presentation on grooved rubber sole plate beneath railway track

8/10/2019 Presentation on Grooved Rubber Sole Plate beneath Railway Track

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GROOVED RUBBER SOLE PLATEGRSP) 6MM

QUALITY ASSURANCE CIVIL DIRECTORATE

RESEARCH DESIGNS & STANDARDS ORGANISATION,(MINISTRY OF RAILWAYS)

MANAK NAGAR, LUCKNOW-226011


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SAILENT FEATURES OF GRSP 6mm

Specific Guidelines: QC-G-7.1-3 Ver. 1) Specification : IRS:T-47-2006

Raw Material : Natural Rubber (Ribbed SmokedSheet Grade I to IV)

Drawing No. : RDSO/T-3703, RDSO/T-3711

Gauge Drg. No.: RDSO/T-8119 & RDSO/T-8120
http://localhost/var/www/apps/conversion/tmp/scratch_10/grade%201%20to%20IV.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/grade%201%20to%20IV.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/grade%201%20to%20IV.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/grade%201%20to%20IV.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/grade%201%20to%20IV.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/grade%201%20to%20IV.pdf


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GROOVED RUBBER SOLE PLATE

COMPONENTS

TYPICAL MIX PROPORTIONS

PROCESS


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PRODUCTION INFRASTRUCTURE

KNEADER

MIXING MILL

HYDRAULIC PRESS

TESTING EQUIPMENT


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TEST PARAMETERS

PRE-PRODUCTION TESTPilot Test Study is conducted at regular interval toascertain 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 accuracyof production process as per clause 3.1.2 of IRS- T-47/2006.

Rheometer is used to ascertain properties like optimumcuring time and curing temperature
http://localhost/var/www/apps/conversion/tmp/scratch_10/Pilot%20Study%20Test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/Pilot%20Study%20Test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/Pilot%20Study%20Test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/mix%20batch%20testing.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/Pilot%20Study%20Test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/Pilot%20Study%20Test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/Pilot%20Study%20Test.pdf


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TEST PARAMETERS

FINISHED PRODUCTHardness 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
http://localhost/var/www/apps/conversion/tmp/scratch_10/hardness%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/ts%20elongation%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/relaxed%20modulus.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/tension%20set%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/compression%20set.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/load%20deflection.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/electrical%20resistence%20test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/ash%20content.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/sp%20gr%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/dimensional.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/dimensional.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/sp%20gr%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/ash%20content.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/electrical%20resistence%20test.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/load%20deflection.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/compression%20set.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/tension%20set%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/relaxed%20modulus.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/ts%20elongation%20sheet.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_10/hardness%20sheet.pdf


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FINAL LOT-WISE INTERNAL INSPECTION(A lot shall consist of 10000 nos. of GRSP)

Parameter SampleSize

Frequency

Acceptance Limit /Specified Value

Method of Insp. Equipment Used

Shore A Hardness 5 Each Lot 75 (Min) Hardness TesterTensile Strength (before ageing) 5 Each Lot

120 Kg/cm2

(Min)

Tensile testing machine

Tensile Strength (after ageing ) 5 Each Lot 100 Kg/cm 2 (Min)Tensile Retention (after Ageing) 5 Each Lot 80% MinElongation at Break (before ageing) 5 Each Lot 200 % (Min)

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/cm 2

Relaxed Modulus change (afterageing)

3 Each Lot +30% /-10% (Max)

Compression set test 3 Each Lot 30% Max Compression set apparatus

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 MachineElectrical Resistance (beforeimmersion)

3 Each Lot100 M (Min)

Million Mega ohm meter

Electrical Resistance (afterimmersion)

3 Each Lot100 M (Min)

Million Mega ohm meter

Specific Gravity 3 Each Lot 1.35 (Max) Analytical BalanceAsh Content 3 Each Lot 30% (Max) Muffle furnace & Analytical Balance

Dimensional / Visual Checking As per

Spec.

Each Lot As per Drg. Dimensional Gauges

Marking 100% Each Lot As per Drg Visual


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LIMITS OF TEST RESULTS OF INSPECTION

(RDSO/M&C/RP-198/2006 (Provisional) )

S.N. Characterstics Specified Value Specified Value Specified Value

COMPOSITE PAD COMPOUND A COMPOUND B

1 Hardness, Shore A (for A side + 2 of hardness of test pad A, for B side +2 ofhardness of test pad B) 75 min. 60 min.

2

Tensile strengtha) Before Ageing (Kg/cm) 120 min 120 min 150 min

b) After ageing (Kg/cm) 100 1.C for 96 +0/-2 hrs. 100 min 100 min 125 min

c) Retention After ageing (%) 80 min 80 min 80 min

3

Elongation at Break

a) Before Ageing (%) 250 min 200 min 350 min

b) After ageing (%) 100 1C for 96 +0/-2 hrs. 180 min 150 min 270 min

c) Retention After ageing (%) 60 min 65 min 70 min

4 Relaxed Modulus at 100% elongationa) Before Ageing (Kg/cm) 25 - 45 45 - 60 20 -35

b) % Change after ageing at 1001C for 96+0/-2 hrs. (+30/-10) (+30/-10) (+30/-10)

5 Compression Set.(%) Subject to 50% compression at 100+/-1 deg.C for 24 +0/-2hrs. 30 max

30 max 25 max

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


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TH NK YOU


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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.


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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


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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 N OZZLES.

.


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FILLER CAN BE REACTIVE (TO IMPROVE PROPERTIES) OR NON

REACTIVE JUST TO FILL THE SPACE. CARBON BLACK/SILICA ISACTIVE FILLER WHEREAS CHINA CLAY IS INACTIVE FILLER


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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 usedin small quantities only (namely protective agents andaccelerators), are added so that they are well dispersed. Then

fillers, softeners, sulphur are added in sequence. Mixing is doneto make rubber more homogeneous and achieving uniformdispersion of various additives.

Vulcanization: Compound is vulcanized in all commonly usedprocesses hot air with pressure, as transfer moulding, The rawmaterial is cured and through cross linking and other reactionconvert into stable usable product.


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RHEOMETER

Rheometer is an simple and reliable testingequipment which describes precisely andquickly curing and processing characteristicsof vulcanizable rubber compounds.The Rheograph (torque Vs time) indicates:

process behaviorcuring characteristicsindication of physical properties


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TESTING EQUIPMENTSTension TestingMachine

For testing of tensile strength , elongation andrelaxed moduls

Compression TensingMachine

To check load compression

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


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HARDNESS TEST


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TENSILE STRENGTH TEST


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ELONGATION TEST


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RELAXED MODULUS TEST


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LOAD DEFLECTION TEST


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ASH CONTENT TEST


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SPECIFIC GRAVITY TEST


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ELECTRICAL RESISTANCE TEST


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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 becut 37 mm in diameter and whose axial plane coincides with that of one of thegrooves.

For testing IS.3400 (Part X) shall apply.

Thickness of test specimen (To) shall be measured and it shall be compressed in acompression 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 thedevice. The thickness (Tr) of test specimen shall be measured after 24 hours but notlater 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 seriesof three measurements arranged in order of decreasing values.


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TENSION SET TEST


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VISUAL & DIMENSIONAL TEST

presentation on grooved rubber sole plate beneath railway track

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