The presentation is based upon the quality testing and procedures of natural rubber and synthetic rubber. This presentation also contains part of Mouding process in rubbers.
2. INDEX
Introduction
Polymers
Classification of polymers
Rubber Compounding
Quality Control Testing
Result
Moulding Process
Applications
Conclusion
3. INTRODUCTION
COMPANY PROFILE
Bony Polymers (P) Ltd. was established in the year
1981
Bony Polymers (P) Ltd. manufacturing Rubber
Moulded Parts are Rubber to Metal Bonded Parts,
Gaskets Materials, Hoses, Hose Assemblies & Fuel
Tubes for automotive and non automotive sectors.
The annual turnover of the Bony Polymer Private
limited was almost 106 Millions$ in 2016-2017
session.
5. POLYMER
The term polymer was coined by Jones Jacob Berzelius
in 1833.
The word polymer comes from the Greek prefix poly-,
which means "many", and the suffix -mer, which means
"parts".
RUBBER- These may describe as the material having
the Elastic properties
Natural rubber is obtained from nearly from five
hundred different plants, but the main source is Hevea
braziliensis tree and its milky sap is known as Latex.
Synthetic Rubber are mainly polymers of 1, 3-
Butadiene and Styrene form Styrene-Butadiene
Rubber (SBR) and Neoprene
6.
7. RUBBER
COMPOUNDING
RUBBER/POLYMER
Natural Rubber- Latex(1,4-
polyisoprene) and
Synthetic Rubber-Neoprene
and Styrene butadiene (SBR)
FILLERS
White Fillers-Silica, Calcium
Silicates, Talc, China Clay, CaCO3
etc.
Black Fillers-Carbon Black etc.
OILS & CHEMICALS
OILS- Naphthenic, Paraffinic,
Aromatic etc.
CHEMICALS-
,
,
,
8. QUALITY CONTROL TESTING
DUROMETER
Its is a simplest method to measure the
hardness the rubber compound
The diameter of the rubber compound is
about 6-12mm
This device measure the hardness of
compound in the unit Shore.
Hardness is inversely proportional to
Penetration
The shape of the penetrator, the force
applied, and the duration of the test influence
the result
9. ELECTRONIC DENSIMETER
It is used to calculate the density of the rubber
compound.
The size of rubber compound should be 6-12
mm in diameter.
The load carrying capacity of this instrument
lies between 0.1- 300g.
It has resolution power about 0.0001gm/cm3
This is the best instrument which is used in
the industry
It calculate the result or density by using
follow equation:
Air Weight of rubber button ˟ 100
(Air weight- Liquid Weight)
10. RHEOMETER
Rheo- To flow
Logos- Science
Rheology is the study of the flow and deformation of matter
under stress.
The rheometer has following
specifications-
Average Time-5-7 Min.
Temperature- 1700 C
Pressure-5-6 Kg/cm2
Torque Angle-3600
11. MOONEY VISCOMETER
It is called as Mooney
viscometer as it invented by Melvin
Mooney.
It is used to measure viscosity of
rubber and elastomers
It consists of rotating spindle and
heated dies, the substance encloses and
overflows the spindle and the viscosity
is calculated by from the toque on the
spindle.
Specifications-
Sample Weight- 3-5 gm
Average Time- 5 Min. Avg. Temp.-130-1500 C
Pressure Applied- 4-5 kg/cm2
13. RESULT
NATURAL RUBBER SYNTHETIC RUBBER
DUROMETER
ELECTRO DENSIMETER
RHEOLOGY
TT
COMPOUND HARDNESS
(SHORE)
1. NR (Natural
Rubber)
55 + 5
COMPOUND HARDNESS
2. EPDM 70 + 5
COMPOUND DENSITY (gm/cm3)
1. NR (Natural
Rubber)
0.906-0.916
COMPOUND DENSITY(gm/c
m3)
2. EPDM 1.145-1.149
COMPOUND
ML(lb-in) MH(lb-in) Ts2 (Sec) Ts90 (Sec)
NR 18-25 33-55 0.50-1.0 1.20-1.80
COMPOUND
ML(lb-
in)
MH(lb-
in)
Ts2
(Sec)
Ts90
(Sec)
EP 4-7 28-39 1.30-
2.0
2.0-3.0
TO BE
14. MOONEY VISCOSITY
TENSILE TESTING
Industry is following three Standards for the quality control process
ASTM – AMERICAN SOCIETY OF TESTING MATERIAL
JIS- JAPANESE INDUSTRY STANDARD
IS- INDIAN STANDARD
COMPOUND
ML ML(1+4)
NATURAL
RUBBER
27-33 35-45
COMPOUN
D
ML ML(1+4)
EP(Ethylen
e
propylene)
41-51 50-60
Time(Min
)
Hardnes
s
Tensile(k
g/cm2)
Elongati
on
(%)
6 50 170.91 239
8 50 185.71 223
10 52 193.20 243
12 52 195.08 245
15 55 195.82 248
Time
(Min)
Hardness Tensile
(kg/cm2)
Elongation
(%)
6 70 95.91 383
8 70 100.71 390
10 72 101.20 382
12 72 103.08 393
15 75 104.82 407
15. MOULDING
Moulding is the process of manufacturing by shaping liquid or pliable
raw material using a rigid frame called a mould or matrix. This it may
have been made using a pattern or model of the final object.
There are three basic techniques of the Moulding-
1. Injection Moulding
2. Compression Moulding
3. Transfer Moulding
17. CONCLUSION
There are various differences in the properties and quality of
natural rubber and the synthetic rubber.
The greatest tensile and elongation properties are obtained for
synthetic rubber compounds at 1500C and for Natural rubber
compound the tensile strength and elongation properties are
best obtained at room temperature.
Warm maturing does not cause much lessening in ductile
properties of Rubber Compound. The shape and size of rubber
compound sample is according to standard designed by
industry.
The rubber compounds should be check in quality control lab
before dispatch and if any measurement issues observe it goes
to R&D lab for further mastication process and again all
properties of rubber sample is check (Rheology, Viscosity,
Tensile strength, Density, Elongation Etc.)