Presentation - Tyre Manufacturing[1]

8/11/2019 Presentation - Tyre Manufacturing[1]

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MOHAMAD REDZUAN BIN ABDULLAH ZAWAWI

ISWANDI BIN WI

HILMI BIN NANDAN

MOHD HIZAR

MANSHID @ SHAHEMANJA


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DEFINITION

A tyreis a ring-shaped covering that fits around awheel rim to protect it and enable better vehicleperformance by providing a flexible cushion that

absorbs shock while keeping the wheel in closecontact with the ground.

BACKGROUND

The fundamental materials of modern tires are

rubber and fabric along with other compoundchemicals. They consist of a tread and a body. Thetread provides traction while the body ensuressupport.


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APPLICATION

Before rubber was invented, the first versions of tireswere simply bands of metal that fitted around woodenwheels in order to prevent wear and tear. Today, thevast majority of tires are pneumatic, comprising a

doughnut-shaped body of cords and wires encased inrubber and generally filled with compressed air toform an inflatable cushion. Pneumatic tires are usedon many types of vehicles, such as bicycles,

motorcycles, cars, trucks, earthmovers and sircraft.


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14% NATURAL RUBBER

27% SYNTHETIC POLYMERS

28% CARBON BLACK

10% OIL 4% OTHER PETROCHEM

4% FABRIC

10% WIRE 3% OTHERS


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1) Natural rubber/polyisoprene The basic elastomeric used in tyre making.

It was derived from latex, a milky colloid found in the sap of someplants. Rubber's stress-strain behaviour is often modelled as hyperelastic. Rubber strain crystallizes. Natural rubber is sensitive to ozone

cracking.2) Styrene-Butadiene-Rubber (SBR) a synthetic rubber copolymer consisting of styrene and butadiene.

has good abrasion resistance and good aging stability when protected

by additives can be produced from solution or as emulsion. Pressure reaction

vessels are required and usually charged with the two monomers, a freeradical acid and a chain transfer agent such as an alkyl mercaptan.

The latter prevents high molecular weight and high viscosity product

from forming


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3) Polybutadiene a synthetic rubber that is a polymer formed from the polymerization of

the monomer 1,3-butadiene.

has a high resistance to wear It is a highly resilient synthetic rubber.Heat build-up is subjected to repeat flexing during serviceLow rollingresistance of this rubber also leads to its use in the tread portion of tires

4) Butyl rubber a synthetic rubber, a copolymer of isobutylene with isoprene. Butyl rubber is produced by polymerization of about 98% of

isobutylene with about 2% of isoprene.

Butyl rubber is used for the tubeless inner liner compounds, because ofits low air permeability.

The halogen atoms provide a bond with the carcass compounds whichare mainly natural rubber.


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5) Carbon black a material produced by the incomplete combustion of heavy petroleum

products such as FCC tar, coal tar, ethylene cracking tar, and a small

amount from vegetable oil.

a form of amorphous carbon that has a high surface-area-to-volumeratio.

the most common use [70%] is as a pigment and reinforcing phase inautomobile tires.

helps conduct heat away from the tread and belt area of the tire,reducing thermal damage and increasing tire life.

6) Silica the chemical compound silicon dioxide with a chemical formula of

SiO2and has been known for its hardness since antiquity.

is most commonly found in nature as sand or quartz, as well as in thecell walls of diatoms. It used together with carbon black in highperformance tires, as a low heat build up reinforcement.


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7) Sulphur is the chemical element that has the atomic number 16.

it crosslink the rubber molecules in the vulcanization process.

8)Vulcanizing Accelerators are complex organic compounds that speed up the vulcanization.

these additives modify the polymer by forming crosslink (bridges)between individual polymer chains.

The vulcanized material is less sticky and has superior mechanicalproperties.


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9)Activators assist the vulcanization.

the main one is zinc oxide.

10) Antioxidants and antiozonants prevent sidewall cracking due to the action of sunlight and ozone.

11) Textile fabric and steel wire reinforces the carcass of the tire.


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TYRE CONSTRUCTION


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CASING or CARCASS

The casing is the framework of thetyre. It must be strong enough to

withstand high inflation pressure, yetflexible enough to absorb loadchanges and impact.

It consists of tyre cords coated with

compounded rubber. Generally, tyresare classified into Bias or Radial plyconstruction.


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PLY This is a layer tyre cord (textile or

steel) extending from bead to bead

makes up the carcass of the tyre. Plies are turned up and around the

beads which lock the bead into thecarcass.


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BEAD This is part of tyre which is

shaped to fit on the rim.

is made of continuous hightensile wire wound to form ahigh strength unit, the bead wirecore is the anchor foundation ofthe casing which maintain therequired tyre diameter on therim.


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TREAD

Tread rubber provides the interface between thetyre structure and road.

Primary purpose is to provide traction and wear.


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BREAKER This is the layers of tyre cord

(textile or steel) directly under

the tread,run circumferentiallyaround the tyre.

Breaker plies provide strengthto the tyre stabilize the treadand protect external damageto the casing.


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SIDEWALL

This is the part betweentread and bead and is

directly related to the ridecharacteristics of the tyre. Itis specially compounded to

withstand flexing and

weathering while providingprotection for the casing.

SIDEWALL


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APEX

Triangle rubber piece withselected characteristics are

used to fill in the bead andlower sidewall area toprovide a smooth transitionfrom the stiff bead area to

the flexible sidewall.

APEX


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CHAFER

It consists of narrow stripsof specially compounded

rubber or ply materialaround the outside of thebead that reinforces andstabilizes the bead to

sidewall' transition zone. Itprotects the bead area fromchafing or cutting by therim.

CHAFER


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LINER

A layer of non-porousrubber incorporated at the

internal part of the casing.Its purpose is to provide acomplete seal which retainthe inflation pressure.

LINER


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MIXING PROCESS

Equipment = BanburyMixer

Input Material = naturalrubber, syntheticrubber, carbon black &chemicals

Output = slabcompound


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EXTRUSION PROCESS

Equipment = Extruder

Input Material = slabcompound

Output = tread, sidewall& apex


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CALENDERINGPROCESS

Equipment = 4 RollCalender

Input Material = fabric,steel wire & slab

compound Output = calendered

fabric/steel ply & liner


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PLY/BREAKER CUTTINGPROCESS

Equipment =ply/breaker cutter

Input Material = fabric& steel plies

Output = ply & breaker


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BEAD PROCESS

Equipment = bead

insulation Input Material = steel

wire & slab compound

Output = bead


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TYRE BUILDINGPROCESS

Equipment = tyrebuilding machine

Input Material = liner,chafer, ply, breaker,

bead, apex, sidewall &tread

Output = green tyre


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CURING PROCESS

Equipment = curing

press Input Material = green

tyre

Output = finish tyre


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FINAL FINISHING

After the tire has been cured, there are several

additional operations.

Tire uniformity measurement is a test where

the tire is automatically mounted on wheelhalves, inflated, run against a simulated road

surface, and measured for force variation.

Tire balance measurement is a test where the

tire is automatically placed on wheel halves,

rotated at a high speed and measured forimbalance.


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TWEELan experimental tyre design

developed by the French tyrecompany Michelin.

uses no air, cannot burst or

become flat.the Tweel's hub connects to

flexible polyurethane spokeswhich are used to support anouter rim and assume theshock-absorbing role of atraditional tyre's pneumaticproperties.


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AIRLESS TYRENon-pneumatic tires or Airless

tires, are tires that are not supportedby air pressure

used on some small vehicles such asriding lawn mowers and motorized

golf carts, heavy equipment such asbackhoes

have higher rolling friction andprovide much less suspension thansimilarly shaped and sized

pneumatic tires.cannot go flat, but they are far less

common than air filled tires.


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RUN FLAT TYRENon-pneumatic tires or Airless

tires, are tires that are notsupported by air pressure

used on some small vehicles such asriding lawn mowers and motorized

golf carts, heavy equipment such asbackhoes

have higher rolling friction andprovide much less suspension thansimilarly shaped and sized

pneumatic tires.cannot go flat, but they are far less

common than air filled tires.


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Pneumatic tires are used on many types of vehicles,such as bicycles, motorcycles, cars, trucks,earthmovers and aircraft.

Tires enable better vehicle performance by providingtraction, braking, steering and load support.

Tires form a flexible cushion between the vehicle andthe road, which smoothes out shock and makes for a

comfortable ride.

Presentation - Tyre Manufacturing[1]

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