Lecture 3 Rubber Processing Ch14
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Transcript of Lecture 3 Rubber Processing Ch14
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Lecture # 3
RUBBER PROCESSING
TECHNOLOGY
1. Rubber Processing n! S"ing
$. %nu&cture o& Tires n! Ot"er Rubber Pro!ucts
3. Pro!uct 'esign Consi!ertions
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O(er(ie) o& Rubber Processing
%n* o& t"e ro!uction +et"o!s use! &or ,stics re
,so ,icb,e to rubbers
Ho)e(er- rubber rocessing tec"no,og* is !i&&erent incertin resects- n! t"e rubber in!ustr* is ,rge,*
serte &ro+ t"e ,stics in!ustr*
T"e rubber in!ustr* n! goo!s +!e o& rubber re
!o+inte! b* one ro!uct tires Tires re use! in ,rge nu+bers on uto+obi,es-
truc/s- ircr&t- n! bic*c,es
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T)o Bsic Stes in
Rubber Goo!s Pro!uction
1. Pro!uction o& t"e rubber itse,&
Ntur, rubber 0NR is n gricu,tur, cro
S*nt"etic rubbers is bse! on etro,eu+
$. Processing into &inis"e! goo!s
Co+oun!ing
%i2ing S"ing
u,cni4ing
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T"e Rubber In!ustries
Pro!uction o& r) NR is n gricu,tur, in!ustr*
becuse latex- t"e strting ingre!ient- is gro)n on
,nttions in troic, c,i+tes B* contrst- s*nt"etic rubbers re ro!uce! b* t"e
etroc"e+ic, in!ustr*
5in,,*- rocessing into tires n! ot"er ro!ucts occurs
t rocessor 0&brictor ,nts- co++on,* /no)n st"e rubber in!ustr*
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Pro!uction o& Ntur, Rubber
Ntur, rubber is te! &ro+ rubber trees 0Hevea
brasiliensis s ,te2
In Sout"est 6si n! ot"er rts o& t"e )or,! Lte2 is co,,oi!, !isersion o& so,i! rtic,es o& t"e
o,*+erpolyisoprenein )ter
Po,*isorene 0C7H8nis t"e c"e+ic, substnce
t"t co+rises NR- n! its content in t"e e+u,sionis bout 39:
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Reco(ering t"e Rubber
Pre&erre! +et"o! to reco(er rubber &ro+ ,te2
in(o,(es cogu,tion ; !!ing n ci! suc" s &or+ic
ci! 0HCOOH Cogu,tion t/es bout 1$ "ours
T"e cogu,u+- no) so&t so,i! s,bs- is t"en s
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Gr!es o& Ntur, Rubber
T"e resu,ting rubber- no) in &or+ c,,e! ribbed
smoked sheet- is &o,!e! into ,rge b,es &or s"i+ent
to t"e rocessor In so+e cses- t"e s"eets re !rie! in "ot ir rt"er
t"n s+o/e"ouses- n! t"e ter+ air dried sheet is
use!
T"is is consi!ere! better gr!e o& rubber
6 sti,, better gr!e- c,,e!pale creperubber- in(o,(es
t)o cogu,tion stes- &o,,o)e! b* )r+ ir !r*ing
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S*nt"etic Rubber
%ost s*nt"etic rubbers re ro!uce! &ro+ etro,eu+
b* t"e s+e o,*+eri4tion tec"ni
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Co+oun!ing
Rubber is ,)*s co+oun!e! )it" !!iti(es
Co+oun!ing !!s c"e+ic,s &or (u,cni4tion-
suc" s su,&ur 6!!iti(es inc,u!e &i,,ers t"t eit"er en"nce t"e
rubber>s +ec"nic, roerties 0rein&orcing&i,,ers or e2ten! t"e rubber to re!uce cost
0non rein&orcing &i,,ers
It is t"roug" co+oun!ing t"t t"e seci&icrubber is !esigne! to stis&* gi(en ,ictionin ter+s o& roerties- cost- n! rocessbi,it*
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Crbon B,c/ in Rubber
T"e sing,e +ost i+ortnt rein&orcing &i,,er in rubber
is carbon black- co,,oi!, &or+ o& crbon obtine!
b* t"er+, !eco+osition o& "*!rocrbons 0soot It increses tensi,e strengt" n! resistnce to
brsion n! tering o& t"e &in, rubber ro!uct
Crbon b,c/ ,so ro(i!es rotection &ro+
u,tr(io,et r!ition %ost rubber rts re b,c/ in co,or becuse o&
t"eir crbon b,c/ content
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Ot"er 5i,,ers n! 6!!iti(es in
Rubber
C"in c,*s "*!rous ,u+inu+ si,ictes06,$Si$O70OH? rein&orce ,ess t"n crbon b,c/ but re
use! )"en t"e co,or b,c/ is not ccetb,e Ot"er o,*+ers- suc" s st*rene- PC- n! "eno,ics
Rec*c,e! rubber !!e! in so+e rubber ro!ucts- butusu,,* 19: or ,ess
6ntio2i!nts@ &tigue n! o4one rotecti(e c"e+ic,s@
co,oring ig+ents@ ,stici4ers n! so&tening oi,s@b,o)ing gents in t"e ro!uction o& &o+e! rubber@ +o,!re,ese co+oun!s
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%i2ing
T"e !!iti(es +ust be t"oroug",* +i2e! )it" t"e
bse rubber to c"ie(e uni&or+ !isersion o&
ingre!ients Uncure! rubbers "(e "ig" (iscosit* so +ec"nic,
)or/ing o& t"e rubber cn increse its te+erture u
to 179C 03995
I& (u,cni4ing gents )ere resent &ro+ t"e strt o&+i2ing- re+ture (u,cni4tion )ou,! resu,t t"e
Arubber rocessor>s nig"t+re
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%i2ers in Rubber Processing
0 T)o;ro,, +i,, n!
0b Bnbur*;t*e
intern, +i2er
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T)o;Stge %i2ing
To (oi! re+ture (u,cni4tion- t)o stge +i2ing
rocess is usu,,* e+,o*e!
Stge 1 ; crbon b,c/ n! ot"er non (u,cni4ing
!!iti(es re co+bine! )it" t"e r) rubber
T"is stge 1 +i2ture is c,,e! t"e +ster btc"
Stge $ ; &ter stge 1 +i2ing is co+,ete!- n!
coo,ing ti+e "s been ,,o)e!- stge $ +i2ing is
crrie! out in )"ic" (u,cni4ing gents re !!e!
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5i,+ent Rein&orce+ent in
Rubber
%n* ro!ucts re
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S"ing n! Re,te! Processes
&or Rubber Pro!ucts
5our bsic ctegories o& s"ing rocesses
1. E2trusion
$. C,en!ering
3. Coting
?. %o,!ing n! csting
So+e ro!ucts re
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E2trusion
Scre) e2tru!ers re gener,,* use!
T"e L=' rtio o& t"e e2tru!er brre, is ,ess t"n &or
t"er+o,stics T*ic, rnge 19 to 17
Re!uces ris/ o& re+ture cross ,in/ing
'ie s)e,, occurs in rubber e2tru!tes
T"e "ig",* ,stic o,*+er e2"ibits A+e+or*
T"e rubber "s not *et been (u,cni4e!
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Rubber stoc/ is sse!
t"roug" series o& gs
o& !ecresing si4e b* stn! o& rotting ro,,s
Rubber s"eet t"ic/ness
is s,ig"t,* greter t"n
&in, ro,, g !ue to !ies)e,,
C,en!ering
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Co+bintion o& e2trusion n! c,en!ering t"t resu,tsin better
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I+ortnt in!ustri, rocess &or ro!ucing tires-con(e*or be,ts- in&,tb,e r&ts- n! )terroo& c,ot"
Coting or I+regnting 5brics
)it" Rubber
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%o,!e! Rubber Pro!ucts
%o,!e! rubber ro!ucts inc,u!e s"oe so,es n!
"e,s- gs/ets n! se,s- suction cus- n! bott,e
stos 6,so- +n* &o+e! rubber rts re ro!uce! b*
+o,!ing
In !!ition- +o,!ing is n i+ortnt rocess in tire
ro!uction
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%o,!ing Processes &or Rubber
Princi, +o,!ing rocesses &or rubber re
1. Co+ression +o,!ing
$. Trns&er +o,!ing
3. Inection +o,!ing
Co+ression +o,!ing is t"e +ost i+ortnt becuse
o& its use in tire +nu&cture
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%o,!ing Processes &or Rubber
Curing 0(u,cni4ing is cco+,is"e! in t"e +o,! in ,,
t"ree +o,!ing rocesses
T"is reresents !erture &ro+ re(ious s"ing+et"o!s
Ot"er s"ing +et"o!s use serte
(u,cni4ing ste
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D"t is u,cni4tion
T"e tret+ent t"t cco+,is"es cross ,in/ing o&
e,sto+er +o,ecu,es
%/es t"e rubber sti&&er n! stronger but retine2tensibi,it*
T"e ,ong c"in +o,ecu,es beco+e oine! t certin
tie oints- )"ic" is re!uces t"e bi,it* to &,o)
So&t rubber "s 1 or $ cross ,in/s er 1999 +ers
6s t"e nu+ber o& cross ,in/s increses- t"e
o,*+er beco+es sti&&er 0e.g.- "r! rubber
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01 r) rubber- n! 0$ (u,cni4e! 0cross ,in/e! rubber
0 so&t rubber n! 0b "r! rubber
E&&ect o& u,cni4tion on
Rubber %o,ecu,es
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u,cni4tion C"e+ic,s n!
Ti+es
D"en &irst in(ente! b* Goo!*er in 183F- (u,cni4tion
use! su,&ur 0bout 8 rts b* )eig"t o& S +i2e! )it"
199 rts o& NR t 1?9C 0$89
5 &or bout 7 "ours
u,cni4tion )it" su,&ur ,one is no ,onger use!-
!ue to ,ong curing ti+es
rious ot"er c"e+ic,s 0e.g.- 4inc o2i!e- steric ci!
re co+bine! )it" s+,,er !oses o& su,&ur to cce,erten! strengt"en t"e tret+ent
Resu,ting cure ti+e is 17 $9 +inutes
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Tires n! Ot"er Rubber Pro!ucts
Tires re bout 7: o& tot, rubber tonnge
Ot"er i+ortnt ro!ucts
5oot)er Se,s
S"oc/ bsorbing rts
Con(e*or be,ts
Hose 5o+e! rubber ro!ucts
Sorts e
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Pneu+tic Tires
5unctions o& neu+tic tires on (e"ic,e
Suort t"e )eig"t o& t"e (e"ic,e- ssengers-
n! crgo Trns+it t"e +otor tor
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Tire Construction
6 tire is n sse+b,* o& +n* co+onents
6bout 79 &or ssenger cr tire
Lrge ert"+o(er tire "s s +n* s 17
T"e intern, structure o& t"e tire- /no)n s t"e
carcass- consists o& +u,ti,e ,*ers o& rubber;cote!
cor!s- c,,e!plies
T"e cor!s re strn!s o& n*,on- o,*ester- &iber
g,ss- or stee,- )"ic" ro(i!e ine2tensibi,it* to
rein&orce t"e rubber in t"e crcss
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T"ree Tire constructions 0 !igon,
,*- 0b be,te! bis- n! 0c r!i, ,*
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Tire Pro!uction Se
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Pre&or+ing o& Co+onents
Crcss consists o& +u,ti,e co+onents- +ost o&
)"ic" re rubber or rein&orce! rubber
T"ese co+onents n! ot"ers re ro!uce! b*continuous rocesses
T"e* re t"en re cut to si4e n! s"e &or
subse
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Prior to +o,!ing n! curing- t"e crcss is
sse+b,e! on building drum- )"ose +in e,e+ent
is c*,in!ric, rbor t"t rottes
Bui,!ing t"e Crcss
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%o,!ing n! Curing
01 Uncure! tire ,ce! o(er e2n!b,e !i"rg+-0$ s,it +o,! is c,ose! n! !i"rg+ is e2n!e!
to &orce uncure! rubber ginst c(it* )it" tre!ttern@ +o,! !i"rg+ re "ete! to cure rubber
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Ot"er Rubber Pro!ucts
Rubber Be,ts
Di!e,* use! in con(e*ors n! u,,e* s*ste+s
Rubber is i!e, &or t"ese ro!ucts !ue to its &,e2ibi,it*-
but t"e be,t +ust "(e ,itt,e or no e2tensibi,it* 6ccor!ing,*- it is rein&orce! )it" &ibers- co++on,*
o,*ester or n*,on
5brics o& t"ese o,*+ers re usu,,* cote! b*
c,en!ering- sse+b,e! toget"er to obtin re
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Ot"er Rubber Pro!ucts
Hose
T)o bsic t*es
1. P,in "ose 0no rein&orce+ent is e2tru!e! tubing
$. Rein&orce! tube- )"ic" consists o&
Inner tube ; e2tru!e! o& rubber co+oun!e!
&or rticu,r ,i
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Ot"er Rubber Pro!ucts
5oot)er
Rubber co+onents in &oot)er so,es- "ee,s- rubber
o(ers"oes- n! certin uer rts
%o,!e! rts re ro!uce! b* inection +o,!ing-co+ression +o,!ing- n! certin seci, +o,!ing
tec"ni
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Processing o& T"er+o,stic
E,sto+ers
6 t"er+o,stic e,sto+er 0TPE is t"er+o,stic
o,*+er t"t ossesses t"e roerties o& rubber
TPEs re rocesse! ,i/e t"er+o,stics- but t"eir,ictions re t"ose o& n e,sto+er
%ost co++on s"ing rocesses re inection
+o,!ing n! e2trusion
Gener,,* +ore econo+ic, n! &ster t"n t"etr!ition, rocesses &or rubbers t"t +ust be
(u,cni4e!
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TPE Pro!ucts
%o,!e! ro!ucts s"oe so,es- t",etic &oot)er- n!
uto+oti(e co+onents suc" s &en!er e2tensions
n! corner ne,s E2tru!e! ite+s insu,tion coting &or e,ectric, )ire-
tubing &or +e!ic, ,ictions- con(e*or be,ts- s"eet
n! &i,+ stoc/
No tires o& TPE
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Pro!uct 'esign Consi!ertions
Econo+ic Pro!uction Juntities
Rubber rts ro!uce! b* co+ression +o,!ing 0t"e
tr!ition, rocess cn o&ten be ro!uce! in
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Pro!uct 'esign Consi!ertions
'r&t
'r&t is usu,,* unnecessr* &or +o,!e! rts o&
rubber- becuse its &,e2ibi,it* ,,o)s it to !e&or+ &orre+o(, &ro+ t"e +o,!
S",,o) un!ercuts- ,t"oug" un!esirb,e- re
ossib,e )it" rubber +o,!e! rts &or t"e s+e
reson T"e ,o) sti&&ness n! "ig" e,sticit* o& t"e +teri,
er+its re+o(, &ro+ t"e +o,!