(SHREYA) Chakan Call Girls Just Call 7001035870 [ Cash on Delivery ] Pune Esc...
industrial prctice and presentation (prs tyres) ppt.pptx
1. DEPARTMENT OF MECHANICAL ENGINEERING
SREENEVAS. M (201083859)
NIRMAL PRAKASH. S( 201083838)
PRABAKARAN. P( 201083843)
NITHISH. K( 201083839)
Mahendhirapuri, Mallasamudram, Namakkal DT -637 503.
November -2022
1
19ME25601-INDUSTRIAL PRACTICE AND
PRESENTATION
IPP CO-ORDINATOR
Mr .C. K. Murugesan, ME
.Assistant Professor,
Dept. of Mechanical Engineering.
2. CHAPTER-1
INTRODUCTION
PROFILE OF THE COMPANY:
Prs Tyres Private Limited is a Private incorporated on 01 September 1987. It is
classified as Non-govt company and is registered at Registrar of Companies,
Coimbatore. Rs.50,000,000anditspaidupcapitalisRs.48,780,700.ItisinolvedinFORESTRY
RELATED SERVICE ACTIVITIES.Prs Tyres Private Limited’s Annual General
Meeting (AGM) was last held on 30 November 2021and as per records from Ministry
of Corporate Affairs (MCA), its balance sheet was last filed on 31 March2021.
DirectorsofPrsTyresPrivateLimitedarePrasanthPalanisamy,PrasanthKavitha,SellamPalani
samy,Palanisamyand.PrsTyresPrivateLimited’sCorporateIdentificationNumberis(
CIN)U02511TZ1987PTC002030 and its registration number is 2030.It
EMAIL:prstyres@gmail.comanditsregisteredaddressis2,SIVAGNANAMSTREET,GAN
ESAPURAM,NAMAKKALNamakkalTN637001 IN. The rubber tire manufacturing
industry is the subject of a New Source Performance Standard(NSPS)published
in40CFRPart60SubpartBBB, September15,1987.EPAis in process of developing a
regulation that would establish limits on the HAPs emitted from the rubber tire
manufacturing process.
Tyres are the only point of contact of the vehicle with the road. The intentions of the
driver are finally executed by the tyres only, hence the quality and design of the
tyres is important. The rubber tube inflated with air supports the whole weight of the
car, but the rubber tube cannot directly come in contact with the road as it cannot resist
wear and it lacks strength. Tyre encases the rubber tube.
2
3. CHAPTER-2
INTRODUCTION OF PROJECT
1. Tyre is a composite structure consisting of many layers. They usually consist of
1. Inner liner
2. Body ply
3. Side wall
4. Beads, Apex
5. Belt Package
6. Tread
7. Cushion Gum.
8. Fig.2.1 Schematic of the components of a tyre
3
4. 4
Steering: Tyres should steer the vehicle with precision irrespective of surface of the
road, weather conditions. The stability of a vehicle's path depends upon ability of tyre
to hold its course by maintaining proper traction with the road. It should stand upto
transversal forces without drifting from its path.
Carrying load: Tyres should carry lot of weight usually more 50 times its own weight
not only when it is in motion but also at rest. Car usually weighs around 1.6 tonnes
and the area of contact of a single tyre with road is size of a post card. Hence each tyre
experiences a compressive stresses of the order of few MPa.
Cushioning: Tyres absorb the shock due to obstacles or irregularities present on the
surface of the road, providing a comfort travel to the passenger as well as ensuring
long life of the vehicle. The main characteristic of tyre is its ability to yield when stress
is applied and return to its original shape when stress is removed, with the tyre lasts, or
in other words, keeps its optimumperformance level for millions of wheel revolutions.
The tyre’s wear depends on its conditions of use (load, speed, condition of the road
surface, state of the vehicle, style of driving, etc.) but above all the quality of its
contact with the ground. Pressure therefore plays a major role. e stress cycle occurring
at very high frequencies.
Transmitting Drive: Tyres transmit drive namely the engine's usable power, braking
effort with the help of the friction. Superior quality and efficient design of the tyre helps
in making complete use of engine's power and braking facility.
Long Lasting Life: Tyres should be able to give optimum performance for millions
of revolutions. Life of a tyre depends on a variety of factors like quality of contact
INNER LINER:
It is an extruded halobutyl rubber sheet compounded with additives that result in low
air permeability. The inner liner assures that the tire will hold high-pressure air inside,
without theair gradually diffusing through the rubber structure.
5. 5
BODY PLY:
The body ply is a calendered sheet (two or more sheets are rolled together such that
mechanically they are bonded) consisting of consecutive layers of rubber and
reinforcing fabric. They give the structural strength to the tyre. Passenger tyres
typically have one or two body plies. Truck tires, off-road tires, and aircraft tires have
progressively more plies. The fabric cords are highly flexible but relatively inelastic.
The textile materials used are cotton in early years now replaced by rayon, nylon,
kevlar, polyester.
Sidewalls:
Sidewalls are non-reinforced extruded profiles with additives to give the sides of the
tire good abrasion resistance and environmental resistance. Additives used in sidewall
compounds include antioxidants and antiozonants to protect the tyre from
decomposition when exposed to ultra violet light. Sidewall extrusions are
nonsymmetrical and provide a thick rubber area to enable molding of raised letters and
sidewall ornamentation.
Beads:
Beads are bands of high tensile-strength steel wire encased in a rubber compound.
Bead wire is coated with special alloys of bronze or brass. Coatings protect the steel
from corrosion. Copper in the alloy and sulphur in the rubber cross-link to produce
copper sulphide, which improves bonding of the bead to the rubber. Beads are
inflexible and inelastic, and provide the mechanical strength to fit the tyre to the
wheel. Bead rubber includes additives to maximize strength and toughness.
Apex:
The apex is a triangular extruded profile that mates against the bead. The apex
provides a cushion between the rigid bead and the flexible inner liner and body ply
assembly. It is alternatively called as "filler" in literature and industry.
Belt Package:
Belts are calendered sheets consisting of a layer of rubber, a layer of closely spaced
steel cords, and a second layer of rubber. The steel cords are oriented radially in radial
6. 6
tire construction, and at opposing angles in bias tire construction. Belts give the tyre
strength and dent resistance while allowing it to remain flexible. Passenger tires are
usually made with two or three belts.
Tread:
The tread is a thick extruded profile that surrounds the tire carcass and this
is the layer which comes directly in contact with the. Tread compounds
include additives to impart wear resistance and traction in addition to
environmental resistance. Tread compound development is an exercise in
compromise, as hard compounds have long wear characteristics but poor
traction whereas soft compounds have good traction but poor wear
characteristics.
Cushion Gum:
Many higher-performing tyres include an extruded component between the belt
package and the tread to isolate the tread from mechanical wear from the steel
belts.
Many higher-performing tyres include an extruded component between the belt package
and the tread to isolate the tread from mechanical wear from the belt.
2.2 MixingMill-(UsedinProcessofCompounding&Mixing)
working to the rubber, and produce a thick rubber sheet. This mill is used
of hard foreign bodies between the rolls. In contrast to mechanical overload
protection systems utilizing shear plates or bolts, no time is lost replacing
damaged safety components. Control system The control system consists of a
control cabinet and an operating panel. The control cabinet contains the power
supply, main . The components include compounds which act as accelerators, anti-
oxidants, anti-ozonants, extenders, vulcanizers, pigments, plasticizers, reinforcing
7. agents and resins. Most constituents are unregulated and may not have had extensive
toxicological evaluations. Generally speaking, the Banbury operators' occupational
exposures to the raw materials have been reduced by improvements in administrative
and engineering controls. However, concern remains due to the nature and quantity of
components which make up the exposure.
isolator elements, push buttons, indicator lights and a graphic display showing.
FIG:2.2 MixingMill
7
8. CHAPTER-3
3.1RAW MATERIALS USED
The above mentioned tyre components use a broad variety of materials like different
rubber compounds, different types of carbon black, fillers like clay and silica, chemicals
or minerals added to accelerate/decelerate vulcanisation. The tyres also have several
types of fabric for reinforcement, several kinds and sizes of steel.
Fig no 3.1 Approximate amount of various materials used in different tyres
8
9. 9
3.2 Natural Rubber:
Natural Rubber is an elastomer derived from latex, a milky colloid produced by some
of the plants like Hevea brasiliensis. These plants produce latex when they are
wounded as a healing mechanism. The latex is collected in a vessel and it is allowed to
coagulate which gives you the solid rubber which can be further processed in to
sheets. The coagulation process can be controlled by chemicals like Ammonia, Formic
acid. Ammonia decelerates the coagulation process whereas Formic acid accelerates it.
The purified natural rubber is same as polyisoprene. The butadiene,CH2=C(CH3)-
CH=CH2.
Synthetic Rubber
Synthetic rubber can be made from the polymerization of a variety of monomers
including isoprene (2-methyl-1,3-butadiene), 1,3-butadiene, chloroprene (2-chloro-1,3-
butadiene), and isobutylene (methylpropene) with a small percentage of isoprene for
crosslinking. These and other monomers can be mixed in various desirable proportions
copolymerized for a wide range of physical, mechanical, and chemical properties.The
monomers can be produced pure and the addition of impurities or additives can be
controlled by design to give optimal properties. Polymerization of pure monomers can
be stereospecifically regulated through various catalysts to acheive the desired cis or
trans doublebonds.
10. Fig.3.2 Various Polymerized products obtained from polymerization of
polyisoprene
Carbon Black:
Carbon black is a material produced by the incomplete combustion of heavy petroleum
products such as coal tar, ethylene cracking tar etc., It is a form of amorphous carbon
that has a high surface-area-to-volume ratio and significantly lower PAH (polycyclic
aromatic hydrocarbon). It is used as a pigment and reinforcement filler in the tyre. It
helps in conductingheat away from the tread and belt area of the tire, reducing thermal
damage and increasing tire life. While a pure styrene-butadiene rubber has a tensile-
strength of no more than 2.5MPa, and almost nonexistent abrasion resistance,
compounding it with 50% of its weight of carbon black improves its tensile strength to
20MPa and considerable wear resistance.
Fumed Silica:
It is also known as pyrogenic silica as it is produced in a flame, consisting of
microscopic droplets of amorphous silica fused into branched, chainlike, three-
dimensional secondary particles which then agglomerate into tertiary particles. The
resulting powder has an extremely low bulk density and high surface area. Its three-
dimensional structure results in viscosity- increasing behavior when used as a
thickener or reinforcing filler.
10
11. 11
Fumed silica also provides better trade-off for fuel efficiency and wet handling
due to a lower rolling loss compared to carbon black-filled tires. Traditionally silica
fillers had worse abrasion wear properties, but the technology has gradually improved
to where they can match carbon black abrasion performance.
Vulcanization:
Natural Rubber is sticky, deforms easily when warm, and is brittle when cold.
Vulcanization is a chemical reaction which helps in betterment of some of the
properties like removes the sticky behavior, increases the young's modulus etc., in this
chemical reaction elements/compounds like Sulphur are added which have the ability
to form cross-links between the long chain polymer molecules, converting the rubber
from a thermoplastic to a thermosetting polymer. The extent of vulcanization reaction
can be controlled by accelerators and retarders.A derivative of aniline called
thiocarbanilide, zinc oxide accelerates the action of sulfur to rubber, leading to shorter
cure times.
Antioxidant:
An antioxidant is a molecule capable of preventing oxidation of other
molecules. We say something is oxidized if it loses electrons, hence moving to a
higher oxidation state. Oxidation reactions can produce free radicals which can result
in polymerization.As the tyre components are exposed to sunlight free radicals may
get generated, antioxidants essentially terminate these free radicals preventing
extraneous polymerization reactions. Antioxidants basically undergo oxidation
reaction themselves, thus preventing oxidation of other compounds.
Antiozonant:
Rubber contains an unsaturated double bond, as the tyre is always exposed to
atmosphere ozone gas present in the atmosphere may break the double bond in to
aldehydes or ketones. Thus reducing the degree of polymerization results into the
degradation of properties. Cracks start to appear on the tyre, which are called as ozone
cracks. Antiozonants are chemical compounds that prevent or slow down the
degradation of material caused by ozone gas in the air. Paraffin wax acts as an
12. 12
antiozonant by the means of formation of a surface barrier.
In its simplest format, a curing oven achieves this by elevating the temperature of a
sample material to within or above a specific limit.An industrial curing oven is a
piece of thermal processing equipment designed to improve the strength and
durability of a material by accelerating a desirable chemical reaction. In its simplest
format, a curing oven achieves this by elevating the temperature of a sample
material to within or above a specific limit.his may be enough to improve the
physiochemical linkages within the material and improve the mechanical
characteristics of the product. More often, one or more catalyzing agents are
introduced into the curing oven to facilitate the required reaction.
This may entail extensive lifting and handling of heavy rolls in a limited space. The
nature of assembly also requires the tyre builder to perform a series of similar or
identical motions on each assembly. Tyre builders utilize solvents, such as hexane,
which allow the tread and plies of rubber to adhere. Exposure to the solvents is an area
of concern. After being assembled, the green tyre is sprayed with a solvent- or water-
based material to keep it away from adhering to the curing mould.
. Components, often in heavy rolls, are placed onto the feeding portions of the assembly
equipment. This may entail extensive lifting and handling of heavy rolls in a limited
space. The nature of assembly also requires the tyre builder to perform a series of similar
or identical motions on each assembly. Tyre builders utilize solvents, such as hexane,
which allow the tread and plies of rubber to adhere.
13. CHAPTER-4
4.1 TYRE MANUFACTURING PROCESS:
Fig. 4.1 SCHEMATIC OF TYRE MANUFACTURE PROCESS
4.3 Compounding and Banbury mixing
A Banbury mixer combines rubber stock, carbon black and other
chemical ingredients tocreate a homogeneous rubber material. Time, heat and
raw materials are factors utilized to engineer material composition. The
ingredients are generally provided to the plant in pre- weighed packages or
are prepared and weighed by the Banbury operator from bulk quantities.
Measured ingredients are placed onto a conveyor system, and the Banbury is
charged to initiate the mixing process. Hundreds of components are combined
1
14. to form rubber utilized for tyre manufacturing. The components include
compounds which act as accelerators, anti-oxidants, anti-ozonants, extenders,
vulcanizers, pigments, plasticizers, reinforcing agents and resins. Most
constituents are unregulated and may not have had extensive toxicological
evaluations. Generally speaking, the Banbury operators' occupational
exposures to the raw materials have been reduced by improvements in
administrative and engineering controls. However, concern remains due to the
nature and quantity of components which make up the exposure.
1
Fig. 4.3.a) Mill for calender line with a body bar guard that shuts down the mill
if tripped by workers
Fig. 4.3.b) Drop mill and dryer with canopy hood and trip wires
Extruding and Calendering:
The extruder is often referred to as a “tuber”
because it creates tube-like rubber components. The extruder functions by
forcing rubber through dies of appropriate shape. The extruder consists of a
screw, barrel or cylinder, head and die. A core hollow inside of tubing.
15. 1
Extruder and calender operators may be exposed to talc and solvents, which
are used inthe process. Also, the workers at the end of the extrusion operation
are exposed to a highly repetitive task of placing the tread onto multi-tiered
carts. This operation is often referred to as booking treads, because the cart
looks like a book with the trays being the pages.The configuration of the
extruder as well as the weight and quantities of tread to be booked contribute
to the ergonomic impact of this operation. Numerous changes have been made
to lessen this, and some operations have been automated.
Component Assembly and Building:
, The tyre assembly machine consists of a rotating drum, on which the
components are assembled, and feeding devices to supply the tyre builder
with the components to assemble (see figure 80.7). The components of a tyre
include beads, plies, side walls and treads. After the components are
assembled, the tyre is often referred to as a “green tyre”.Tyre builders and
other workers in this area of the process are exposed to a number of repetitive
motion operations. Componentsoften in heavy rolls, are placed onto the
feeding portions of the assembly equipment. This may entail extensive lifting
and handling of heavy rolls in a limited space. The nature of assembly also
requires the tyre builder to perform a series of similar or identical motions on
each assembly. Tyre builders utilize solvents, such as hexane, which allow the
tread and plies of rubber to adhere. Exposure to the solvents is an area of
concern. After being assembled, the green tyre is sprayed with a solvent- or
water-based material to keep it away from adhering to the curing mould.
These solvents potentially expose the spray operator, material handler and
curing press operator. Nowadays, water-based materials are mostly used.
4.4 TyreBuilding:
Mostofthecomponentsarevariouskindsofreinforcements.Tyremakersassembleth
ecomponentsintogreentyresusingassemblymachinery.The frame is then
pressurised and stretched to fuse with the above-mentioned unity.
16. FIG: 4.4TyreBuilding
The tyre assembly machine consists of a rotating drum, on which the
components are assembled, and feeding devices to supply the tyre builder with
the components to assemble (see figure 80.7). The components of a tyre
include beads, plies, side walls and treads. After thecomponents are assembled,
the tyre is often referred to as a “green tyre”.
Tyre builders and other workers in this area of the process are exposed to a
number of repetitive motion operations. Components, often in heavy rolls, are
placed onto the feeding portions of the assembly equipment. This may entail
extensive lifting and handling of heavy rolls in a limited space. The nature of
assembly also requires the tyre builder to perform a series of similar or
identical motions on each assembly. Tyre builders utilize solvents, such as
hexane, which allow the tread and plies of rubber to adhere. Exposure to the
solvents is an area of concern. After being assembled, the green tyre is sprayed
1
17. 1
with a solvent- or water-based material to keep it away from adhering to the
curing mould. These solvents potentially expose the spray operator, material
handler and curing press operator. Nowadays, water-based materials are mostly
used.
Inspection and Finishing:
Following curing, finishing operations and inspection remain to be
performed before the tyre is stored or shipped. The finishing operation trims
flash or excess rubber from the tyre.This excess rubber remains on the tyre
from vents in the curing mould. Additionally, excess layers of rubber may need
to be ground from the side walls or raised lettering on the tyre. One of the
major health hazards that workers are exposed to while handling a cured tyre is
repetitive motion. The tyre finishing or grinding operations typically expose
workers to cured rubber dust or particulate. This contributes to respiratory
illness in workers in the finishingarea. In addition, a potential exists for solvent
exposure from the protective paint which is often used to protect the side-wall
or tyre lettering. After finishing, the tyre is ready to be stored in a warehouse or
shipped from the plant
LIMITATIONS OF EXISTING SYSTEM :
MajorBy-productsandCo-products:
Based on the bar coding, the tyre is now set for curing.
The plant has hundreds of moulding machines. For the TBR’s there is a lift
machine that carries the Green Tyre from the tyre building to the curing
area. For PCR’s this is done manually using forklifts. The curing machine
consists of a mould that is as per the specifications of that exact tyre size
and model. There are hundreds of curing machines with moulds for the
tyres that match. The Green Tyre is placed inside the mould and a rubber
18. 1
bladder inside inflates inside (similar to a the tube of a tyre). This bladder
applies pressure outwards so that the tyre pushes out to the mould. The
curing process is at a temperature of around 300 degrees C and the
duration varies from 8 minutes to 20 minutes depending on the tyre and
compound. The mould has the tread pattern and the sidewall lettering on it,
including the date code which has week and year of manufacture
mentioned. Every week the mould is modified with the current week code.
What finally emerges post curing is the finished tyre. This is then moved
onto a conveyor belt and sent for inspection.
In its simplest format, a curing oven achieves this by elevating the
temperature of a sample material to within or above a specific limit.An
industrial curing oven is a piece of thermal processing equipment designed
to improve the strength and durability of a material by accelerating a
desirable chemical reaction. In its simplest format, a curing oven achieves
this by elevating the temperature of a sample material to within or above a
specific limit.his may be enough to improve the physiochemical linkages
within the material and improve the mechanical characteristics of the
product. More often, one or more catalyzing agents are introduced into the
curing oven to facilitate the required reaction.
Curing ovens are commonly used to engineer raw materials such as
synthetic adhesives, thermoset polymers, and rubber. Chemical curing is
also used to enhance the properties of construction materials in situ, but
this application requires highly-specialized curing apparatuses to
encourage thermosetting in situ over extended periods.
IMPLEMENTATIONAND TESTING:
Following curing, finishing operations and inspection remain to be performed
before the tyre is stored or shipped. The finishing operation trims flash or
excess rubber from the tyre.
This excess rubber remains on the tyre from vents in the curing mould.
Additionally, excess layers of rubber may need to be ground from the side
19. 1
walls or raised lettering on the tyre. One of the major health hazards that
workers are exposed to while handling a cured tyre is repetitive motion. The
tyre finishing or grinding operations typically expose workers to curedrubber
dust or particulate. This contributes to respiratory illness in workers in the
finishingarea. In addition, a potential exists for solvent exposure from the
protective paint which is oftenused to protect the side-wall or tyre lettering.
After finishing, the tyre is ready to be stored in a warehouse or shipped from
the plant.
20. 2
CONCLUTION:
Constant improvements in rubber chemistry and tire design are creating
exciting new tires that offer greater mileage and improved performance in
extreme weather conditions. Manufacturers now offer tires estimated to last
up to 80,000 miles. Treads, designed and tested by computer, now feature
unique asymmetrical bands for improved traction and safety on wet or snowy
roads.Tire design engineers are also experimenting with non-pneumatic tires
that can never go flat because they don't contain air under pressure. One such
non-pneumatic tire is simply one slab of thick plastic attached to the wheel
rim. The plastic curves out from the rim to a point where a rubber tread is
secured to the plastic for contact with the road. Such a tire offers lower rolling
resistance for greater fuel economy and superior handling because of a greater
area of contact between tread and road.
