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Rational :
Metrology is the science of measurement. Technician working in industries
should understand various instrument used. The subject imparts the necessary knowledge
so that student can select & use various instrument for measurement.
ISO-9000 emphasizes on the Quality system & total quality management the
success of any industry depends on quality of its product. Technician placed in quality
control or inspection department has to take various decision such of a acceptance or
rejection investigating reasons for defects & giving suggestions etc. the subject imparts
necessary knowledge so that student can perform the job of quality control supervisor
effectively & efficiently.
Objectives: At the end of course the student will able to
1 Understand the concept & principles required to develop the ability of using
different types of measuring instruments.
2 Understand the principles, construction & use of various measuring instrument.
3 Understand the technique of handling & maintaining measuring instrument.
4 Select the measuring instruments to suit different needs.
5. Develop the ability of analysis, interpretation and drawing conclusion of the data,
Graph / chart pertaining to the area of quality control.
6. Developing an ability of problem solving and decision making.
7. Plot and use of quality control charts.
8. Suggests measure to improve the quality of the product and reduce cost.
9. To understand the quality system, ISO- 9000.
Programme : Rubber Technology
Course Code : ME 14 401 Course Title : Metrology and Quality Control
C / O : Compulsory
Credits
Duration of
Written
Examination
Examination Scheme
TH TU PR TOTAL TH TS TH TS PR OR TW TOTAL
4 - 2 6 3hrs - 80 20 50* - - 150
( * ) The assessment is internal and external.
Sections I Content Hours
32
Marks
40
1.
Introduction :
1.1 Scientific metrology, industrial metrology and legal
metrology.
1.2 Needs of inspection.
1.3 Precision, accuracy, interchangeability sensitivity,
Reliability, calibration, repeatability, reproducibility.
1.4 Sources and types of errors.
04 06
2.
Standard of measurement and Comparator:
2.1 Standard of measurement, line and end standard,
Wavelength standard.
2.2 Definition, requirement and uses of comparators.
2.3 Mechanical comparators, Pneumatic comparators and
optical comparator, construction working and their
relative merits and demerits.
2.4 Construction & working and applications of dial
indictor.
04 06
3.
Angular measurement:
Construction working and applications of :
3.1 Universal bevel protector
3.2 Sine bars, sine centers, sine table
3.3 Clinometers.
3.4 Angle gauges.
04 06
4
Gear Measurement: 4.1 Gear terminology
4.2 Measurement of tooth thickness using gear tooth
Vernier caliper
4.3 Parkinson gear tester,
4.4 Backlash and Run out
.
04 04
5.
Threads measurement
5.1 Thread terminology
5.2 Measurement of minor diameter, major diameter,
effective diameter, and pitch by using ;
5.3 Thread micrometer,
5.4 Floating carriage micrometer.
5.1 Profile projector and microscope
04 04
6.
Gauge Design :
6.1 Introduction to gauges ,
04 04
6.2 Classification of gauges.
6.3 Elementary design concepts.
6.4 Taylor’s principle for gauge design
7
Testing Methods :
7.1 Roughness testing
7.2 Terminology
7.3 Measurement of CLA and RMS values,
7.4 Stylus probe type instruments.
7.5 Qualitative method of analysis.
04 04
8
Machine Tools Testing:
8.1 Methods of machine foundations.
8.2 Needs of alignment test.
8.3 Different alignment tests.
8.4 Equipment needed.
8.5 Alignment test on centre lathe and Drilling machine.
04 06
Sections II Content Hours
32
Marks
40
9
Introduction to quality and quality control:
9.1 Meaning of the word Quality and control, quality
control,
9.2 Abilities of product for satisfactory performance
9.3 Quality function , quality system
9.4 Quality of design, the factors to be considered for
quality of design,
9.5 Quality of conformance , the factors influences the
quality of conformance
9.6 Quality of performance.
9.7 Concept of reliability and maintainability.
9.8 Quality policy .
9.9 Objectives of quality control,
9.10 Economics of quality, cost of quality, types of
quality cost : cost of prevention, cost of appraisal,
cost of internal failure, cost of external failure.
Cost considered for different types of costs.
9.11 Value of quality, how it is assessed , optimum
quality level
9.11 Quality characteristics.
9.12 Quality characteristics
Quality specifications: standard specifications,
company specifications, customer specifications, process
specifications.
07 10
10
Different aspects of quality control
06 08
10.1 Quality assurance functions.
10.2 Activities assigned to quality assurance functions.
10.3 Quality audit.
10.4 Scope of quality audit.
10.5 Objectives of quality audit.
10.6 Types of quality audit.
10.7 Vendor quality rating.
10.8 Vendor rating.
10.9 Organization set up for quality management and
requirement of quality organization.
10.10 Inspection, types of inspection.
10.11 Difference between inspection and quality control.
11
Techniques of quality Improvement and Management.
11.1 Quality circles - basic concept, purpose and
Functioning
11.2 ISO – 9000-2000, what is ISO 9000, principle of
ISO 9000, quality system ,the procedure to acquire
ISO 9000 certification,
11.3 KIAZEN – only introduction and meaning
11.4 POKAYOKE - only introduction and meaning
03 04
12
Statistical Quality control
12.1 Importance of Statistic in quality control. un
12.2 Causes of variation- chance causes, assignable
Causes
12.3 Variable data, attribute data
12.4 Frequency distribution, preparation of frequency
table
12.5Graphical representation of frequency distribution-
Histogram, bar chart, frequency polygon
12.6 Quantitative analysis of frequency distribution-
mean, range, standard deviation, variance.
12.7 Normal distribution curve, area under the normal
distribution curve, characteristics
12.8 Concept of universe or population and sample
12.9 Control charts for variables - X chart, R – Chart
12.10 Control charts for attributes P chart, C – Chart
09 10
13
Process capability
13.1 Definition
13.2 Statistical limits
13.3 Tolerance limits
13.4 Methods of finding out process capability of a
Process
13.5 Analysis of process capability study
13.6 Rejection areas
13.7 Interpretation of capable and in capable process
04 04
13.8 Different possibilities related to process capability
and the specification limits
14
Acceptance sampling
14.1 Introduction to acceptance sampling
14.2 Advantages and disadvantages of sampling
Inspection
14.3 Operation characteristic curve.
14.4 Important characteristic of O.C. curve.
14.5 Meaning of the items AQL, AOQL, LTPD, consumers
risk and producers risk.
14.6 Single sampling plan.
14.7 Double sampling plan.
03 04
LABORATORY WORK:
Laboratory work should develop the following skills / abilities.
1. Skill in handling different measuring instrument.
2. Ability in planning and setting experiments work to measure the given
production job.
3. Ability of selection measuring instrument.
4. Ability of locating and investigating defects/ errors and suggesting remedial
measures.
5. Ability of collecting analysis and interpretation of data.
6. Ability of problem solving and decision making.
7. To develop an attitude of enquiry.
8. Safety and cost consciousness.
9. Ability of using different control charts.
List of Practical
1. Use of surface plate, V block, feeler gauge, radius gauge, pith screw gauge and
slip gauges.
2. Use of dial indicator,
3. Use of sine bar.
4. Measurement of different parameter of screw i.e. major diameter, minor diameter,
effective diameter and pitch.
5. Measurement of tooth thickness and overall defect of a gear using gear tooth
vernier caliper dial indicator and gear tester.
6. Alignment test on centre lathe or drilling machine.
7. Use of optical profile projector or tool maker microscope.
8. Use of optical flat for flatness testing.
9. Frequency distribution with precise instruments. Take minimum 50 readings
tabulate them; find std. deviation, range and draw following graphs.
a. Frequency Bar chart
b. Frequency Histogram
c. Frequency polygon
d. Frequency Curve
e. Normal distribution curve
Show three limits, interpret the result and suggest the change to be done. if any.
10. Construction of charts for variable measurement (X, R Chart) takes readings.
Draw the control chart on graph. Interpret the result, suggest the options if any.
Reference Book:
Sr. No. Title Author Publisher
1 Engineering Metrology R. K.Jain Khanna Publisher
2 Metrology for Engineers JFWGaler,CR hotbolt ELBS
3 Engineering Metrology K. J. Hume Kalyani Publisher
4 A Textbook of Metrology I. C. Gupta Dhanpatrai & Sons
5 Quality Planing and analysis Juran J. M. Tata M’Graw Hill
6 Handbook of Industrial engg. H. B. Maynard -
7 Quality Control M. S. Mahajan Dhanpatrai & Co. P
8 Total Quality control Feigenbaum Tata M’Graw Hill
Intetrnational
9 Quality Control - Tata M’Graw Hill
10 I S O- 9000 Brian Rothery Productivity &
quality Publishung
Co.Ltd
Academic Co-ordinator Programme Co-ordinator Principal
Govt. Polytechnic Mumbai
Rationale:
A Rubber Technologist must have understanding of various machinery
used in Rubber industry for conversion of raw rubber into finished rubber
product.
Objectives: At the end of course the students will be able to
Understand different machinery in rubber industry.
Understand their operation.
Programme Code : RT
Course Code : RT 14 203 Course Title : Machinery for Mixing and Processing of Rubber
Prerequisite : Nil C / O : Compulsory
Credits Duration of Written
Examination Examination Scheme
TH TU PR TOTAL TH TS TH TS PR OR TW TOTAL
3 - - 3 3 hrs 2 Tests of 1 Hour
Each 80 20 - - - 100
( * ) indicates assessment by Internal and External examiners
Section I (40 marks)
Table of Contents : Theory Hrs. Marks
Unit 1: Machinery used for a Rubber Compounds. 13 20
1.1 Two roll mixing mill:-
1.1.1 Construction of mixing mill- cooling system , concept of
friction ratio, various sizes.
1.1.2 Double geared , single geared mills- relative
advantages , disadvantages.
1.1.3 Ancillary Equipments for mixing mills – Apron , stock blender,
cutting knives, Collector, safety devices on the mill.
1.1.4 How to calculate mill capacity, Output of production.
1.1.5 Mastication on Mill , Compound mixing, Mixing sequence,
Precautions with different rubbers.
1.2 Internal Mixer:- 1.2.1 Types of Internal mixers –Banbury, intermix.
1.2.2 Sizes available.
1.2.3 Construction - Rotor design, Speed, Drop door, Ram thrust , Fill
Factor.
1.2.4 Mixing – Energy v/s Time, Torque v/s Time, Power requirement ,
1.2.5 Importance of Dump temperature. Batch Weight.
1.2.6 Cooling system.
1.2.7 Techniques of mixing, Mixing sequence, Compounds with different
polymers and hardness.
.
1.3 Kneaders:-
1.3.1 Construction of Kneaders, Rotors, various sizes. 1.3.2 Difference between kneader, Banbury and Intermix. The their efficiency and Investment cost.
04
06
03
07
08
05
Unit 2: Machinery used for Processing of Rubber. 11 20
2.1 Extruders
2.1.1 Principle and function.
2.1.2 Construction-ram type, Screw type.
2.2 Hot feed extruder, Cold feed extruder
2.2.1 Principle, construction & Comparison, Advantages and
disadvantages of each. Cross head extrusion, Co extrusion.
2.3 Pin Barrel and Dual feed extruder
2.3.1 Principle, construction & comparison. Advantages and
disadvantages of each. Vacuum extruders, degassing zone.
2.4 Processing of Compound by Extruder
2.4.1 Mill setup, temperature control, control on dimension of extrudate,
defects in extrusion, die-swell, compound preparation.
2.5 Types of heads
2.5.1 Importance of straining, sitfing of fivers, importance of mastication
influence of compound ingredients on extrudability, importance of
process aids.
03
02
02
02
02
05
05
04
03
03
Section II (40 marks)
Table of Contents : Theory Hrs. Marks
Unit 3: Machinery for Calendaring 06 10
3.1 Function of a calender, skimming , coating, frictioning, embossing,
profiling, sheeting,
3.2 Construction of calendar 3 roll & 4 Roll, Roll configuration.
3.3 Vertical and inverted – L& Z type, offset top roll, cambering and
crowning of rolls, various calendaring arrangements.
3.4 Compound requirement, defects in calendaring , mill set up for
calenders.
3.5 Devices available on calender for gauge control.
02
01
01
01
01
02
02
02
02
02
Unit 4: Machinery for Vulcanization & Moulding 18 30
4.1 Compression Moulding. Machine, Hand presses, Hydraulic presses- construction, single daylight, multi daylight. 4.2 Injection Moulding Machine, Principle, construction, types. advantages & disadvantages, compound designing, mould flow.
4.3 Direct and Indirect Autoclaves, Open steam type, jacketed steam
type, hot air type their uses with different rubbers & system of
Vulcanizations. Free heating:- vulcanization in free steam, hot air
and hot water.
4.4 UHF Vulcanization - Principle, Applications, Compound preparation,
advantages & disadvantages Characteristics and use.
4.5 Rotational Vulcanization, Principle& Applications.
4.6 LCM Vulcanization, Principle , application, advantages &
disadvantages and safety hazards.
4.7 Fluid bed vulcanization continuous vulcanization in steam pipe.
4.8 Moulding presses used in Tyre manufacture
03
03
03
02
02
02
02
01
05
05
06
03
03
03
03
02
References:
Sr. No. Author Title Publication
1 C.M. Blow. Rubber Technology & Manufacturing
Butterworth Scientific, London.
2 Freakley Rubber Engineering Plenum Press
Academic Co-ordinator Programme Co-ordinator Principal
Rubber Tech. Deptt. Rubber Tech. Deptt. Govt. Polytechnic Mumbai
RATIONALE: Technicians engaged in engineering production should be competent in the selection and use of machining processes, machines & tools. Study of mechanical and Practical aspects of this subject will help to develop this competence. OBJECTIVES: After the end of the course students will:-
Understand the theory of metal cutting and operations.
Understand the principle of working of the following machines & processes of drilling, boring. Broaching, milling machines.
Programme Code : RT
Course Code : RT 14 204 Course Title : Basic Machine Tools & Operations
Prerequisite : Nil C / O : Compulsory
Credits Duration of Written
Examination Examination Scheme
TH TU PR TOTAL TH TS TH TS PR OR TW TOTAL
3 - 4 7 3 hrs 2 Tests of 1 Hrs.
each 80 20 - 25 25 150
( * ) indicates assessment by Internal and External examiners
Section I
(40 Marks)
Table of Contents: Hours Marks
Unit 1: Metal Turning 10 12
1.1 Introduction to center lathe, simple turning processes, related cutting tools. 1.2 Thread cutting, taper turning & constructional details of all geared lathe.
Unit 2: Drilling Machine 05 12
2.1 Classification of drilling machines, 2.2 Specifications, Accessories operations such as drilling reaming, 2.3 Tapping, tapping attachment, 2.4 Deep drilling, step drilling, counter sunk drilling.
Unit 3: Boring 05 11
3.1 Introduction to boring machine,
3.2 Description of boring machines, 3.3 Standard specification of boring machines, 3.4 Boring bars, boring heads, boring tools.
Unit 4: Fabrication of sheet metal 04 05
Fabrication of sheet metal and fitment of male and female components
Section I
Practicals Hrs.
Unit 1: 1. Composite job of Eccentric turning drilling and boring. 16
Unit 2: 1. Composite job of Eccentric turning drilling and boring.
4
Unit 3: 1. Composite job of Eccentric turning drilling and boring.
4
Unit 4: 2. Simple job on sheet metal. 8
Section II
(40 Marks)
Table of Contents: Hours Marks
Unit 4: Milling Machines 10 16
4.1 Types of milling machines. 4.2 Principle of working, Description, construction of universal 4.3 milling machines, specification of milling machines. 4.4 Milling operations, milling cutters. 4.5 Universal dividing head different types of Indexing methods, Helical milling.
Unit 5: CNC 09 16
5.1 Concept, advantages, disadvantages.
5.2 Principles of control, open and closed loops.
5.3 Part programming – drilling, turning.
5.4 Fundamentals of CAD & CAM. 5.5 ARC welding & Gas Welding processes Principle, Construction and working material handling equipments used in the industries.
Unit 6: Group Technology 05 08
6.1 Flexible Manufacturing System and Automated material handling
factories of future.
Section II
Practicals Hrs.
Unit 4: 3. Gear cutting- one job involving, gear cutting 24
Unit 5: 4. Demonstration on CNC turning and CNC milling 4
Unit 6: 5. Demonstration of FMS. 4
References:
Sr.No. Author Title Publication
1 Hajara Choudhary –Vol. II. Workshop Technology Amold Publication
2 Raghuwanshi Workshop Technology Dhanpatrai & Co.
3 Y.Y. Deshmukh Fundamentals of Tool Engg. -------
4 H.M.T. Handbook Production Technology Tata Mc-Graw hill
5 P.C. Sharma Production Technology S.Chand & Co.
6 Panday & Singh Production Engg. Science Standard Publication
Academic Co-ordinator Programme Co-ordinator Principal
Rubber Tech. Deptt. Rubber Tech. Deptt. Govt. Polytechnic Mumbai
Rationale:
A rubber technologist must have an understanding of various compounding
ingredients used in making the rubber articles as raw rubber is seldom useful without
compounding. The ingredients used in compounding plays a very important part in the
properties of final products, its cost of manufacture etc. It will help him understand the
fundamental principles of Rubber compounding.
Objectives:
At the end of the course the student will be able to:-
Understand physical nature of raw rubber.
Understand their role in the final properties of the article.
Conduct laboratory tests for analyzing the ingredients
Prepare standard formulations of typical products.
Programme Code : RT
Course Code : RT 14 302 Course Title : Rubber Material & Compounding Principles
Prerequisite : Nil C / O : Compulsory
Credits Duration of Written
Examination Examination Scheme
TH TU PR TOTAL TH TS TH TS PR OR TW TOTAL
4 - 4 8 3 Hrs. 2 Tests of 1 Hour
Each 80 20 50* - - 150
( * ) indicates assessment by Internal and External examiners
Section I
(40 Marks)
Topic No. Contents Hrs. Marks
1 Unit 1: Rubbers. 6 8
1.1 Rubbers – their basic properties, their comparison.
1.2 Comparison of properties like tensile strength, Abrasion,
Swelling, Temperature resistance, Ozone resistance,
Resilience, Flex etc.
1.3 General purpose & Speciality rubbers.
2 Unit 2: Reinforcing Fillers. 11 12
2.1 Carbon Black :- Channel Black, Furnace blacks, Thermal Black , Acetylene Black, Manufacturing process,
Different grades.
2.2 Characterization of Carbon Blacks : Structure by DBP absorption, Surface area by Iodine adsorption, Particle size
by Tint value, pH , Ash content, Fineness, Sieve Residue
& their practical significance.
2.3 ASTM gradation of Furnace Blacks and their significance.
2.4 Mechanism of Reinforcement, Concept of Bound Rubber.
2.5 Rubber fillers effect of structure and particle size on
processing and physical properties of rubbers. Hardness,
Imparting ratio of carbon black. Equal hardness and equal
loading.
2.6 Surface chemistry of carbon and its influence on
rubber filler interaction. Graphatization effect.
2.7 Non Black Reinforcing Fillers: Precipitated Silica,
Manufacturing process, Properties and Applications.
2.8 Semi/ Non Reinforcing Fillers :Calcium carbonate, Clay,
Barytes, Silicates, Talc – Grades and Applications.
Rubber and its compounding ingredients.
3 Unit 3: Plasticizers & Process Aids. 4 6
3.1 Petroleum based Process Oils – Aromatic , Naphthenic, &
Paraffinic, their properties & compatibility with different
Rubbers.
3.2 Characteristics and identification, Viscosity, Gravity
Constant, Aniline Point, Refractive Index & Intercept.
3.3 Applications and relative comparisons.
3.4 Synthetic Plasticizers: DOP, DBP, CPW.
3.5 Polymeric plasticizers and others:- Their properties,
characteristics, Applications Resins, Factice, Resins, Zinc
Stearate etc. their importance in Compounding.
3.6 Oleo type of derivatives REACH Norms On Petroleum
Oils, Different types of REACH compliant oils.
4 Unit 4: Vulcanization Agents & Antidegradents. 4 6
4.1 Zinc Oxide.
4.2 Stearic Acid.
4.3 Accelerators.
4.4 Peroxides, Sulphur etc. – their importance in compounding.
4.5 Antioxidants.
4.6 Antiozonants.
4.7 Waxes – their importance in compounding.
4.8 Food grade Accelerators like TBBS type, Also REACH
Compliant Accelerator
4.9 Nitrosamine liberating accelerator.
4.10 Carcinogenic Accelerator.
4.11 Food grade Accelerator.
5 Unit 5: Textiles for Rubber Reinforcement. 4 6
5.1 Definition of the terms –Filament, Monofilament Yarn
5.2 Fabric:- Types of fabrics with respect to construction.
Denier, Tex, Count, Twist, cords-Various construction of
cords .Materials used for rubber reinforcement- Cotton,
Rayon, Nylon, Polyester, Glass Polyaramid, Steel.
Advantage, disadvantages, Applications of each.
6 Unit 6: Misc. Ingredients & Reclaim Rubber. 3 2
6.1 Peptizers, Stabilizers
6.2 Colors
6.3 Compatibilisers
6.4 Coupling agents etc. their importance in Compounding
6.5 Internal and External lubricants
6.6 Blowing agents,
6.7 bonding agents like Resins
6.8 Resins, their origin, composition, types - tackifying,
vulcanizing, thermosetting, thermoplastic.
6.9 VP latex etc.
Rubber Crumb different mesh, Reclaim rubber: Manufacturing
method, Types, Advantages, Disadvantages, and Use
Section – II
(40 Marks)
7 Unit 7: Compounding. 3 4
7.1 Definition importance & principle of Compounding in general.
8 Unit 8: Techniques of Compounding. 9 10
8.1 Difference in compounding in rubber like NR, IR, CR, BR,
SBR, NBR, IIR, EPDM, AU, Q, FKM, CSM by Vulcanizing agents, protective agents, Oils and plasticizers, fillers. Blending and selection of effects on properties, processing, compatibility.
8.2 Fillers- Mechanism of Rubber filler interaction, bound
rubber,oils, Plasticizers – Its influence on various
Compounding characteristics, activators, vulcanizing
agents.
8.3 Accelerators- selection of Accelerators from the
processing point of view, fabrics, wires etc. Selection of
various compounding ingredients for different rubbers,
their effect on processing / properties.
9 Unit 9: Compounding to meet the required specification. 08 10
9.1 Base hardness of raw rubbers , Selection of polymers,
Density, Base Hardness, Computation of Hardness with
different black and different rubbers.
9.2 Physical Properties, Oil swelling resistance, compression set,
Ozone resistance, heat ageing at different temp., low temp.
properties.,
10 Unit 10: Properties of Compound. 2 6
10.1 Effect of various ingredients.
Changes in property from unvulcanized (green) compound to
vulcanized ( cured ) state.
11 Unit 11: Compounding recipes for various products from
different Polymers.
10 10
11.1 Costing of rubber compound, Volume cost, Weight cost,
Computation of density of compound.
11.2 Recipe of important products like Auto tyres- its various
components, Auto tubes, Hawai chappal, Tank lining
Calendered sheets, Retreading material, Baby nipples,
Conveyor belt, Hoses, Car profiles , Dehusking
roller, Printing rollers from different rubbers. etc.
Practicals
1. Analysis of Carbon black :- Iodine No., DBP No.
2. Analysis of Petroleum oil:- Flash Point , Aniline Point, VGC.
3. Analysis of Zinc Oxide, Stearic acid & important accelarators.
4. Melting point of Rubber Chemical.
5. Sieve residue of fillers
6. Moisture and ash content
7. determination of pH filler
8. Mixing of formulation on mill.
9. Theoretical & practical density of Rubber Compound.
10. Compound preparation for given hardness.
11. Calculation of Die swell
12. Compound preparation & physical properties of certain formulations in NBR,
EPDM,NR, Silicone , SBR, Polyurethane etc.
13. Comparison of compounds for oil resistance, tear resistance, & abrasion resistance.
PH of white fillers.
Reference Books:
Sr.No Author Title Publication
01 C.M.Blow Rubber Technology Butterworth Scientific,
London.
02 H.J. Stern Natural & Synthetic rubber --------
03 R.T. Vanderbilt Rubber Technology Hand
Book
R.T. Vanderbilt Co., Inc
04 Indian Rubber Institute. Rubber Engineering I.R.I.
05 Werner Hoffman Rubber Technology Handbook Hanser Publishers,
Munich & Vienna
06 John S.Dick Rubber Technology
compounding and Testing
Hanser Publishers,
Munich & Vienna
07 W.Barlow Rubber Compounding
Principles Materials &
Techniques
Marcel Dekker, Inc.
New York & Basel
08 R.P.Brown Physical Testing of Rubbers Chapman & Hall
Academic Co-ordinator Programme Co-ordinator Principal
Rubber Tech. Deptt. Rubber Tech. Deptt. Govt. Polytechnic, Mumbai
RATIONALE:
Vulcanization is the most important step in the manufacture of rubber products. Design
of vulcanization system for a compound influences its processing characteristics and
product properties. A judicious selection of the vulcanization system is therefore
required for the processing, curing technique and product property requirements. A
student of rubber technology must therefore understand the Chemistry and physics of
vulcanization. He should also understand the various vulcanization techniques.
OBJECTIVES:
At the end of course the students will be able to:-
Understand various vulcanization systems and techniques.
Understand relation between vulcanization system, type and their effect
on various properties of rubber.
Programme : Rubber Technology
Course Code : RT 14 304 Course Title : Vulcanization System
C / O : Compulsory
Credits Duration of Written
Examination Examination Scheme
TH TU PR TOTA
L TH TS TH TS PR OR TW TOTAL
3 - 2 5 3
Hrs
2 Tests of 1
Hour Each 80 20 25* -- 25 150
( * ) The assessment is internal and external.
Section – I
(40 Marks)
Topic
No
Contents
Hrs. Marks
1 Vulcanizing Agents. 8 15
1.1 Cross linking agents, Activators, Accelerators, sulphur
donors. Reach norms, Nitrosamine liberating
accelerators, safe accelerators. Shelf life of accelerators.
2 Theory of vulcanization. 12 18
2.1 Theory of sulphur vulcanization: Conventional cure
system, semi efficient cure system, efficient cure
system.
2.2 Peroxides-types of peroxide, half life period
decomposition temp, steam curing, air curing.
2.3 Theory of peroxide vulcanization: Various peroxides that
can be used for the vulcanization of rubbers.
2.4 Theory of metal oxide vulcanization.
2.5 Theory of resin curing in Butyl rubber.
2.6 Theory of diamine cure system in Fluoroelastomers.
2.7 Theory of diisocyanate cure system in Polyurethane.
2.8 Characteristics of each curing system. Their relative
advantages and disadvantages.
3
Curing systems for individual polymers.
3.1 List of polymers cured with peroxide
3.2 List of polymers not cured with peroxide giving
reason.
4 7
Section –II
(40 Marks)
4 Assessment of the state of cure. 14 22
4.1 Concept of cross link density, evaluation of crosslink
density by the swelling techniques. Effect of the
cure on the physical properties of the rubber
vulcanizates.
4.2 Application of Rheometer: Analysis of the curve and its
use to evaluate the processing characteristics and the
product properties.
4.3 Mooney Scorch time : its practical significance.
difference between Mooney scorch & Rheo scorch.
5 Vulcanization Techniques. 10 18
5.1 Moulding: Principle of moulding, characteristics of
moulding, Effect of thickness on the moulding conditions,
step moulding.
5.2 Steam curing : Principle of steam curing, influence of
various parameters.
5.3 Hot air curing : Principle and characteristics.
5.4 Microwave curing, Rotocure, LCM- Principles and
characteristics.
5.5 Heating medium – HP Steam , Saturated steam pressure
– Temp. relationship. Thermic Fluid, Electrical Heating.
Practicals :-
1. Study of Rheometer graph, Calculation of cure rate, scorch time, etc. 2. Study of accelerators in Rubber. 3. Study of C.V., Semi E.V., E.V. system on cure, physical and ageing properties of Natural / synthetic rubber. 4. Study of peroxide cure in synthetic rubber ( NBR, SBR & EPDM ). 5. Study of cure system in CR rubber. 6. Study of effect of state of cure on swelling of rubber compound in fluids. 7. Study of effect of state of cure on Compression set of rubber compound.
Reference Books:
Sr.No Author Title Publication
01 Hoffman Vulcanization of rubber Hanser Publishers,
Munich & Vienna
02 C.M. Blow Rubber Technology Butterworth Scientific,
London.
03 H. J. Stern Natural & Synthetic rubber ---------
04 R.T. Vanderbilt Rubber Technology Hand Book R.T. Vanderbilt
Co.Inc.
05 I.R.I. Rubber Engineering I.R.I.
Academic Co-ordinator Programme Co-ordinator Principal Rubber Tech. Deptt. Rubber Tech. Deptt. Govt. Polytechnic, Mumbai
RATIONALE:
A rubber technologist must understand fully testing of Un vulcanized rubber compounds
for its processing and curing characteristics and rubber products for various physical
properties such as stress-strain properties, hardness, abrasion resistance, tear
resistance etc. This will enable him to determine whether the compound he has
prepared is satisfactory and whether the product cured is according to specification.
Understanding of various national and international standards will be required for day to
day working in testing laboratory. Understanding of testing methods of incoming raw
materials, raw rubbers, textiles etc. for various test will enable him to know if raw
materials are received as per required quality.
OBJECTIVES:
At the end of course the students will be able to:-
Understand methods of testing of compounded rubber, cured rubber
compound and incoming raw materials.
Carry out laboratory tests for the above.
To understand and follow national / international standard procedures to
evaluate.
Programme : Rubber Technology
Course Code : RT 11 306 Course Title : Testing of Rubbers
C / O : Compulsory
Credits Duration of Written
Examination Examination Scheme
TH TU PR TOTAL TH TS TH TS PR OR TW TOTAL
3 - 4 7 3hrs 2 Tests of 1
Hour Each 80 20 50* - - 150
( * ) The assessment is internal and external.
Section - I
(40 Marks)
Topic No
Contents Hrs. Marks
TESTING OF UNVULCANIZED RUBBER
Intoduction - Rubber testing, purpose of testing, QC,R &
D,Designing.
1 Testing on raw rubbers. 7 11
1.1 Mooney Viscosity. ML ( 1+4 ), MS ( 1+4 ),
1.2 Moisture its significance and importance.
1.3 Ash content its significance and importance.
1.4 Density.
1.5 Standard ASTM formulations for evaluation of raw
rubbers. NR, SBR, NBR, PBR,EPDM& CR.
1.6 Burning test.
1.7 Acetone extract test. Chloroform Extract.
1.8 ML ( 1+8 ) for butyl rubber.
2 Characteristics of Rubbers. – Instrumental Analysis 8 11
2.1 IR: Principle and use for identification of functional
groups.
2.2 DSC : Principle and use for determination of Tg ,
crystallinity, Problem discussion.
2.3 TGA: Principle and use for determination of ash
content and polymer composition, Problem discussion.
2.4 GPC: Principle and use for determination of Mol. Wt.,
MWD. Problem discussion.
Advantages and limitations of above.
3 Chemical analysis of rubbers for identification of elements. 4 6
3.1 Using ASTM solutions, Advantages, Limitations.
4 Compound Testing. 5 12
4.1 Mooney viscosity, importance & significance..
4.2 Mooney scorch & Rheo Scorch, Difference between the two.
4.3 Study of Rheograph types of Rheometer.
4.4 ODR/MDR,. Garvey die extrusion: Die swell, Rate of
extrusion. Rating,
4.5 Density – Theoretical and practical methods of measurement, Importance of density.
Section - II
(40 Marks)
Topic No
Contents Hrs. Marks
5
Moulding of compounds and preparation of samples for
testing. Standard Test Methods.
2
5
6 Testing For Physical Properties. 14 18
6.1 Density : stress strain properties- of vulcanized rubber.
6.2 Tear Resistance, Hardness (Shore A and Shore D).
6.3 Rebound Resilience. DeMattia flex test, Ross Flex test,
Fatigue to failure test. Heat Build up.
6.4 Abrasion testing, Ozone resistance and hysterisis.
6.5 BIS or ASTM to be used for explanation of above.
Analysis of Rubber Compound ASH, RHC, Acetone Extract,
Chloroform Extract, Carbon .black other hardness scales.
6.6 Dunlop, Tripsometer, Goodrich Flexometer, coefficient of
friction, flame retardant testing.
7 Accelerated ageing Tests. 4 7
7.1 In air, Tension set. Compression set. Swelling in oils, fluids,
solvents. Retention of properties.
7.2 ASTM fuels ,ASTM oils.
8 Electrical Tests. 2 5
8.1 Volume Resistivity, Surface Resistivity, Dielectric constant,
Breakdown voltage.
8.2 ASTM D2000 / SAE J200 ,Decoding system.
9 Standard institutions. 2 5
9.1 Their importance in testing & specification
SAE, DIN, JIS, ASTM, ISO, BIS, ITTAC , ETRTO, TRA
standards.
Practicals :-
3. Identification of rubbers by burning test.
4. Determination of Mooney Viscosity of rubbers.
5. Determination of Volatile matter and Ash content in rubber.
6. Analysis of rubber compound by Acetone extract test.
7. Determination of Mooney Viscosity, Mooney scorch and Rheometric properties of
rubber compound
8. Determination of Specific gravity, Tensile strength, Elongation at Break and modulus
properties of vulcanized rubber compound.
9. Determination of volume swell and retention of physical properties of vulcanized
rubber compound in Fluids / solvents.
10. Determination of compression set / tension set of vulcanized rubber.
11. Determination of DeMattia flex resistance of tyre tread compound.
12. Retention of physical properties of rubber on accelerated ageing test.
Reference Books:
Sr.No Author Title Publication
01 Roger Brown Physical Testing Of Rubber Chapman & Hall
Publication
02 John S.Dick Rubber Technology
Compounding & Testing
Hanser Publication
Academic Co-ordinator Programme Co-ordinator Principal
Rubber Tech. Deptt. Rubber Tech. Deptt. Govt. Polytechnic, Mumbai
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