training report goodyear tyres

8/10/2019 Training Report Goodyear Tyres

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TYRE MANUFACTURING PROCESSES

INDUSTRIAL TRAINING REPORT

(JUNE 2014JULY 2014)

SUBMITTED FOR

THE PARTIAL FULFILMENT OF THE AWARD OF

THE DEGREE OF

B.TECH (MECHANICAL & AUTOMATION ENGINEERING)

Prepared by:

NAMAN TANEJA 070/BTechMAE/ASET/15

AMITY SCHOOL OF ENGINEERING & TECHNOLOGYBIJWASAN, NEW DELHI-110061

Affiliated to

GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY

DWARKA SEC.16,, NEW DELHI-110006

DEPARTMENT OF MECHANICAL & AUTOMATION ENGINEERING


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CERTIFICATE


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ACKNOWLEDGEMENT

Final year project is an indispensable part of any engineering curriculum. It provides the

students with an opportunity to gain experience on the practical application of their

technical knowledge.

I would like to express my deepest appreciation to all those who provided me the possibility

to complete my industrial training. A special gratitude I give to our Training incharge, Mr

Pradeep Singhal (Production Manager), whose contribution in stimulating suggestions and

encouragement, helped me to coordinate in my training period.

Furthermore I would also like to acknowledge with much appreciation the crucial role of the

employee of other sections who gave the permission to use all required equipment and the

necessary materials to complete the task. A special thanks goes to my team mate, who help

me to assemble the parts and gave suggestion about the task. .

Naman Taneja


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CONTENTS

1.

Introduction to Goodyear Tyres Pvt. Ltd 5

2. Different Components of Tyres 6

2.1. Components of Tyres 6

2.2. Types of Tyres 9

2.3. Tyre Regions 12

3.

Tyre Nomenclature 13

4. Compounding in rubber Industry 15

5. Conclusion 19

6.

References 20


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INTRODUCTION TO GOODYEAR TYRES

Goodyear Tyre and Rubber Company is the pioneer in tyre making, one of the largest

rubber manufacturing companies in the world. It is the first among the tyre companies to

obtain the prestigious ISO 9002 certification. Our training experience has here been very

pleasant and educative throughout.

The company was set up in 1898 by Frank Seiberling naming it after the great Charles

Goodyear, who discovered the process of vulcanization the cornerstone of all rubber

processing. The newel past study statuette of mercury, the ancient Greek god of trade and

commerce, inspired the wing and foot of the symbol of the company.

Since then the company has not only been the world no. 1 in the field of tyres but has also

included chemicals, polyesters for tyre cords, automotive components, automotive belts and

hoses, shoe sales and heels, metal wheels and rims, packaging firms, aircraft brakes and

wheels, aerospace products, computers and enriched uranium products for atomic energy in

its product lines.

Even though the company has a long product line, yet the tyre and rubber remain its major

assets. The company has set up more than 80 production facilities with 90000 associates all

around the world. In India it has two production plants, one in Faridabad and Aurangabad.

Some of the remarkable achievements of Goodyear are:-

1. First to produce the pneumatic tyres and nylon cord tyres.

2.

First to produce the detachable rim and aircraft tyre.

3. First to produce bias belted polyglass and low resistance rolling tyres.

4.

The world largest tyre manufacturer.

5.

First Tyre Company in the world to be awarded with ISO 9002 certification indicating

excellence in the production standards.

The Faridabad plant was installed in 1961 and since then has come a long way. Today the

plant churns out a turnover of whooping 700 Crores.


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DIFFERENT COMPONENTS OF TYRES

Tyre is a flexible membrane pressure container that encircles the wheel rim in order to

perform functions for locomotion. It is made of materials containing long chain polymers. On

the other hand, tyres may be defined as an envelope of rubbers and chemical reinforced

fabrics, being held on the rim by compressive forces of the wire beads. The primary function

of the tyre is to contain a sufficient volume of compressed air which in turn creates and

internal pressure sufficient to carry the load imposed and also to move that load in the desired

direction with the desired speed.

A tyre must perform the following functions:-

1.

It must posse load bearing capacity.

2. It should provide grip on the road.

3.

It should resist abrasion and provide low rolling resistance.

4. It must exhibit durability, flexibility and safety.

5. It should provide lateral and dimensional stability.

6. It must act as a cushion and as envelope as well.

2.1 Components of Tyres

Figure 1Components of tyre

The components are divided into two groups:-

A. Primary Components


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These are responsible for fundamental tyre characteristics. These include:-

1.

Thread :-

It is the wearing surface of the tyre that acts, as a protective cover to the carcass. It is the

portion of the tyre that comes in direct contact with the road.

It is designed to offer good abrasion resistance, good traction; low noise and heat build-up. It

takes care of rebounding and antiskid. It is compounded from natural rubber or a blend of oil

extended SBR (to provide abrasion resistance) and polybutadiene rubber (to provide good

rebounding properties) mixed with carbon black and oil, curatives, antidegradants etc.

2. Sidewall

It constitutes the region of the shoulder and the bead. It protects the carcass from external

damages like weather, dust, moisture and radiations. It must provide high flexibility and

weather resistance. Together with the tread it forms the outermost layer of the tyre.

3.

Carcass Plies:-

It gives the tyre the strength that is necessary if it has to handle the load of the vehicles. Plies

consist of the carcass of the tyre is made up of the cord of rayon, nylon or polyester woven as

a wrap of a fabric.

The fabric is treated with an adhesive and rubberized to thickness of approximately 1mm and

interleaved with low moisture containing textile lining. The large rolls rubberized textile

about 1.5 mm wide and 300 m long is cut into the strips known as piles. These piles may be

cut at a bias angle between 45 to 90 degrees.

4.

Beads

It is a combination of copper and high tensile strength steel wires to provide rigidity to the

inflated tyre. Layers of wire coated with rubber are coiled into the ring shape. To eliminate

any possibility of loosening of the bead coil is further cross woven with rubberized textile. It

holds the tyre on the rim and prevents rocking or slipping of the rim.

5. Breakers


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They are short plies especially cut at an angle and positioned centrally between the casing

tread to strengthen the carcass against impact. They have nearly the same angle as that of the

tyre body. They add bulk and cushion to the tyre body in the tread area.

6.

Belts

They restrict the circumferential growth and hence maintain the aspect ratio of the tyre during

running condition. They also break the load uniformity.

B. Secondary Components

They are the primary components for distributing stress. These include:-

1.

Chaffer:-

It is a narrow circumferential strip that encloses the completed bead area. It is a narrow strip

of square woven rubberized fabric of cotton, rayon or polyester places around the ply lock

assemble outside bead. It protects the cords plies against wear and chaffing by the rim and

also avoids penetration of the moisture and foreign particles like dust into the tyre. Upper

edge of the chaffer is located slightly above the rim flange height and extends downwards

around the base. This arrangement provides protection from the rim chaffing and in case of

the tubeless tyre it serves to protect air leakage either into the tyre or out of it.

2. Inner liner:-

It depends on the type of tyre. For the tube tyre it is usually a thin layer of the compound

directly calendared on the underside of the first ply after it has been joined and batched in

continuous length. It serves to insulate the tyre chords from the inner tube so as to prevent the

tube from the chaffing damage. It also protects chords from the possible degradation due to

the absorption of the atmosphere moisture.

However in the tubeless tyre, it is the air retaining membrane and is calendared as a two layer

laminate stepped edges.

3. Bead Apex

It consists of a band of fabric or steel cord at the lower sidewalk and bead areas and

reinforces the bead region. It also served as a ply transition, extension to reduce ply and

rubber cracking


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2.2 Types of Tyres

A tyre is classified according to the following tyres: -

A. Tyre construction

Tyre may be classified by the type of casing construction used. These are two types of tyre:-

1. Bias Tyre

These are called across ply or conventional types. It uses the traditional method of tyre

building in which reinforcing cords are diagonally across the tyre from the bead at an angle of

29 to 33 degrees to the centreline of the tyre. Each successive layer of the ply runs in the

opposite direction that results in a crisis cross pattern.

Figure 2Bias and Radial Tyres

2. Radial Tyre

This tyre building is a new technology that offers better performance than the usual diagonal

ply tyres. Their superior performance is because of the fact that plies in the carcass areaperpendicular to the beads. So they provide more cushioned ride as the shock absorbing

ability increases because the ply can flex easily. Ability of the radials to absorb the road

shocks has allowed innovation advancement of the entire automobile suspension as well as

the handling characteristics.

In radials, the plies of the reinforcing cords extend from bead to bead at an angle of 40

degrees to the centreline of the radial. Directly on the top of the radial plies and under the

tread there is a full- length belt made of several plies of tyre cords that run circumferentially


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around the body of the radial. Cords are placed in the belt at a low angle of 15 to 25 degrees

and act as restrictor to the 88 degree body plies. Increased bulging of the sidewall even when

fully inflated is a unique characteristic of the radial.

Advantages of the radial tyres over the bias one:-

a. More Mileage

b. Lessor rolling resistance

c.

Better Fuel efficiency

d. Ride Comfort

e.

Higher penetration resistance

B. Tread Pattern

Although there may be many combinations, generally a tyre can be classified into four ways:

-

1. Ribs Pattern: -

This type of tyre is mainly used in front wheel. Its main function is to control the steering

action.

2. Lug Pattern:-

This is mainly used in rear axle. Its main function is road gripping.

3.

Mud and Snow Pattern

This is especially designed for use in muddy and off the road use.


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Figure 3 - Lug, Mud and Rib Pattern Tyres

C. Field of Applications

According to this, tyres are classified into the following types:-

1.

Bicycle type/ Richshaw Type

2.

Motor Cycle Type

3. Scooter Type

4.

Jeep Tyre

5. Passenger Tyre Type

6. Bus Tyre Type

7. High Loading truck tyre Type

8. Off- the road tyre Type

9.

Agricultural tyre Type10.Air-craft tyre Type

11.Earth mover tyre Type

D.

Tube and Tubeless Tyre: -

Air at high inflation pressure is to be enclosed between the tyres and the rim. In general this

is achieved by using an air light elastic tube, generally made of BUTYL RUBBER, having


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low permeability, is placed inside the tyre and the rim assembly. These types of tyres are

known as tube or conventional tyres.

In some cases it is possible to achieve air seal between the tyre and the rim, without the use of

tubes. This type of tyre was first developed by Litchfield of Goodyear Tyre having an extra

layer of rubber inside the tyre, which acts as an envelope. These tyres are known as tubeless

tyres.

2.3

Tyre Regions

For convenience the outer has four different regions, namely:-

A. Crown/ Tread Region

It is the portion of the tyre that is always in contact with the road. This is the wear resistant

component that provides traction, silent running and low heat build-up. The tread consist of:-

1. Ribs/ Cap

It is the circumferential roll of tread rubber designed for noise suspension and traction.

2.

Grooves/ Base

These are the circumferential channels, which are essential for traction, directional control

and cool running.

B. Shoulder Region

It is the portion between the crown regions to the portion along the height where maximum

flexing is not stated. It affects heat behaviour and cornering characteristics.

C. Side wall regions;-

It is the portion of the tyre between the shoulder region and the bead which primarily controls

ride and support. It consists of a side wall compound on the outside, plies in the middle and

inner liner compound on the inside.


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Radial tyres have thicker, more flexible side walls than the bais tyres due to a need for greater

deflection characteristics. Its main functions are

Takes most flexing

Dissipates heat to air

Protects heat and impact penetration to the body plies.

D. Bead Region

It is the part of the tyre which is connected to the rim. It is a structure composed of high

tensile strength steel wire coated with copper, formed into inextensible hoops functioning as

anchors for the plies and holding the assembly on the rim of the wheel. The shape of the bead

confirms to the flange of the wheel to prevent the tyre from slipping of the rim. It shapes the

tyre to fit on the rim and holds the tyre tight on the rim.


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TYRE NOMENCLATURE

A.

For Bias Tyres:-

Tyre is generally signified by its inflated section in inches and nominal bead diameter.

E.g.

A tyre having specification 9.00-20 means

Inflated section in inches = 9.00

Nominal bead diameter in inches = 20

B.

For radial TyresA radial tyre is normally nomenclated like this

145/70S R 14

It means

Inflated section width in inches = 145

Aspect Ration = 70

Speed = S

Radial = R

Bead diameter in inches = 14


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COMPOUNDING IN RUBBER INDUSTRIES

There are number of chemicals used in the tyre that induce requisite properties like rigidity,

resistance to heat and water etc. in the tyres. Specifications of materials to be used are issued

by Goodyear, Akron, USA. Of the various materials used in the tyre industry the chief and

the commons are: -

1. Rubber

It may be defined as the captive liquid, which has external and internal Brownian motion. It

has very high elasticity, flexibility and im-permeability to air and water. Rubber used in thetyres may be natural or synthetic. Natural rubber is obtained from the latex of the plant while

synthetic rubber may be

Butyl RubberPolymer of isobutylene and isoprene

Styrene Butadiene RubberCopolymer of butadiene and styrene.

2. Fillers

The fillers are added to the rubber so as to:-

A.

Increase the mechanical strength.

B. Extend and dilute

C. Decrease the cost

D. Alter the processing characteristics

E. Increase the adhesion property

The size of the filler particle is important in determining their use. If the particle size is

greater than 10 micron then the filler decreases the strength because of the localized area of

stresses. If the particle size is 1- 10 then the strength neither increases nor decreases. If the

particle size is 0.1-1; the filler will be semi-reinforcing and if in between 0.01- 0.1 then the

filler will be reinforcing one.

The filler generally used in the industry are carbon black and silica.

3.

Plasticizers or Softeners: -


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The softeners are added so as to improve the processing by decreasing the viscosity. The

castor oil and sulphated petroleum oil which are added for softening is loaded up to 10 parts.

The paraffinic and aromatic oils are used at a higher loading to extend the rubber and to

lower the cost. At high loading compatibility the polymer and the oil is required.

Paraffinic is compatible with highly saturated rubber like EPDM and IIR.

Aromatic oil is compatible with highly unsaturated rubber like SBR and NR. Staining is a

phenomenon, which decreases in the order: -

Aromatic > Naphthenic > Paraffinic

They are used to improve the flexibility at lower temperatures. Plasticizers also help in

dispersion of other compounding ingredients.

E.g. Pentachlorothiobenxol

4. Vulcanizers or Curatives:-

Inter and intra molecular thioetherification process by which elasticity is attained at the cost

of plasticity i.e. transfer from fusible to infusible state occurs is called vulcanizing or curing.

The agents, which cause this process, are curatives or vulcanizing agents. Curing actually

increases the viscosity, hardness, modulus, tensile strength and abrasion resistance.

Sulfur and peroxide curing are generally practiced.

3.

Accelerators

These are the chemicals, which are used to increase the rate of curing by lowering curing

time. They basically help in producing activated sulphur rhombic one, which actually

participates in the formation of polysulfide linkages. Accelerators are mainly divided into:-

A. Delayed action acceleratorN-cyclohexyl benzthiazyle sulphonamide

B. Slow acceleratorTriphenyl guanidine

C.

Semirapid acceleratorMercapto benz thiazole.

D. Rapid acceleratorTetramethyl thiuram disulphide

E. Ultra rapid acceleratorZinc diethyl dithio carbamate

F.

Sulfur dnorBismorpholine disulphide


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Each of which is used in specific amount and in specific compounds as each gives the

compounds different properties. Also the accelerators are used in synergy with other

accelerators to provide better properties of the compound and also better use of the

accelerator itself. E.g. MBT, ZDC.

6. Antioxidants:-

These are the chemicals, which are added to the compound to prevent the changes in the

properties of the compound due to the action of oxygen in services. Oxidation during the

course of service causes the compound either to harden or soften. There are two types of

antioxidants:-

a.

Primary Antioxidants

These chemicals scavenge and destroy oxy radicals before they react with rubber. They are

either secondary amines or substituted phenols with highly reactive hydrogen atoms.

b.

Secondary Antioxidants

These are the chemicals, which destroy the hydro peroxides formed during the course of the

oxidative action before they decompose and start new chains. These materials are mainly

phosphates and sulphides.

7.

Antiozonants: -

Ozone mainly attacks the double bonds and therefore only unsaturated rubber when stretched

becomes highly vulnerable to ozone attack. This can be mainly prevented by coating the

surface or adding an antiozonants.

Waxes are added to the rubber as they bloom to the surface and form a protective layer

around the compound but these breaks on flexing. So for products like tyres, which are prone

to flexing in services, antiozonants like p-phenylene diamine are added as they scavenge

ozone before they react with the compound.

8. Activators


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These chemicals are used for activating the accelerators by helping in the easy mobility of the

accelerators and are therefore helpful in quick and uniform curing. E.g. Zinc Oxide, Stearic

acid.

9.

Retarders

They are used in the rubber industry to prevent scorch i.e. to prevent the premature curing of

rubber, which might spoil the compound due to uneven dispersion and non-uniform curing,

also decreasing the workability of the compound. Retarder mainly captures the anion of the

accelerator and thereby prevents the salt formation, which is the primary cause of scorching.

E.g. N- cyclohexyl thiopthalamide in the forms of crystals.

10.

Tackifiers: -

They are a class of additives, which impart good tack to the mixed compound. Tack is very

much necessary in tyre building for it is the tack that is responsible for the good strength and

shape retention nature of a green tyre. Tackiness also aids in the expulsion of entrapped air

molecules, so that blister formation and tyre weakening are prevented during curing.

Common tackifiers are classified as natural and synthetic. Natural tackifiers such as wood

resin are used to improve that tack of the natural rubber compounds whereas synthetictackifiers such as cumarone indene resins may also be used if required.


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CONCLUSION

As an undergraduate student of the Amity School of Engineering and Technology, Delhi I

would like to say that this training program by Goodyear Tyres Pvt Ltd is an excellent

opportunity for us to get to the ground level and experience the things that we would have

never gained through Academic study of related subjects. I am grateful to the ASET and

Goodyear Tyres Pvt Ltd for giving us this wonderful opportunity. The main objective of the

industrial training is to provide an opportunity to undergraduate students to identify, observe

and practice how engineering is applicable in the real industry. It is not only to get experience

on technical practices but also to observe management practices and to interact with fellow

workers. It is easy to work with sophisticated machines, but not with people. The only chance

that an undergraduate student has to have this experience is the industrial training period. I

feel I got the maximum out of that experience. Also I learnt the way of work in an

organization, the importance of being punctual, the importance of maximum commitment,

and the importance of team spirit. The training program having three destinations was a lot

more useful than staying at one place throughout the whole six weeks. In my opinion, I have

gained lots of knowledge and experience needed to be successful in a great engineering

challenge, as in my opinion, Engineering is after all a Challenge, and not a Job.


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REFERENCES

1.

Goodyear Pvt Ltd Website- www.Goodyear.co.in

2. Automotive Engineering by Kirpal Singh(Vol. 2 edition 2).

3.

Automotive Tyres by L. J. K. Setright(Illustrated Volume, Edition 3).

training report goodyear tyres

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