated by internal firing.
2.     The cylinder revolves slowly opposite to fabric direction.
3.     The face and back surface of the fabric may be singed in single passage by using two rollers.
Parameters of Flame singeing Machine:
         1.      Composition of flam
*      1 part LPG (liquid petroleum gas)
*      2 parts Air
         2.      Nature of flame
*      Use oxidizing flame because it produces minimum amount of ash
*      Temperature of the flame is about 1300°C

Zones of Singeing Machine .
Ø There are five zones of singeing Machine
Ø Entrance Zone
Ø Brushing Zone
Ø Singeing Zone
Ø Washing Zone

         3.      Distance of flame from fabric surface should be 1.5 to 4 mm.
         4.      Speed of the fabric
·         Speed of the fabric depends upon quality of the fabric
·         Speed of low quality fabric should be 120 meter per minute.
·         Speed of High quality fabric should be 60 to 80 meter per minute.

          5.      Angle of the flame
· Perpendicular to fabric structure(for heavy weight fabric)
· Tangential to fabric structure(for light weight fabric)













Inspection of gray fabric


Inspection of gray fabric:
            The process of observing and locating different types of faults in gray fabric is known as inspection of gray fabric.
Types of faults in the gray fabric:

  • v  Broken picks
  • v  Broken ends
  • v  Cut weft (pinhole in fabric due to cut r breakage of pick)
  • v  Neps, peels, and cracks
  • v  Missing of interlacement of pick and end
  • v  Yarn contamination
  • v  Floating or protruding fibers
  • v  Hang Pick( a pick is out of line for short distance creating hole cavity)
  • v  Wrong Drawing (wrong order of drawing ends through heals and reeds


  Four Point inspection system of fabric:
           The 4-Point System assigns 1, 2, 3 and 4 penalty points according to the size and significance of the defect. Points are assigned according to the following criteria:

                           
Penalty Point
Defects in Warp Except Holes Torn
1
Up to 3²
2
From1²to 6²
3
From 1²to 9²
4
From1² to 36²

Cutting Faults

Hole and Tear ¼ and over Heavy Crack and Float

Penalty points grading:
The following fabric penalty point grading standards are to be used during inspection.
  1. No more than 4 penalty points may be assigned for any single defect.
  2. No more than 4 penalty points may be assigned to one linear meter, regardless of the number of defects with in that one meter.
  3. A continuous defect shall be assigned 4 points for each meter in which it occurs.
  4. Any roll having a running defect through more than three continuous meters shall be rejected regardless of points count.
  5. No roll shall be accepted that contains a full width defect in the first or last three meters.
  6. A hole or torn is considered to be a major defect and shall be penalized 4 points.

No roll shall be accepted as first quality that exhibits a noticeable degree of looseness of tightness or ripples, puckers, folds or creases in the body of the fabric

Major & minor Penalty Points

           
Average Point: Average point is calculated by following formula.
                                                                                (Total Points) X (3937)
Total Average Points=
Per 100 Meter2                                               (Total length in Meters) X (Width)

                                                                              (Total Points) X 3600
Total Average Points =
Per 100 Yards2                                              (Total length in Meters) X (Width)


  • Ø According to SOP (Standard operating Procedure) if there are 15 faults in 100 square meter then the fabric is acceptable for further processes.
  • Ø If the faults are in between 15-18 then we correspond with the customer for its requirement. Customer decides whether it is acceptable or not.
  • Ø If total faults in 100 sq meter are more than 18 then the fabric is rejected.

Pretreatment

What is Pretreatment?
                   Textile Pre-treatment, considered to be a series of cleaning operations starting from the raw state of fiber, and lays the foundation for the quality in textile processing.

Importance of Pretreatment

                   Pre-treatment have same importance as coloration and finishing of textile materials, about 60%-70% faults that appears in processing unit are due to inadequate pre-treatment process.

 Objectives of Pretreatment
                   The main objective of textiles Pre-treatment is to produce a clean and absorbent cloth or to pass the textile materials by standard procedure; so that, it may brought to the state; which can be dyed or printed and finished without any hurdle and displaying any kind of faults.

1.     Complete removal of all kinds of Impurities

2.     Removal of all Projecting/Protruding fibers (Fibers hanging on fabric surface due to spinning of carded yarn)

3.     To get uniform absorbency(pick up) throughout the fabric
4.     To get maximum whiteness
5.     To have minimum damage of fibers constituting fabric.
6.     To neutralize pH of the fabric, necessary for further process.
7.     To remove Natural impurities (Fats, natural pigments, mineral substances and seed particles).
8.     To remove Artificial impurities (Sizes, mineral oils, fungus, rust and coloring materials)

   Pretreatment:
          The sequences of process starting from inspection of gray fabric to mercerization is called pretreatment.
   Objective of pretreatment:

  • ·        To get uniform absorbency(pick up) throughout the fabric
  • ·        To get maximum whiteness
  •       To remove Protruding or floating fibers (fibers hanging up on fiber surface)
  •       To remove all kind of impurities completely
  • ·        To have minimum damage to fabric
  • ·        To neutralize the pH of the fabric that is necessary for further process
  • ·        To make fabric ready for dyeing and printing.

Mechanics of materials by Beer Johnston

A helping book of Mechanics and machine mechanism and designing available now only my blog... download and continue learning. . .