programme : rubber technology - government … · · 2015-07-20angular measurement: ... 3. use of...

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


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


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





3 - 4 7 3 hrs 2 Tests of 1 Hrs.

each 80 20 - 25 25 150


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


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





4 - 4 8 3 Hrs. 2 Tests of 1 Hour

Each 80 20 50* - - 150


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


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.


Course Code : RT 14 304 Course Title : Vulcanization System

C / O : Compulsory



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


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:


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.


Course Code : RT 11 306 Course Title : Testing of Rubbers

C / O : Compulsory




3 - 4 7 3hrs 2 Tests of 1

Hour Each 80 20 50* - - 150


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:


01 Roger Brown Physical Testing Of Rubber Chapman & Hall

Publication

02 John S.Dick Rubber Technology

Compounding & Testing

Hanser Publication


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

programme : rubber technology - government … · · 2015-07-20angular measurement: ... 3. use of...

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