GROOVED RUBBER SOLE PLATE

(GRSP) 6MM

QUALITY ASSURANCE CIVIL DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION,

(MINISTRY OF RAILWAYS)
MANAK NAGAR, LUCKNOW-226011
 SAILENT FEATURES OF GRSP 6mm

 Specific Guidelines: QC-G-7.1-3 Ver. 1)

 Specification : IRS:T-47-2006
 Raw Material : Natural Rubber (Ribbed Smoked
Sheet Grade I to IV)
 Drawing No. : RDSO/T-3703, RDSO/T-3711
 Gauge Drg. No.: RDSO/T-8119 & RDSO/T-8120
GROOVED RUBBER SOLE PLATE

 COMPONENTS

 TYPICAL MIX PROPORTIONS

 PROCESS
PRODUCTION INFRASTRUCTURE

 KNEADER

 MIXING MILL

 HYDRAULIC PRESS

 TESTING EQUIPMENT
TEST PARAMETERS

 PRE-PRODUCTION TEST
 Pilot Test Study is conducted at regular interval to
ascertain the properties of major raw material. If results
are satisfactory only then further production is allowed.
 Mix/Batch Testing is carried out to ascertain the accuracy
of production process as per clause 3.1.2 of IRS- T-
47/2006.
 Rheometer is used to ascertain properties like optimum
curing time and curing temperature
TEST PARAMETERS
 FINISHED PRODUCT
 Hardness Test
 Tensile & Elongation test before & after aging
 Relaxed Modulus
 Tension set test
 Compression Set Test
 Load Deflection Test
 Electrical Resistance Test
 Ash Content Test
 Specific Gravity Test
 Dimensional Test
FINAL LOT-WISE INTERNAL INSPECTION(A lot shall consist of 10000 nos. of GRSP)

Parameter Sample Frequenc Acceptance Limit / Method of Insp. Equipment Used

Size y Specified Value
Shore ‘A’ Hardness 5 Each Lot 75 (Min) Hardness Tester
Tensile Strength (before ageing) 5 Each Lot 120 Kg/cm2 (Min)
Tensile Strength (after ageing ) 5 Each Lot 100 Kg/cm2 (Min)
Tensile Retention (after Ageing) 5 Each Lot 80% Min
Elongation at Break (before ageing) 5 Each Lot 200 % (Min) Tensile testing machine

Elongation at Break (after ageing ) 5 Each Lot 150 % (Min)

Elongation at Break retention 5 Each Lot 65% Min

Relaxed Modulus (before ageing) 3 Each Lot 45-60 Kg/cm2

Relaxed Modulus change (after 3 Each Lot +30% /

ageing) -10% (Max)
Compression set test 3 Each Lot Compression set apparatus
30% Max
Tension set test 3 Each Lot 25% Max Tension Set apparatus

Load Compression Test 2 Each Lot 0.4 - 0.6 mm Load deflection Testing Machine
Electrical Resistance (before 3 Each Lot Million Mega ohm meter
100 M  (Min)
immersion)
Electrical Resistance (after 3 Each Lot Million Mega ohm meter
100 M  (Min)
immersion)
Specific Gravity 3 Each Lot 1.35 (Max) Analytical Balance
Ash Content 3 Each Lot 30% (Max) Muffle furnace & Analytical Balance
Dimensional / Visual Checking As per Each Lot As per Drg. Dimensional Gauges
Spec.
Marking 100% Each Lot As per Drg Visual
 LIMITS OF TEST RESULTS OF INSPECTION

(RDSO/M&C/RP-198/2006 (Provisional) )
Specified Value Specified Value Specified Value
S.N. Characterstics
COMPOSITE PAD COMPOUND A COMPOUND B
Hardness, Shore A (for A side + 2 of hardness of test pad A, for B side +2 of
1 hardness of test pad B) 75 min. 60 min.

Tensile strength
a) Before Ageing (Kg/cm²) 120 min 120 min 150 min
2
b) After ageing (Kg/cm²) 100 ± 1°.C for 96 +0/-2 hrs. 100 min 100 min 125 min
c) Retention After ageing (%) 80 min 80 min 80 min
Elongation at Break
a) Before Ageing (%) 250 min 200 min 350 min
3
b) After ageing (%) 100 ± 1°C for 96 +0/-2 hrs. 180 min 150 min 270 min
c) Retention After ageing (%) 60 min 65 min 70 min
Relaxed Modulus at 100% elongation
4 a) Before Ageing (Kg/cm²) 25 - 45 45 - 60 20 -35
b) % Change after ageing at 100±1°C for 96+0/-2 hrs. (+30/-10) (+30/-10) (+30/-10)
Compression Set.(%) Subject to 50% compression at 100+/-1 deg.C for 24 +0/-2
5 30 max 30 max 25 max
hrs.
6 Tension Set. (%) Subject to 50% stretch at 100+/-1 deg.C for 24 +0/-2 hrs. 25 max. 25 max. 20 max.
7 Load Compression at 15 t. Load (mm) 0.60 to 0.9 0.40 to 0.6 0.80 to 1.2
8 Electrical Resistance (Mega Ohms)
(i) Before Immersion 100 Min.

(ii) After Immersion in distilled water for 48 hrs at room temp. 100 Min.

9 Specific gravity

(i) Layer A ±0.02 of specific gravity of test pad A

(ii) Layer B ±0.02 of specific gravity of test pad B

10 Ash Content
(i) Layer A ±1 of ash content of test pad A
(ii) Layer B ±1 of ash content of test pad B
THANK YOU
RAW GUM ELASTOMER IS MIXED BY THE ROTORS.

THE PRESSURE IS CONTROLLED PNEUMATICALLY OR HYDRAULICALLY.

PRESSURE IS ADJUSTED TO GIVE THE BEST CONTROL OF THE MIXING

PROCESS.

MIXING OCCUR BETWEEN THE MIXING CHAMBER WALLS AND THE ROTORS

MASTER BATCH IS THEN TAKEN OUT FROM KNEADER.

MASTER BATCH IS PLACED INTO THE GAP BETWEEN THE TWO MILL ROLLS.

FILLERS ARE THEN ADDED.

WHEN ALL THE INGREDIENTS ARE COMPLETELY BLENDED (DISPERSED)

THE OPERATOR CAN USE A HAND-HELD MILL KNIFE, AND TAKE OFF INDIVIDUAL SHEETS.

SHEETS ARE IMMEDIATELY COOLED FURTHER TO ROOM TEMPERATURE AND STACKED FOR
FUTURE USE.

IN BATCH TESTING IS CARRIED OUT

TO PROVIDE SUFFICIENT HEAT

TO CHANGE THE UNCURED COMPOUND TO A DIMENSIONALLY STABLE ELASTIC SUBSTANCE

TO ACHIEVE A FINAL SHAPE..

THE UNCURED PIECES OF COMPOUND PLACED IN THE MOLD ARE KNOWN AS PREFORMS.

WEIGHT OF PREFORM CHOSEN TO BE A FEW PERCENT ABOVE THE WEIGHT OF THE FINAL PRODUCT.

THE MOLD IS CONTINUOUSLY HEATED TO A TEMPERATURE, TYPICALLY BETWEEN 150 O C AND 180 O C

CURE TIME OF ABOUT 8 TO 10 MINUTES. THE REQUIRED PRESSURE IS TYPICALLY 7-10.5 MPA..

THE COMPRESSION MACHINE IS GENERALLY HYDRAULICALLY OPERATED WITH TEMPERATURE AND TIME CONTROLLER.

THERMAL ENERGY IS PROVIDED EITHER BY ELECTRICAL COILS OR GAS NOZZLES.

.
FILLER CAN BE REACTIVE (TO IMPROVE PROPERTIES) OR NON
REACTIVE JUST TO FILL THE SPACE. CARBON BLACK/SILICA IS
ACTIVE FILLER WHEREAS CHINA CLAY IS INACTIVE FILLER
PROCESSING OF RUBBER PADS:
Manufacturing process of rubber pads involves following stages:

Mastication: NR is very tough. It is modified in a kneader to make

it procesasable for further steps,

Mixing: Chemicals, which are difficult to mix and which are used
in small quantities only (namely protective agents and
accelerators), are added so that they are well dispersed. Then
fillers, softeners, sulphur are added in sequence. Mixing is done
to make rubber more homogeneous and achieving uniform
dispersion of various additives.

Vulcanization: Compound is vulcanized in all commonly used

processes –hot air with pressure, as transfer moulding, The raw
material is cured and through cross linking and other reaction
convert into stable usable product.
RHEOMETER
 Rheometer is an simple and reliable testing
equipment which describes precisely and
quickly curing and processing characteristics
of vulcanizable rubber compounds.
 The Rheograph (torque Vs time) indicates:
 process behavior

 curing characteristics

 indication of physical properties

TESTING EQUIPMENTS
Tension Testing For testing of tensile strength , elongation and
Machine relaxed moduls
Compression Tensing To check load compression
Machine

Muffle Furnace For ash content

24 Hrs Ageing Oven For tension set and compression set

96 Hrs Ageing Oven For accelerated ageing for tensile strength,

elongation and relaxed modulus.
Weigh Balance For specific gravity and muffle furnace

Durometer For surface shore “A” hardness

Gauge & calipers For dimensional , tension & compression set

HARDNESS TEST
TENSILE STRENGTH TEST
ELONGATION TEST
RELAXED MODULUS TEST
LOAD DEFLECTION TEST
ASH CONTENT TEST
SPECIFIC GRAVITY TEST
ELECTRICAL RESISTANCE TEST
COMPRESSION SET TEST
 Three sole plates shall be considered for the tests.
 Three round test specimens, one from each of the three sample sole plates shall be
cut 37 mm in diameter and whose axial plane coincides with that of one of the
grooves.
• For testing IS.3400 (Part X) shall apply.
• Thickness of test specimen (To) shall be measured and it shall be compressed in a
compression device to 50% of its original thickness (To) by using suitable spacers.
• The assembly shall be kept at 100 + 1o- 2C for 24 + 0 hours in an air oven.
• The device shall then be removed from the oven and allowed to cool at ambient
temperature or 30-35 minutes. The test specimen shall then be removed from the
device. The thickness (Tr) of test specimen shall be measured after 24 hours but not
later than 48 hours from the time of removal from the device.
• Compression set (%) shall be calculated by the formula:
Compression set (%) = To - Tr X 100/To
• The results to be taken into account (criteria value) shall be the second in the series
of three measurements arranged in order of decreasing values.
TENSION SET TEST
VISUAL & DIMENSIONAL TEST