Professional Documents
Culture Documents
SAMPLE PAGES - Dick PDF
SAMPLE PAGES - Dick PDF
TECHNOLOGY
SUDHA.P
DEPUTY DIRECTOR(RIDT)
RUBBER TRAINING INSTITUTE
DEPARTMENT OF TRAINING
RUBBER BOARD
KOTTAYAM-686 009
sudha@rubberboard.org.in
Mob: 94964 13731
RUBBER COMPOUNDING
COMPOUND
It is a homogenous mixture of ingredients used in a
particular product manufacture such that the properties
of most of the ingredients are unchanged in the final
product whereby providing a defined set of
mechanical properties.
COMPOUNDING
It is the science of selecting and combining elastomers
and additives to obtain physical and chemical
properties for a finished product.
RUBBER COMPOUNDING
OBJECTIVE
1. To secure certain properties in the finished product to
satisfy the service requirements.
2. To attain processing characteristics necessary for efficient
utilization of available equipment.
3. To achieve desirable properties and processability at the
lowest cost.
plasticization)
Viscosity/process safety (ML1+4, MS)
Abrasion resistance
Electrical properties
Permeability
Swelling
DESIGN REQUIREMENTS
SERVICE REQUIREMENTS/VULCANISATE PROPERTIES
PROCESSABILITY
ECONOMICS
DESIGN BASED ON
CUSTOMER SPECIFICATION/REQUIREMENTS
COMPETITOR'S SAMPLE
Base polymer
Saturated rubber – peroxide e.g. EPR with DCP
Unsaturated rubber-peroxide, sulphur/accelerator & resins, e.g. EPDM
with DCP, NR with sulphur accelerator, IIR with Resin
Special Polymers – Metal oxide, Dioxime, Resin e.g. CR with ZnO/MgO
ACCELERATORS
Service Requirements
Service temperature
Duration of exposure
Mechanical property requirement.
Dynamic property requirement
Ageing behaviour and permanent set requirements.
Special property requirement.
FILLERS
• particle size
• surface area
• geometrical characteristics
FILLERS
Reinforcing Type Carbon Black (listed in N220 (ISAF)
order of increasing N330(HAF)
particle size) N550 (FEF)
N762 (SRF-LM)
N990 (MT)
Non-black Silica
Zinc Oxide
Magnesium Carbonate
Aluminium Silicate
Sodium Aluminosilicate
Magnesium Silicate
Extending Type Calcium Carbonate
Barium Sulfate
Aluminium Trihydrate
Talc and Soapstone
• reinforcing carbon blacks
• non- reinforcing carbon blacks
• reinforcing non- black
• semi reinforcing non- black
• non- reinforcing non- black
FF - Fine Furnace
Selection is based on
• Reinforcement
• Cost
• Processing requirement
• Colour requirement
• Service requirement
• Any other special requirement
Compound Designing –
Hardness
phr required
Polymer Hardness for 1 unit
increase in
Hardness
NR SBR CR NBR
37-40 39-41 41-43 42-44
1.5 1.8 1.3 1.2 2.2 1.7 2.4 SAF N110 113
1.7 2.0 1.5 1.3 2.5 1.9 2.7 ISAF N220 114
1.9 2.3 1.7 1.5 2.8 2.1 3.0 HAF N330 102
2.3 2.8 2.1 1.8 3.4 2.6 3.7 FEF N550 119
Processing aids
A softener is an ingredient that :
1. speeds up the rate of polymer breakdown
2. helps to disperse the other compounding
ingredients
3. helps to reduce nerve within the compound
4 can impart building tack
5. improves the processing properties and
modify the final compound properties
6. adjusts the compound cost and reduce power
consumption during processing
Mineral petroleum oils
They are available from petroleum industry.
paraffinic
naphthenic
aromatic
Plasticizers
They are of the synthetic type , used where mineral oils are not
compatible with the rubber
dibutyl phthalate -DBP
di isobutyl phthalate-DIB
di octyl phthalate - DOP
*Factices
They are vulcanized vegetable oils used as plasticizers to get
smooth compound in extrusion (brown) & to reduce abrasion
resistance in products like erasers (white)
PROCESSING AIDS
COMPOSITION EXAMPLE FUNCTION
Activated Dithio- Pepton 44 Peptizer for NR
bisbenzaldihide
Xylyl Mercaptans RPA-3 Peptizer for NR,IR,SBR and
NBR.
Low-molecular-weight A-C Polyethylene Release agent, Lubricant
polyethylene 617A
Calcium Oxide Desical P Desiccant
Aliphatic-naphthenic- Strucktol 60NS Homogenizing agent for all
aromatic resins elastomers.
Paraffin wax Release agent, lubricant
Polyethylene glycol Carbowax Activator for silica, lubricant
PEG3350
Petroleum hydrocarbon Petrolatum Release agent, lubricant
PROCESSING AIDS
Selection is based on
Nature of polymer
Solubility parameter
Viscosity requirement
Filler dispersion
Processing requirement
Any other special requirement
ANTI-DEGRADANTS- They are agents added to rubber to improve
ageing properties, resistance to oxygen, ozone, alkali, acid, chemicals etc
Selection is based on
Peptizers : They speed up the rate of polymer break down and also
control the speed of breakdown, decreasing nerve within the
compound and shrinkage during subsequent processing.
penta chloro thiophenol Renacit VII
azocarbonamide (ADC)
Cost/price
Processing
Performance
Lab Evaluation,
Validation of manufacturing
process.
MIXING
38
MIXING Five main steps involved in the Mixing Operations :
1. Sub Division
Of larger lumps & aggregates,
2. Incorporation
Of powders or liquids
3. Dispersion
Involves reduction of the size of agglomerates,
4. Simple Mixing
Involves moving particles from one point to another.
39
MIXING
• A good Dispersion rating requires :
High Shear Stress (i.e. High mix viscosity),
High Filler Loading,
Polymers of not too low viscosity,
Low Mixing temperatures,
Charging oils at the end of mixing cycle.
42
NR Mastication & Blending NR+SR
0 95 95 95 95
3 76 85 58 56
6 57 83 40 40
9 47 68 33 28
12 45 65 30 24
START TEMPERATURE, MOONEY VISCOSITY (ML1+4 AT 100°C), UNITS
OPEN MILL (TIME = 8 MIN) PEPTIZER = 0 PEPTIZER = 0.25 PEPTIZER = 0.5
70 °C 55 42 36
100 °C 75 42 37
INTERNAL MIXER (TIME 4
MIN)
90 54 42
150 °C
88 48 36
160 °C
45
Mixing Mixer Speed 25 rpm Mixer Speed 50 rpm
Time, No Peptizer 0.1 Phr PCTP No Peptizer 0.1 Phr PCTP
Min
0 90 90 90 90
2 74 69 69 52
4 68.5 60 50 37
6 67 56 42 29
8 65 53 34 -
Note10the rapid reduction
61 of Mooney
50 viscosity at
- higher rotor speeds
-
in the presence of chemical Peptizer at a very small dosage.
46
Effects of “Under Mastication” of NR
47
Effects of “Over Mastication” of NR
Lower shrinkage of extrudates / calendared sheets,
• Lower die swell & loss of dimensional control,
• Increased curing defects in finished products due to excessive
flow and air entrapment,
• Compounded sheets stick to each other during storage and
sagging of sheets,
• Excessive surface tack due to poor green compound strength,
• Loss of dynamic, tensile & tear strength properties of the
vulcanizate,
• Changes in the viscosity of solvent based solutions & loss of
surface tack.
48
MIXING PROBLEMS & REASONS
PROBLEMS REASONS
Batch size not optimized, mixing time is
lower, filler addition time not proper,
insufficient ram pressure, poor temp.
Poor
control, poor / inconsistent raw material
Dispersion
quality, excessive moisture content in
polymer and fillers, under / over
mastication of NR.
Variation of start temp., variation in dump
time and / or temp. , poor dispersion,
Batch to Batch
variation in ram pressure, variation in
Variations
polymer / filler/ oil quality / rework quality,
under / over mastication of NR
Compound viscosity not within controlled
limits, under / over mastication of NR,
Poor
Processing temp. not under control, poor
Processability 49
Manufacturing process
Unvulcanized rubber, whether natural or synthetic
behaves as a viscoelastic fluid during mixing. It is the
operation required to obtain a thorough and uniform
dispersion of all ingredients called for by the formulae in
the rubber
Machinery
2-roll mixing mill
kneader
internal mixers
Continuous, automatic high speed mixing
2 –ROLL MIXING MILL
KNEADER
Two Roll Mill with stock blender & individual roll drives
53
F 270 Banbury Mixer K 6A INTERMIX
54
Capacities: Banbury Mixers
Mixer Mixing Torque rating
Approx. kW / RPM Approx.
Banbury Chamber Speed
Batch Wt * Machine
Mixer Net Volume, Range, Compact Uni
kg Weight, MT
ltr RPM Drive Drive
F 50 50 50 40 - 120 2.2 4.6 13.2
F 80 80 60 30 - 105 3.7 6.3 16.1
F 120 120 90 30 - 90 5.6 9.0 19.5
F 160 160 120 20 - 80 7.5 12.0 30.2
F 200 200 165 20 - 60 8.9 12.7 30.5
F 270 270 202 20 - 60 13.1 24.6 43.0
F 370 414 310 20 - 60 - 37.3 54.0
F 440 438 330 20 - 60 - - -
F 620 672 500 20 - 50 - 52.2 110.5
shaping
vulcanization
MIXING PROCEDURE
Weighing compounding ingrediants as per
formulation
Mastication
Maturation
Prewarming
Blank preparation
DRY RUBBER PRODUCTS MANUFACTURE
MATURATION
PRE-
WARMING
TESTING& QC
MOULDING
(HYDRAULIC
PRESS) VULCANISATION