government polytechnic, mumbai diploma in … polytechnic, mumbai diploma in rubber technology...

Government Polytechnic, Mumbai Diploma in Rubber Technology

Curriculum- 2012-13

RT 11 402 (Revision No.4) S.K.S. of 4

RATIONALE:-

Since rubbers are normally derived from the latex, a student of rubber technology must have

understanding of various characteristics of latex, its compounding and processing and Testing,

physical properties and their applications.

OBJECTIVES:-

At the end of course student will be able to:-

Understand different types lattices.

Understand the chemistry of lattices.

Understand compounding of lattices.

Understand processing, Testing and physical properties.

Programme Code : RT (Rubber Technology)

Course Code : RT 14 402 Course Title: Latex Technology

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 - 2 5 3 hrs 2 Tests of 1 Hour each

80 20 25* - 25 150

( * ) indicates assessment by External examiners


Curriculum- 2012-13


Section I

(40 Marks)

Table of Contents: Hours Marks

Unit 1: Natural Rubber Latex :- 14 23

1.1 Definition of various terminologies in latex: Brownian movement,

Isoelectric point etc. Tapping, Preservation, Preservation in addition

to Ammonia.

1.2 Concentration: Centrifuging, Evaporation, Electro decantation, creaming.

1.3 Composition of Latex, impurities in latex, stability.

1.4 Conservation, Gelation, Stability of Latex & Flocking

1.5 Definition, mechanism and effect on properties.

1.6 Chemical modifications of Natural Latex :- Prevulcanisation, Grafting,

Halogenations, Hydro halogenations.

Unit 2: Synthetic Latex :- 10 17

2.1 SBR lattices and its types like XSBR, their properties.

2.2 NBR lattices and its types, their properties.

2.3 Poly chloroprene and its types, their properties.

2.4 Butyl lattices.

2.5 Applications of the synthetic lattices.

2.6 Comparative study of Natural, SBR, NBR & Poly chloroprene, Butyl

lattices and their types.

2.7 IIR, CR, EPDM – Recipe will be provided by MMP.


Curriculum- 2012-13


Section - II

(40 Marks)


Unit 3: Latex Testing :- 04 07

3.1 Sampling.

3.2 Total solids.

3.3 Dry rubber content.

3.4 pH, VFA number.

3.5 KOH number, mechanical & chemical stability.

Unit 4: Compounding Ingredients and its methods for lattices :- 08 12

4.1 Various Accelerators, Vulcanizing system, Antioxidants, emulsifiers, thickener used for latex compounding, Emulsifier dispensing agent.

4.2 Methods of Compounding – Ball milling, Pearl mill. Preparation of dispersion, emulsion, extrusion and planetary mixing.

Unit 5: Manufacturing Techniques and Application of latex for rubber

products :- 12 21

5.1 Dipping: Principle, Process, after treatment, Defects: causes and remedies. Formulating for dipping. Gloves, balloons: prophylactics, bladders.

5.2 Foam making: Principle, Dunlop Process. Talalay Process. Structure and Properties of foam, Formulating for foam.

5.3 Latex threads, Extrusion, Tubes: Principle, Process & Formulation.

5.4 Latex as Binders for Textiles and Papers: Principle, Binders for

Nonwoven Fabrics, Asbestos based linings for coated papers.

Formulating for above.

5.5 Other applications: Cement modification, Asphalt modification, adhesives, carpet backing.


Curriculum- 2012-13


References:-

Academic Co-ordinator Programme Co-ordinator Principal

Rubber Tech. Deptt. Rubber Tech. Deptt. Govt. Polytechnic, Mumbai

Practical’s

Unit 6: Complete Any Nine of the Following :- 1. Mechanical stability of latex.

2. Performance of various stabilizers of M.S.T. of Latex.

3. Coagulation of NR Latex – Determination of pH, Total Solids, Ash

4. Determination of DRC/VFA/NH3/KOH number.

5. Preparation of dispersions of Sulphur/ZnO/ZDC/Clay.

6. Film formation from the compounded NR Latex, Measurement of physical

properties.

7. Preparation of Emulsion of Antioxidant, plasticizers.

8. Compounding of NR latex with fillers, testing of physical properties.

9. Comparison of various cure systems for the NR, latex, synthetic – measure

of physical properties.

10. Synthetic Lattices – SBR, XSBR, NBR, XNBR Their study pH, Total Solids,

Ash.

11. Preparation of dipped articles – Balloons, gloves etc.

Sr.No. Author Title Publication

1 D.C. Blackley Polymer lattices, Science and

Technology Chapman & Hall

2 R.T. Vanderbilt Handbook of Latex Technology R.T. Vanderbilt

Company, Inc.

3 Martin & Smith Hand Book of Rubber Technology CBS Publishers


Curriculum- 2012-13


RATIONALE:-

The Technicians (Mechanical) are likely to perform supervisory role on shop floor of the

manufacturing units. In addition to this they are also expected to improve the working

environment / methods and productivity. Principles of Production Engineering help them to

understand the measures of productivity, plant layout, process planning and project management.

While Industrial Engineering helps them to carry out work-study and motion study. They should

be aware of modern manufacturing techniques in Production Engineering.

OBJECTIVES:-

After studying this subject students will be able to:

1. Understand the Production systems and Productivity.

2. Understand and prepare a process planning for product.

3. Understand the functions of PPC.

4. Design Jig and Fixture.

5. Carry out method study, motion study for given product or process considering

ergonomics and aesthetic aspects.

6. Understand the different modern production systems which connect them with present

era of industries.

Programme Code : Diploma in Mechanical / Rubber Technology

Course Code : ME 14 308 Course Title: Production & Industrial Engineering






80 20 - - 50 150


Curriculum- 2012-13


SECTION I

(40 MARKS)

Sr. No. Topics Hrs. Marks

1. Production Systems :

1.1 Definition.

1.2 Types of Production Systems (Intermittent / continuous) their

types and comparison.

1.3 Productivity :

Importance.

Measurement of Productivity.

Techniques of improving productivity.

05 08

2. Plant Layout :

2.1 Objective.

2.2 Types of plant layout.

2.3 Design Principles.

2.4 Factor affecting plant layout.

04 06

3. Process Planning :

3.1 Planning of Process from Raw material to finish product.

3.2 Deciding sequence of operation.

3.3 Operation Sheet.

3.4 Combine operations and Determination of inspection stage.

05 08

4. Production Planning and Control :

4.1 Definitions.

4.2 Functions and Importance of PPC.

4.3 Meaning of Control.

4.4 Progressive Control.

4.5 Routing, Sequencing (n job 2 machine), Scheduling, Dispatching.

4.6 Gantt Chart, Flow process sheet and Line Balancing.

05 10

5. Jigs And Fixtures :

5.1 Introduction.

5.2 Difference between Jigs and Fixtures.

5.3 Different components of Jig / Fixture.

5.4 Types of Jigs and Fixtures.

5.5 Types of Locators and Clamping devices.

5.6 3-2-1 principle of location.

5.7 Fool proofing of Jigs and Fixtures.

5.8 General principles of Jig and Fixture design.

05 08


Curriculum- 2012-13


SECTION II

(40 MARKS)

Sr. No. Topics Hrs. Marks

6. Method Study :

6.1 Definition, Objectives and Procedure.

6.2 Selection of Work Charting Techniques.

Flow process charts.

Outline process chart.

Flow diagram.

Travel chart.

Critical examination and analysis.

05 08

7. Principle of Motion Economy :

7.1 General consideration.

7.2 Tool and equipments.

7.3 Two handed process.

7.4 Multiple activity charts.

7.5 Therblings.

7.6 Cycle and Chronocycle graph.

7.4 SIMO chart.

05 08

8. Time Study :

8.1 Definition and Procedure.

8.2 Factor affecting the rate of working.

8.3 Equipments for Time Study.

8.4 Types of Elements.

8.5 Rating and Allowances.

8.6 Normal Time, Standard Time, Work sampling and MOST.

05 08

9. Ergonomics and Aesthetics consideration :

9.1 Introduction, Definition and Objective.

9.2 Man–Machine system and its three aspects.

9.3 Display and Control design.

9.4 Environmental factor.

9.5 Layout of Panels.

9.6 Design of Workplace.

04 08

10. Modern Production Systems :

10.1 Kaizen, Just in time Systems and Kanban.

10.2 Group Technology Flexible Manufacturing System.

10.3 Lean Manufacturing System.

05 08


Curriculum- 2012-13


Assignments / Activity to be Performed :

1. Study of production systems and productivity.

2. Design of the plant layout for manufacturing of a simple product.

3. Preparation of process planning and operation sheet for a simple component.

4. Production Planning and Control of simple product.

5. Assignment based on design of simple Jig and Fixture.

6. Method study for a component of a selected product in assignment 2, 3 and 4.

7. Motion economy for a simple component or process.

8. Calculation of standard time for selected simple product or process.

9. Design of workplace layout for manufacturing a product or single process using

ergonomics and aesthetic principles.

10. Assignment based on any one modern production system.

References :

Sr.No. Title Authors Publications

1 Work Study - ILO, Geneva.

2 Production Planning and Control L. C. Jhamb Everest

3 Production System, Planning,

Analysis and Control James C. Rigs Wiley and Sons

4 Industrial Engineering and

Management O. P. Khanna Dhanpat Rai and Sons

5 Industrial Engineering and

Production Management Martand Telsang S. Chand Publication




Curriculum- 2012-13


Rationale:

Basically entrepreneur is a person responsible for setting up a business or an

enterprise. He is an important input of economic development of the country. Talented

personalities are exploring new opportunities into business ventures such as BPO, contact

manufacturing, trading, service sectors etc.

Entrepreneur puts up new projects that create wealth and opens up many employment

opportunities.

This subject/course is introduced to encourage the Diploma-Engg. Holders to make a

profitable carrier by self employment in limited and highly competitive market.

Objectives:

Students will be able to

1. Understand the basic concept of entrepreneurial process, scope and various support systems to entrepreneur.

2. Marketing techniques.

3. To prepare the business plan (project report).

4. Develop awareness about enterprise management.

Programme : RUBBER TECHNOLOGY

Course Code : MG 14 541 Course Title : Entrepreneurship Development


Credits

Duration of

Written

Examination

Examination Scheme


3 - - 3 - - - - - 25 25 50


Curriculum- 2012-13


Contents

Sr.No.

Topics

Hours

48

1. INTRODUCTION

1.1 Definition of Entrepreneur.

1.2 Characteristics of Entrepreneur.

1.3 Functions of an Entrepreneur.

1.4 Barriers to Entrepreneur.

1.5 Distinction between Entrepreneur and Manager.

1.6 Women Entrepreneur-problems and developing trends.

1.7 Entrepreneurship-definition, need, EDP.

10

2. SCOPE

2.1 Trading, consultancy, franchises, service sectors, emerging areas.

2.5 Small enterprise.

-Definition, characteristics, types.

-Problems faced by SSI.

-Industrial sickness-causes and corrective measures.

8

3. SUPPORT SYSTEMS

3.1 Functions of supporting institutes.

(MSME, SIDBI, DICS, SSIB, NSIC, MITCON, TCO’s, MIDC.)

3.2 Govt. agencies and functions of financial institutes.

(IDBI, IFCI, ICICI, SFC, LIC, NABARD, KVIC, Banks.)

3.3 Industrial estates.

6

4. PROJECT/BUSINESS PLAN

4.1 Meaning of project.

4.2 Project classification.

4.3 Project identification- ideas, opportunities.

12


Curriculum- 2012-13


4.4 Project selection (SWOT analysis )

4.5 Project report.

-Definition, importance, contents.

4.6 Project appraisal.

(definition, Techno-economical feasibility of report, cost benefit

analysis.)

5.

MARKETING

5.1 Concept of Marketing and selling.

5.2 Functions of marketing.

5.3 Market Research.

5.4 Product development process.

5.5 Product life cycle.

8

6. MODERN TRENDS

6.1 Management of SSI.

6.2 E-commerce.

6.3 Global trends and opportunities.

6.4 Steps in starting a SSI.

4

ASSIGNMENTS:

1. About Entrepreneur.

2. Assess yourself are you an entrepreneur.

3. Information and sources required for preparing the project report.

4. Steps in setting up a SSI unit.

5. Visit to SSI/Service sector/Consultancy unit.


Curriculum- 2012-13


REFERENCE BOOK:-

Sr.No. Name of Book Authors Publisher

1. Entrepreneurial

Development

S.S.Khanka. S.Chand & Company: Fifth

Edition.

2. Dynamics of

Entrepreneurial

Development and

Management

Vasant Desai

Himalaya Publishing House:

Third Revised Edition.

3. Entrepreneurship

Development

Colombo Plan Staff

College for Technician

Education Manila

Tata McGraw Hill: First Edition

4. Entrepreneurship

Development

Special Edition for

MSBTE

Tata McGraw Hill

Publications.

5. A Manual or How to

Prepare a project report

J.B. Patel & D.B

Allampally

------------------------


Govt. Polytechnic Mumbai


Curriculum- 2012-13


RATIONALE:-

The Project Work is carried out to understand the method of manufacturing of

any single products from its raw materials to its final usable stage.

The material adopted for manufacturing should be discussed amongst the

experts from Industries into the seminar conducted. The satisfactory remark from the experts is

the success of the project.

OBJECTIVES:-

To develop the skills to identify the problem and to develop attitude to take seek solution to the problem.

To develop skill of preparing report for presentation.

Problem identification, problem solving and improved communication.

Every student will prepare a project report in duplicate. One report copy should be submitted to the institute. Seminar should be evaluated through following points.

Work involved.

Understanding.

Presentation techniques.

Other work / book referred.

Project / seminar work must be in proportion with marks, allotted and duration of semester.

Final project report should be neatly typed.

Programme Code : Rubber Technology

Course Code : RT 14 404 Course Title: PROJECT WORK & SEMINAR





- - 8 8 - - - - - 50* 50 100

( * ) indicates assessment by Internal and External examiners


Curriculum- 2012-13


.Section - I


Unit 1:- How the Project work to be done?

1. Project work will basically include manufacturing a product to meet a certain product specification. Product specification shall be either based on a problem from the industry or one designed by the guide.

2. Step-by-Step time bound programme should be followed during the completion of project. The Steps are :

Selection of product. (1 Week)

The product drawing. (2 Weeks)

The cost of raw material of the product. (1 Week)

Designing a mould for the product. (2 Weeks)

Decide the cost of mould. (1 Week)

Manufacturing of the mould. (2 Weeks)

Preparation of raw material i.e. mixing. (1 Week)

Testing of raw material, both physical and chemical tests. (1 Week)

Manufacturing of the product on the hydraulic moulding press. (2 Weeks)

Decide cost of the product. (1 Week)

Preparation of the project report. (2 Weeks)

Presentation to be made at the end.

- -




Curriculum- 2012-13


RATIONALE:-

Students of rubber technology must have understanding of various products that can be

manufactured from different types of rubbers. He should also have the understanding of their

manufacturing methods.

OBJECTIVES:-

At the end of the course student will be able to

Understand various type of products that can be manufactured from rubbers.

It is very important to visit various manufacturing units to understand

the process. Students must have to see all machines in operation.


Course Code : RT 14 405 Course Title: Rubber Product Manufacturing






80 20 - 25* 25 150



Curriculum- 2012-13


Section I

(40 Marks)


Unit 1: Tyres and Tubes :- 22 28

1.1 Brief history on design and development. Kinds and types of Tyres.

1.2 Marking on Tyres -size, ply rating, construction material, Load Carrying Capacity, Speed symbol, Load index etc. Explanation on different series of tyres (sizes). 1.3 Different construction of tyres-Bias, bias belted, Radial, tube type and

tubeless-their basic features and comparison of performance.

1.4 Functions of a pneumatic tyre, Requirement of modern tyre Concept of steering control, rolling resistance, Traction Aspect Ratio, Internal heat generation, abrasion and skid resistance, water removal, tread design and contact area.

1.5 Components of tyres and their basic functions . Manufacturing process of tyres-various steps involved, block diagram of mfg. Process. Tyre related products-tube, flap and bladder tube valves and their unction.

1.6 Introduction to ITTAC, TRA, ETRO, JATMA etc.

1.7 Introduction to RIMS (for tyres).

1.8 Tyre related products like tubes, flaps, bladders, valves their design and manufacturing.

1.9 Classification of tyres as per application :- bicycle, motorcycle, passenger car, light truck, truck-bus, agricultural ,industrial & aero tyres.

1.10 Retreading Hot / Cold retreading. Method of retreading, comparison between new and retreaded tyre, hot and cold retreads.

1.11 Manufacturing process of automotive tubes, various rubbers used. Functions of tube in a tyre.

1.12 Green Tyre ( low rolling resistance ).

a.) Mfgr. of tyre bladder.

b.) Labeling of Tyre.


Curriculum- 2012-13


Unit 2: Hoses and tubing :- 06 06

2.1 Definition of a hose, functions.

2.2 Design of hose, construction of a hose-inner tube, outer tube.

2.3 Various applications-fabric reinforced, textile braided hose, wire braided hose, hand built hose, moulded hose.

2.4 Manufacturing technique for above.

2.5 Applications.

Unit 3: Calendered sheeting :- 04 06

3.1 Manufacturing Process of Calendering, Frictioning, Spread coating, Applications.

3.2 Different products & its formulation: Formulation of Hospital Sheet / Tyre sidewall, Printing Blanket respectively.


Curriculum- 2012-13


Section II

(40 Marks)


Unit 4: Extruded profiles :- 06 06

4.1 Simple extruded profiles

4.2 Microwave cured profiles.

4.3 Principle of microwave curing.

4.4 Polarization concept, formulation design.

4.5 Extruded sponge profiles.

4.6 Metal inserted profiles.

4.7 Recipe for LCM curing and microwave curing.

Unit 5: Moulded Goods :- 06 08

5.1 Simple moulded articles, rubber to metal bonded products, metal treatment / preparation, mechanical and chemical moulding..

5.2 Fabric reinforced articles-fabric preparation. Automotive, Industrial, Pharmaceuticals.

5.3 Transfer Moulded articles-principle and application.

5.4 Injection Moulded articles – principle, formulation and application.

Unit 6: Foot Wear :- 04 05

6.1 Basic construction of a footwear, Gum Boots, Canvas shoes, Hawaii

chappals, banwar and neolight sole.


Curriculum- 2012-13


Unit 7: Adhesives :- 06 06

7.1 Definition of a adhesive.

7.2 Advantages of adhesive jointing over other jointing techniques.

Concept of surface wetting, surface energy.

7.3 Resins for adhesives, solvents for adhesives-criteria for selection.

7.4 Adhesives based on Natural, Neoprene, Nitrile, Polyurethane and isocyanate, cynoacrylate.

7.5 Typical formulations and applications.

Unit 8: Belting :- 04 06

8.1 Types-Conveyor belts, V-Belts, Transmission belts.

8.2 Construction, Manufacture and Applications.

Unit 9 Cables :- 04 05

9.1 Construction of a cable, manufacturing techniques-C.V. Line.

Unit 10 Rollers :- 02 04

10.1 Industrial Rollers.

10.2 Printing Rollers.

10.3 Rice Dehusking Roller

Practical’s

1.. Preparation of a compound to meet a given hardness.

2. . Calendaring a rubber compound on a fabric and determining the coating

characteristics.

3 Preparation of a rubber moulded articles.

3. Preparation of a rubber to metal bonded item. 5. Preparation of a hose by hand building techniques. 6. Preparation of a rubber roller. 7. Linning of rubber on metal vessel. 8. Preparation of a rubber extruded profile.


Curriculum- 2012-13


References:-


1 C.W. Evans Hose Technology Applied Science Publishers,

England

2 C.M. Blow Rubber Technology Butterworth Scientific, London

3 I.R.I Rubber Engineering -

4 Tom French Tyre Technology Adam Hilger, Bristol & New York

5 I Skeist Handbook of Adhesives -

6 C.W. Evans Pneumatic Tyre Technology -

7 A. L. Gent Engineering with Rubber Hanser Publishers, Munich Vienna

8 H. J. Stern Natural & Synthetic Rubber -




Curriculum- 2012-13


RATIONALE:-

Thermoplastic Rubbers are a relatively new class of polymers which differ from conventional

rubbers in the sense that this product behaves like rubber at normal temperature but can be

processed like plastic at elevated temperatures. There are new engineering plastics entering

automobile and engineering sector as high performance materials. Student must be familiar with

these materials .to understand modern plastics & rubbers used in the industries.

OBJECTIVES:-

At the end of course student will be able to:-

Understand thermoplastic rubbers & Types of TPEs. Their properties and applications.

Understand engineering plastics as high performance materials.

Other work / book referred.


Course Code : RT 14 406 Course Title: THERMOPLASTIC RUBBER &

ENGINEERING PLASTICS





4 - - 4 3 hrs 2 Tests of 1 Hour each

80 20 - - - 100



Curriculum- 2012-13


.Section - I

( MARKS 40 )

Table of Contents: Hrs. Marks

Unit 1:- Introduction :-

1.1 Definition and characteristics of TPE, Classification of TPE.

04 04

Unit 2:- Styrenic TPE :-

2.1 Structure and chemistry.

2.2 Property composition relationship. 2.3 Characteristics & Applications.

04 04

Unit 3:- Poly Olefinic Type:-

3.1 Structure and chemistry. 3.2 Property composition relationship. 3.3 Characteristics & Applications.

04 04

Unit 4:- EPDM / PP & Nitrile / Nylon Blend :-


4.2 Morphology & Dynamic Vulcanizates.

4.3 Applications & Different Vulcanization systems.

04 04

Unit 5:- Co polyester type TPEs (COPE ) :-

5.1 Name of Hard & Soft segments, its ratio and Hardness Vs Dynamic properties variation.

5.2 Dynamic properties of these TPEs. 5.3 Processing and Application.

04 06

Unit 6:- Polyamide Type TPEs ( COPA ) :-

6.1 Name of Hard & Soft segments, its ratio and Hardness Vs Dynamic

properties w.r.t. PU & COPE. 6.2 Characteristics & Applications.

04 06


Curriculum- 2012-13


Unit 7:- Thermoplastic Polyurethanes :-

7.1 Basic chemistry, Morphology.

7.2 Hardness, soft & hard segment ratio & properties variation. 7.3 Effect of Annealing. 7.4 Properties & Applications of TPE’s.

04 06

Unit 8:- Processing of TPEs:-

8.1 Compounding & processing.

8.2 Equipments, compounding ingredients.

8.3 Modification, Moulding: Injection, Blow.

8.4 Thermoforming, Casting/ Calendaring, & Extruders.

04 06


Curriculum- 2012-13


.Section II

( MARKS 40 )


Unit 9:- Polyacetal :-

9.1 Structure, chemistry. 9.3 Properties & Applications.

04 04

Unit 10:- Fluroplastics:-


10.2 Modified & melt processible grades.

10.3 PTFE, FEP, PFA, homo and copolymer.

10.4 Sintering & melt processing of Fluoroplast.

10.5 Properties & Applications.

06 08

Unit 11:- Polyamide & Polyimide:- 05 08


11.2 Comparative studies w.r.t. service temp.,Tg.

11.3 Amorphous / Crystalline mechanical properties.

Unit 12:- Polyether Ether Ketone:-

12.1 Structure, chemistry.

12.2 Properties & Applications.

04 05


Curriculum- 2012-13


Unit 13:- High density polyethylene ultra high molecular weight:- 04 03

13.1 Structure, chemistry. 13.2 Comparison with POM / EE / PA / w.r.t. coefficient of friction izod impact. 13.3 Properties & Applications.

Unit 14:- General characteristics, definition & test procedures used for

engineering practice:-

04

06

14.1 Vicat Softning point.

14.2 Impact Strength.

Unit 15:- Processing of Engineering Plastics :- 05 06

15.1 Compounding & Processing, Equipments.

15.2 Compounding ingredients - Glass fibre, Carbon fibre & PTFE,

15.3 Moulding - Injection, Blow.

15.4 Thermoforming, Casting / Calendaring, & Extruders.


Curriculum- 2012-13


References:-


1 Legge / Walker Handbook of Thermoplastic

Rubber

--------

2 ------- Encyclopedia of Modern Plastics Macgraw Hill Publications



government polytechnic, mumbai diploma in … polytechnic, mumbai diploma in rubber technology...

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