Practicals

3714007 Index
Index
Sr. Page Number Date of Date of Initial
Title From To
No Start Completion of Staff
9
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Practical - 01
Aim: To simulate plant layout process and production rate of manufacturing of automobile tube.
The simulation can be carried out with several factors which are affects. Some of them are as follows and
how can we simulate them, that details are mentioned.
(1) Plant Layout
(2) Formulation
(3) Processing and Controlling in the Plant
(4) Mixing Mill
(5) Internal Mixer
(6) Strainer
(7) Extruder
(8) Valve Installation:
(9) Splicing:
(10) Chilling:
(11) Shaping, curing and vacuum:
(12) Inspection:
(13) Troubleshooting innertube processing and manufacturing
1.1 Plant Layout:

Simulations in plant layout can be highly beneficial for industries in several ways. Plant layout refers to
the arrangement of machines, equipment, workstations, storage areas, and other facilities within a
manufacturing or production facility. Overall, simulation in plant layout offers a cost-effective and risk-
reducing approach to optimizing manufacturing and production processes. It enables industries to make
informed decisions, improve efficiency, and adapt to changing market conditions while minimizing
disruptions and maximizing their competitive advantage. Here's how simulations can benefit the
industry in the context of plant layout:
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Case 1: Present Plant Layout of “Polygold Precured Systems Pvt. Ltd.”.
Figure 1.1 Current Plant Layout
Case 2: We Studied Case 1 Plant Layout and make some of the simulation which will offers a cost-effective
and risk-reducing approach to optimizing manufacturing and production processes.
Extruders; Colling Area; & Raw Tube Stock Area Steam Area
Straining
Kneader
Splicing and Valve Jamming Curing Area

Inspection Area;
(Quality Control)
Quality Control & Tool Design;

Quality Assurance Raw Material
Mixing Area Testing Storage Area
Die Storage; Packing Area Marketing &
(Mixing Mill) Computer
Production
Maintenance Room /
Planning Control
Server Room
Department Purchase Sales
Meeting Room
Mixing Area Admin

(Internal Mixer) Office
Loading / Unloading area
Human Resources Reception
Department
Washroom
Parking Area Security Security

Entry Exit
Figure 1.2 Simulated Plant Layout

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1.2 Formulation
Simulations in formulation offer numerous benefits to industries by enhancing efficiency, reducing costs,
improving product quality, and enabling innovation.
Table 1.1 : Current Formulation Table 1.2 : Simulated Formulation
Compounding Ingredients PHR Compounding Ingredients PHR

Butyl Rubber 100 Butyl Rubber 100
SRF Black 95 Carbon Black N660 70
Paraffinic Oil 30 Paraffinic Oil 25
Soft Clay 40 Resin 4
Zinc Oxide 5 Zinc Oxide 5
St. Acid 1.5 St. Acid 1
Methyl Zimate 0.5 MBT 1
MBT 0.75 DBTU 2
TMTD 1.75 Sulphur 2
Sulphur 1.75
Cure temperature: 160-165 °C.

Cure time: 6-7 minutes.
Table 1.3 : Various Properties
Properties Units and Conditions Typical Value

Mooney Viscosity, ML 1+4 (ASTM D 1646) MU at 100°C 42.6
Mooney Scorch (ASTM D 1646) at 125°C
Minimum Viscosity MU 31,9
Time to 5pt rise minutes 14.1
Time to 10pt rise minutes 18.7
Rheometer (ODR) (ASTM D2048) 160°C, 60 min., 3.0 deg.arc

Mi (Minimum torque) d<nm 8
Mh (Minimum torque) dNm 47.2
Mh - Mi (Delta torque) dNm 39.3
T s2 (time to 2 point rise) minutes 2.3
T c50 (time to 50% torque increase) minutes 14.6

Mi (Minimum torque) d<nm 8
T s2 (time to 2 point rise) minutes 4
T c50 (time to 50% torque increase) minutes 4
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Mi (Minimum torque) d<nm 1.4

Mi (Minimum torque) d<nm 1.3
Tensile Strength MPa 11.2

Elongation at Break % 775
Modulus 100% MPa 0.9
Energy te Break Joules 9.8
Tear Strength (Die B) Mean KN/m 30.8

Tear Strength (Die C) Mean KN/m 31.4
Hardness Shore A 54
Rheometer (ODR) (ASTM D412) Aged 125 deg C, 72 hours

Tensile Strength MPa 8.2
Elongation at Break % 58.5
Modulus 200% MPa 3
Energy at Break Joules 7.2
Tear Strength (Die B) Mean (ASTM D624) KN/m 22.8

Tear Strength (Die C) Mean (ASTM D624) KN/m 27.2
De’Mattia Flex Resistance Kilocycles KC >80 No Cracks

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1.3 Processing and Controlling in the Plant
1.3.1 Overall Process Flow Chart
Incoming Inspection Raw Material Inward Order Booked by Sales

New Tool
Die Room
Raw Material Not Available Planning for Die
Not Ok Ok Old / Mould
Die Design
Raw Material Available
Slip Issued by Production
Back to
Supplier
Mixing Department
Raw Material Storage
Material Weighing in Mixing
Master Batch Mixing Cleaning & Cooling of Mill

Ageing
(If required)
Straining Batchwise Mixing
Final Batch of
Mixing Sheet Conversion
Correction in
Batch
Sample
Preparation for Sheet Cutting for Feeding
Testing Q.C. Not Passed
Extrusion
Testing in Q.C. Q.C. Passed
Heat Box
C.V. Curing (If Required)
In Process Inspection by Q.C.
Corrections & Modification Q.C. Not Passed Q. C. Passed
Cooling
Valve Punching
Cutting and Dusting
Stock Storage
Wastage Splicing
Product Scrap
Removal
Dispatch Splice Chilling
Packaging Re-Work Not Ok Forming / Shaping
Final Inspection by Q. C. Curing

Ok
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1.3.2 P.P.C. Department Process Flow Chart
Product Requirement from Marketing/Sales
Production Planning Control (P.P.C.) Department
Product Stock Available Product Stock Not Available
Partially Stock Fully Stock Die/Mould Not

Available Die/Mould Available
Available Available
Send to Dispatch Ok Apply for New Die/Mould

Q. C. Department T.&D. Department
Not Ok
Re-Work Scrap
Generate Validation Report Validation Report Not

B. O. M. Slip Available Available
Make Validation Report

with Trial & Error Method
Handover to Generate
Mixing Job Card
Department
Ok Testing in Q. C.
Handover to Production Department Not Ok

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1.3.3 Mixing Department Process Flow Chart
Production Planning Control (P. P. C.) Department

send Bill of Materials (B. O. M.) Slip
Raw Material Raw Material

Available Not Available
Weight the compound as Collect Raw

per B. O. M. Slip Material from Store
Re-Work
Not Ok
Send to Take Material for
Scrap
Production/Moulding Testing and Record
Department Ok
Re-Work
Product Not Ok Product Ok
Scrap
Send to Cutting (If Required)
Send to Quality Control Department
1.3.4 Production Department Process Flow Chart
Get Job Card from P. P. C. Department
Collect Uncure Rubber Sheet from Mixing Department
Set Parameters as per Validation Report
After Extruder Machine, Place Beta Tester

(If Required)
Place D. C. Oven/Heat Box/C. V. (If Required)
Continues Quality Checking
Product Ok Product Not Ok
Stop the Process and

Weighting Resolve the Issue(s)
Further Process
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1.3.5 Quality Control Department Process Flow Chart
Product from
Production/Post Curing
Re-Work
Ok Check Dimensions Not Ok
Scrap
Re-Work
Ok Check Defects Not Ok
Scrap
Re-Work
Send to Cutting
Ok Not Ok
(If Required)
Scrap
Weighing/Lebling/
Packaging/Dispatch
1.3.6 Testing Department Process Flow Chart
Testing
Button Sheet
Check Tensile,
Check Hardness
Tear, Elongation
Not Not
Ok Re-Work Ok
Ok Ok
Start Production
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1.3.7 Scrap Management Flow Chart
Head Scrap In Process Scrap Cutting Scrap
Handover to Store
Scrap Yard
1.3.8 Tools and Design Department Process Flow Chart
Get Order from Sales Department
Old Product New Product

Order Order
Receive
Receive
Product
Product
Die/Mould Not Design
Die/Mould Available
Available
Analyse Feasible for

Production
Prepare Die/Mould
Design Cancel
Yes No Order
Make Product Design Send to Customer

(If Required) for Approval
Ok Not Ok
Re-Design
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1.4 Mixing Mill
1.4.1 Roll Gap

1.4.2 Roll Speed Ratio
1.4.3 Material Loading Sequence
1.4.4 Mixing Time
1.4.5 Roll Condition
1.4.6 Material Properties
1.4.7 Friction Ratio:

Choose an appropriate friction ratio to ensure uniform material mixing while preventing excessive heat
generation. Experiment with different ratios to find the optimal balance.
The recommended friction ratio typically falls within the range of 1:1.1 to 1:1.3. This means that the speed
of the front roll (the roll that comes into contact with the rubber compound) is 1:1.1 to 1:1.3 times higher
than the speed of the rear roll (the roll that supports the rubber compound).
1.4.8 Roll Temperature:

Maintain controlled roll temperatures to achieve consistent material behavior and minimize variations.
Use advanced roll cooling systems to regulate temperatures accurately.
IM: Start-120 ; Discharge 180 °C.
IM: Final Batch Temp: 100-105 °C.
1.4.9 Batch Size:

Adjust batch sizes according to the mill's capacity and material properties. Smaller batches may allow for
better mixing control.
Table 1.4 Mixing Mill Configuration
Roll Size (Inches) Power (HP) Batch Capacity (Kgs)

10 × 24 15 6-9
12 × 30 30 15-20
14 × 36 40 25-28
16 × 42 60 35-40
18 × 48 75 40-50
22 × 60 120 60-80
26 × 84 200 90-110
Friction Ratio: 1:1.05 to 1:1.22
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1.5 Internal Mixer:
Majorly these factors affect to the Internal Mixer in

the Rubber Industries:
Batch Size
Mixer Temperature
Mixer Speed and Shear Rate
Rotor Design
Mixing Time
Material Properties
Process Monitoring and Quality Control
We can simulate these factors by these way:
1.5.1 Guidelines for mixing:
Because butyl rubber is primarily a saturated

polyisobutylene polymer with only a minor
quantity of isoprene, it is important that
contamination of butyl rubber stocks with highly
unsaturated elastomers such natural rubber, SBR,
and cis-polybutadiene rubber be avoided.
Contamination results in a difference in the state of
cure for butyl rubber compared to other
unsaturated diene rubbers resulting in variability
and potential loss of mechanical properties.
Internal mixers, two roll
mills, strainers and
extruders used for
processing both butyl
rubber and unsaturated
rubber compounds
should be cleaned
thoroughly before mixing
and processing of butyl
rubber compounds. To do
this, a clean-out
masterbatch of the type of
compound to be
processed next may be
passed through the
equipment. After this step, Figure 1.3 Internal Mixer
a visual inspection may be made to determine if there is no compound remaining in the equipment. These
two steps are typically sufficient to avoid most cases of contamination.
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1.5.2 Masterbatch mixing
Masterbatch mixing of butyl rubber innertube compounds is typically carried out in an internal mixer.
Finalization (i.e. addition of the vulcanization system) may be carried out separately in an internal mixer,
on open mills, or sometimes in a single stage masterbatch mixing/final batch mixing cycle. The mixing of
the butyl rubber innertube masterbatch compound is an important operation in the innertube production
process. The objective is to disperse the carbon black and other materials in the butyl rubber uniformly
with no porosity in the final compound. Poor mixing may have a detrimental effect during later stages of
processing such as:
Strainer screen plugging,
Variability in extruded innertube dimensions (gauge uniformity),
Fold breakdown,
Difficulty in splicing, and,
Uneven thinning during forming, or gauge retention.
The objective for mixing ideally is “the first time right” approach. When a mixed compound contains
imperfections, it may be very difficult to make corrections to the compound. To achieve good dispersion
of the compound, the following parameters are important:
Compound formulation,
Mixer volume loading,
Initial mix temperature,
Timing of black and oil addition,
Order of addition of other compounding ingredients, and,
Compound mixing dump temperature.
1.5.3 Guidelines for mixing of butyl compounds
Hot housing of halo-butyl and butyl rubber up to 40ºC will help in mixing of the materials. However, time
in a hot house should be kept to a minimum and should not exceed 72 hours. Good air circulation around
the bales of rubber and around the pallets is essential.
1.5.4 Internal mixer volume loading
The optimum loading for an internal mixer for general purpose rubbers is defined as the empty volume
multiplied by the fill factor. The empty volume is the volume of liquid it would take to fill the mixing
chamber. Fill factors are normally in the range 0.7 to 0.8 depending on mixer size and design. Since butyl
rubber innertube compounds are softer, it is necessary to increase the batch size by 10 to 15% above the
normally recommended level. Higher loading of butyl rubber compounds enhances the mixing quality
and reduces the chances of air trapped in the compound which is an important step in minimizing
porosity in the finished innertube. Defects in butyl rubber compounds related to trapped air can increase
processing and cured innertube scrap. Once air gets into butyl rubber compounds it cannot escape easily.
Thus, the batch size for a butyl rubber innertube compound is calculated differently:
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Example: 11D Banbury mixer
Empty volume: 34 litres
Fill factor: Butyl rubber non-productive = 0.80 - 0.85
Butyl rubber productive = 0.75 - 0.80
Typical specific gravity = 1.135
Batch volume: 234 x 0.8 = 187 litres
Batch weight: 234 x 0.8 x 1.135 = (187 x S.G) kg = 212 kg
Optimum loading will also depend on the state of wear of the mixer (e.g. mixer rotor flight clearance).
The above formula may be used as a guide to calculate a batch weight starting point. An alternative
starting point guide is to use 12% greater loading than that used for a SBR or NR compound of equal
specific gravity. By mixing a series of batches, where batch weight is increased in 5 kg increments, and
number of imperfections in each batch is assessed the best mixer loadings and run conditions may be
determined.
1.5.5 Internal mixer starting temperature
A temperature of around 90°C is a suggested compromise between cycle time and mixing quality. To
maximize mixing uniformly, consistency in time between consecutive batches is suggested.
1.5.6 Time of carbon black addition
It has often been considered that carbon black addition to a conventional butyl mixing cycle can occur
quite early as the polymer does not undergo peptization during mixing. However, a degree of mastication
of the butyl rubber converts the initial rough lumps into a continuous mass, which more readily accepts
black. This is particularly true in colder climates where undispersed polymer lumps may be more
prevalent. Typically, the first part of carbon black addition is made after approximately 30 seconds of
rubber mastication.
1.5.7 Order of another ingredient addition
Zinc oxide and stearic acid are generally not added with the polymer as they could create a coating, reduce
shear, and adversely affect mix quality. If the carbon black addition is split, zinc oxide may be added with
the first addition of carbon black or with stearic acid during the subsequent remaining carbon black and
oil addition. Process oils, if added with the first addition of carbon black, may reduce viscosity and shear.
The oils may alternatively be added with the last part of carbon black addition.
1.5.8 Dump temperature
Compound dump or drop temperatures of 145°C to 155°C are suggested for the non-productive to obtain
optimum mix quality. Some internal mixers may give adequate mixing at lower dump temperatures.
However, where promoters are used, higher temperatures may be important to ensure complete
chemical reaction. Dump temperatures should always exceed 125°C to ensure melting and dispersion of
the bale wrap film used on butyl rubber bales.
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To further aid in preventing contamination, all stocks should be labelled prominently and carefully
segregated to avoid accidental contamination. The use of distinctively coloured stock markings, batch
cards, segregated stock bins and racks have all been found helpful in this regard. An important factor is
also training of factory personnel on the importance of factory stock handling procedures.
1.5.9 Guidelines for mixing cycle
Table shows two conventional mixes cycles. Normally, good results can be achieved by polymer
mastication and one carbon black addition. Mixing cycle time is dependent on the condition, capacity, and
design features of the internal mixer.
Table 1.5 : A. Conventional method of master batch Table 1.6 : B. Alternate simplified method of mixing
Mix time/dump Mix time/dump
Material or action Material or action
temperature temperature
0 Add polymer 0 Polymer
30 Seconds Add carbon black, zinc oxide 30 Seconds 2/3rd carbon black, zinc oxide
1/3rd carbon black, oil, stearic
130 °C Add oil, stearic acid 3 Minutes
acid
140 °C Clean ram 4.5 Minutes Clean ram
155 °C Dump on mill for sheeting 155 °C Dump on mill for sheeting
1.5.10 Guidelines for mixing sequence

Master Batch:
Butyle Rubber > Carbon Black (Half) > Zinc Oxid > Carbon Black (Half) > Stearic Acid >
Wax (Optional) > Oil
Final Batch:
Master Batch > Sulphur
1.5.11 Guidelines on alternative mix procedures

Two additional mix cycles are of interest here, an “upside down mixing” and mill mixing.
1.5.11.1Upside-down mixing: The upside-down mixing cycle requires the mixer to be in excellent condition
(i.e. temperature control, rotor condition, seals, pressure control, etc). Mix quality may not be
comparable to that obtained with conventional mixing cycles. However, it is generally satisfactory
with medium particle size carbon black (FEF, GPF, SRF), but is less effective with fine particles blacks
such as N330 (HAF). The principal advantage is potential reduction in cycle mix times.
Table 1.6 : Mixing Advisory
Time & dump temperature Material or action
0 Carbon black, zinc oxide, oil, stearic acid, polymer (in this order).
4 Minutes Clean ram
155 °C Dump on mill for sheeting

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1.5.11.2Mill mixing: Masterbatch mixing of butyl rubber innertube compounds is typically carried out in an
internal mixer. Butyl rubber does not break down on milling and the uncompounded polymer has a
tendency to crumble if high mill speeds or wide mill roll openings are used. After incorporation of
about 10 phr of carbon black, butyl rubber behaves relatively smoothly on the mill and readily
accepts additional pigment or oil. Thus, special techniques such as adding the first 10 phr of carbon
black at the beginning of the butyl rubber compound mixing can be very useful. Without these
techniques, the mill mixing of butyl rubber may be difficult.
The best way to avoid crumbling during the early part of mixing is to leave a small portion of the previous
batch on one side of the mill. The first butyl bale of the new batch is added to this “leader”. The “leader”
compound and fresh rubber are allowed to mix in the mill nip without cutting. A blend containing about
10 phr of black will thus be obtained and mixing may then proceed.
If no “leader” is available, the first 10 phr of black should be added to a small portion of the polymer on
one side of a tight mill. Initial mill roll temperatures of 35°C to 55°C are suggested. If stearic acid is used,
it should be added at the beginning of the mix. As soon as sufficient pigment is added to obtain a smooth
band of polymer on the mill, the mill may be opened and the same procedure followed as with a “leader”
compound.
During milling, butyl rubber tends to go to the cooler side of the mill rolls. If the stock “bags” or goes to
the (faster) back roll, the back roll should be kept warmer than the front roll. A temperature differential
of 10°C is usually sufficient to keep the stock on the front roll.
1.5.12 Guidelines for final batch mixing

Curatives may be added to butyl rubber innertube compounds by various methods,
(i) on the extrusion warm-up mill prior to extrusion,
(ii) in a short mix time, low temperature, internal mixer cycle (drop temperature 100°C to 105°C),
(iii) or by a one-pass internal mixer mixing method. In the last two methods, straining of the finalized
compound is suggested due to the possibility of contamination by small, often wholly or partially
cured lumps left in the mixer from previous batches. If the curatives are added on the warm-up mill,
a second feed mill for the extruder is useful to ensure complete dispersion of curatives before feeding
to the extruder. Before finalizing, the master batch is frequently stored for a minimum of two hours,
or preferably for a full shift, to allow cooling and stock relaxation. This allows maximum rubber-
carbon black interaction, which improves green strength.
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1.6 Strainer:
Majorly these factors affect to the Strainer in the Rubber Industries:
A. Mesh Size
B. Pressure Drop
C. Cleaning and Maintenance
D. Material Properties
E. Strainer Position
F. Frequency of Replacement
G. Process Monitoring and Quality Control
1.6.1 Guidelines for straining

Butyl rubber innertube compounds can be strained for foreign material, undispersed carbon black
particles, or other contaminants. The masterbatch is best strained immediately after mixing to eliminate
an extra warm-up operation if suitable capacity straining equipment is available. This can be done by
strip feeding the strainer from the batch-off mill or feeding directly into a batch-off extruder and strainer.
Equipment is available which will handle the dumped stock within the duration of the mixing cycle. If the
treatment is not possible the more common operation of a separate mill warm-up of the stock is usually
adopted. Strainer packs are usually 30 mesh or 20 mesh backed up by 40 mesh. Table shows potential
maximum particle dimensions obtained after passing through various screens of different mesh sizes.
Table 1.7 : Mesh Size Configuration
Mesh Size Dimensions

10 2.00 mm
20 850 μm
30 600 μm
40 425 μm
60 250 μm
80 180 μm
Efficient cooling and minimal heat history are prerequisites for straining finalized compounds. Strained
finalized compound may go directly to the extruder.
Often, straining of finalized stock by a screen pack in the extruder is practiced. The compound must be
particularly well mixed and high-quality curatives used to minimize screen changing. However, this
process may not be suited to good tube dimensional control due to output rate changes as the screen
becomes plugged. A double head extruder is advantageous to minimize time lost during screen changes.
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1.7 Extruder
Majorly these factors affect to the Extruder in the Rubber Industries:
A. Screw Design and Configuration
B. Barrel Temperature Profile
C. Screw Rotation Speed (Screw RPM)
D. Material Feed Rate
E. Die Design and Shape
F. Cooling and Heating Zones
G. Screw and Barrel Wear
H. Material Properties
I. Process Control and Automation
J. Process Monitoring and Quality Control
Figure 1.4 Extruder
1.7.1 Guidelines for extrusion

While hot feed extrusion is a widely practiced technique, cold feed extrusion is used in some newer plants.
In either case, an innertube of uniform dimensions with minimum porosity is the objective.
Care should be taken to assure an adequate supply of compound to the mills, prevent porosity, and
maintain the uniform compound temperature. A small rolling bank should be maintained on the feed
mills.
The mills should not to be overloaded and compound dwell times controlled.
Slight excess of stock is suggested in the extruder feed box to ensure that the screw flights are full, thereby
preventing an excessive intake of air with the compound feed strips.
A force feed roller which will ensure the effective filling of the screw flight at the feed end is useful but
the occasional addition of some extra strips of compound to the hopper may also be advantageous.
Feed strip temperature of between 80°C to 90°C at the mill is suggested.
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Extruder die temperatures of 110°C to 120°C are, again, suggested.
Barrel and screw suggested temperatures should be between 50°C to 60°C with the screw cooler than
the barrel.
Speed of the take-off conveyor should match the extrusion speed.
Pull-down should be avoided as it may result in increased innertube wall porosity and uneven shrinkage
on cooling.
The crown gauge, which undergoes thinning in the forming operation, is usually extruded at 1.5 to 1.6
times the thickness of the base.
1.7.2 Dusting of innertube interior

Talc, or other dusting agents such as starch, is blown into the interior of the innertube during extrusion
to prevent the collapsed innertube from adhering to itself. Zinc stearate may be used but it has to be a
grade of sufficiently high melting point to prevent fluxing in the innertube interior during extrusion.
1.7.3 Identification of butyl innertube

The application of a blue line (Table 1.8) to the butyl innertube during extrusion is useful. It enables the
splice to be detected easily for cured innertube inspection and identifies the innertube as butyl rubber to
reclaim rubber processors. The light thin blue line should be applied so that it dries before entering the
cooling zone.
Table 1.8 : Identification of Butyl Innertube
Blue line compound PHR
Butyl 100
Calcium Carbonate (Whiting) 70
Titanium Dioxide 20
Monastral Blue As Required
Zinc Oxide 5
DBTU 2
MBT 1
Sulphur 2
20% solids in solvent, hexane
1.7.4 Cooling of innertube extrudate

Butyl rubber innertubes should be well cooled after extrusion by passing through a cold-water spray or
immersion system in a synchronized cooling line. It is particularly important that the folds are well
cooled, especially truck, tractor, and OTR tire innertubes. Warm folds are particularly susceptible to fold
breakdown. All water should be blown off the surface of the innertubes after leaving the cooling section.
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1.8 Valve Installation:
Majorly these factors affect to the Valve Installation in the Rubber Industries:
1. Punching Force
2. Punching Speed
3. Punching Tool Design
4. Tube Material Properties
5. Lubrication and Cooling
6. Tool Maintenance
7. Quality Control and Inspection
8. Process Optimization and Testing
1.8.1 Guidelines for valve installation

Butyl rubber innertubes should be fitted with butyl rubber valves that meet the tire standards of various
countries such as the Tire & Rim Association of United States of America, European Tyre and Rim
Technical Organization (ETRTO), Japan Automobile Tire Manufacturing Association (JATMA),
International Standard Organization (ISO), Chinese National Standard, or Indian Tire Technical Advisory
Committee (ITTAC). Innertube valve quality is very important for air pressure retention. Valve
application is sometimes made after cooling on the extrusion line but more commonly immediately
before or after splicing. On-line valve application is usually restricted to passenger car or smaller
innertubes. Pad edge lifting often occurs with this technique due to the shrinkage of the uncured
innertube during storage. Valving after the splicing operation has a number of advantages:
It allows the innertube to be spliced, crown down, if required, which gives improved splicing on
some types of machines.
Minimizes the possibility of valve dislocation at the splicing or earlier installation stages.
Reduces the chances of damage to other innertubes.
Allows recycling of off-specification innertubes without the additional labor of valve removal. The
valve hole can be punched before splicing.
Valve cements are often made from a regular innertube compound containing additional tackifying resin
(typically a phenol formaldehyde resin), and vulcanizates with 1 to 2 phr of the accelerator, DBTU and
MBT, and then dissolved to 10 to 15% solids in a suitable solvent (e.g. 90% hexane 10% MEK). Though
such compounds may be sufficient, it might be inadequate under more severe conditions of hot climates
where cement with higher green strength may be necessary.
Higher green strength could be achieved by adding 30 to 40 phr of carbon black, without oil, and around
20 phr of a phenolic tackifying resin commonly used in tire compounds.
The valve cement is applied to the base of the valve pad, which has been previously buffed to a smooth,
fine edge. A thin single coat of well-compounded cement is suggested. Sufficient drying time to allow all
solvent to evaporate from the adhesive is required (generally 2 hr at 50°C). The cemented pads must be
protected from dust, dirt, and talc. It is not normally necessary to apply adhesive to an innertube, which
has been protected by a polyethylene patch. In the case of online valving, an automatic freshening of the
innertube in the valve area, followed by passing it under an infra-red lamp to dry off solvent, may be
advantageous.
Butyl rubber innertube valves should be applied to the innertube with a soft (45 Shore A) rubber foot
shaped to cover the valve and pressed against the innertube by a pneumatic piston for 4 to 5 seconds.
This pressure application allows the butyl rubber compound time to flow sufficiently to ensure a good
contact. The technique of using a steel-footed tool struck by a mallet or hammer, sometimes used with
GPR innertubes, may not be as effective.
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1.9. Splicing:
Majorly these factors affect to the Splicing in the Rubber Industries:
1. Splice Design:
2. Adhesive Selection:
3. Surface Preparation:
4. Curing Time and Temperature:
5. Pressure and Clamping:
6. Quality Control and Inspection:
7. Operator Training and Skill:
8. Testing and Validation:
1.9.1 Guidelines for splicing

Splicing, like mixing, is an important step in butyl rubber innertube production and should be performed
as efficiently as possible, since splice faults often form a large proportion of total rejects. The worldwide
trend of increasing use of radial ply tires has meant that greater performance demands have been made
upon the innertube splice which must withstand the higher degree of flexing of the radial tire sidewall
and the innerliner splice must continue to do so throughout the much longer life of a radial tire.
Butyl rubber innertubes are spliced by a number of techniques. Fully automated butt splicing machines
may be employed, requiring only the placing of the innertube ends in the clamps of the machine and
activating the ‘start’ to perform the operation. Alternately a manual butt splice, consolidated by
mechanical means (weld stitch) or a manual lap (overlap or telescopic) may be used.
Most automatic or semi-automatic butt splicing machines have the following mode of operation. The ends
of the innertube to be spliced are cut to length by a hot knife and the fresh tacky surfaces are butted
together and consolidated. Equipment for this operation can be classified by two important features: (i)
vertical or horizontal cutting mode, and, (ii) solid metal or rubber-faced clamps. Earlier designs of
machines had vertical cutting knives and solid jaws. Satisfactory butt splice quality was obtained with a
horizontal cut and rubber-faced clamps. These features are integrated into the Exxon Chemical Universal
Innertube Splicing Machine (ECUISM) and other newer machine designs.
1.9.2 Vertical cut, laminated steel clamp innertube splice machine

These machines were introduced before the advent of the radial tire and will produce splices which are
satisfactory for bias ply tires. They can also be used to splice innertubes intended for radial ply tires.
However, an easy splicing, low modulus, compound must be used and close attention to the setting and
maintenance of the machine is necessary. If this is not done, splices of lower quality may result. The
production of good splices in butyl rubber innertubes is strongly influenced by proper adjustment of the
machine. It is suggested that the machine adjustments be checked at frequent intervals, as well as at the
beginning of a shift, or when a size change is made. Settings such as anvil position, overhang, knife
temperature, splicing time, and pressure should be checked at these times. These machines are also
commonly used for splicing bicycle innertubes.
1.9.3 Horizontal cut, rubber faced clamp machine / Chemical Universal Innertube Splicing Machine
This is a versatile type of machine, which will produce a good quality innertube splice, and which is
suitable for use in radial ply tires. There are many manufacturers and suppliers of this equipment
worldwide. Three sizes of machine are available which will cover flat widths from 100 to 600 mm. A few
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suppliers offer adaptors to cover widths below 100 mm. In addition, where jaw widths are continuously
adjustable, the machine can be useful in handling a continuously changing spectrum of sizes.
The general features described in this section are common to most machines but detailed design
difference exists, such as internal or external hydraulic systems, electrically powered ball or screw
drivers, and hydraulic actuation system for the knives. Machine details and operation guidelines are
generally given by the splicing machine suppliers parts and features of the splicing machines should be:
1.9.3.1 Knives: Features include:

Horizontal cut mechanisms.
Programming for temperature and speed.
Long life alloys, materials, largely self-cleaning when processing butyl rubber innertubes.
1.9.3.2 Clamps: Features include:

Universal hydraulic actuation, with rubber clamp faces.
Accepts most common passenger and truck innertube sizes. Tractor and off-the road innertubes can be
processed on some machines.
Easy size change.
Fine adjustment for minor flat width variations.
Automatic gauge compensation.
Reinforced splicing.
1.9.3.3 Butting table: Features include:

Hydraulic actuation with very high butting forces.
Two speeds with a slowdown at final closing and initia opening movements.
1.9.3.4 Safety: Features include:

Twin starter buttons requiring two hand operation.
Clamps lift if the starter buttons are released before they have completely descended.
Kick bar immediately lifts clamps and opens table or lifts clamps and stops knife, according to which part
of cycle is in progress.
Guarded clamp covers table opening on many machines.
1.9.3.5 Operation sequence: the operating sequence can be summarized in a series of points as follows.
Innertube inserted: start buttons pressed.
Clamp arms descend rapidly, then slow down on final approach to prevent. innertube damage, low
pressure applied.
Knife, at low heat, approaches rapidly from rear of the machine.
Knife slows down before entering rear fold.
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Switch on high heat.
Knife enters innertube.
Engage cutting speed.
Knife drops to low speed just before front fold.
Switch from high heat to low heat.
Knife leaves front fold.
1.9.3.6 Knife returns to rear of machine at high speed.

High clamping pressure applied just before butting.
Table closes, initially fast with slow down over final travel; innertube faces deform allowing gauge
increase for splice reinforcement.
Butting pressure applied for preset dwell time.
Table opens, slowly at first, then more rapidly and then lifts clamp arms.
Remove innertube for inspection of splice quality.
1.9.4 Machine set-up for splicing-function of controls

Permanent adjustments are those which, for a given innertube compound, are not changed with a change
in innertube dimensions. Running adjustments are those which may need to be done with innertube size
changes.
1.9.4.1 Safety
Good safety practice suggests that no more than one person at a time can use or adjust the machine. On
some occasions, two mechanics may be required to adjust the machine. In this case, one person must not
operate the machine without first initiating appropriate warnings.
1.9.4.2 Permanent adjustments

Permanent adjustments are made to:
▪ Knife current variance (high heat and low heat).
▪ The clearance between the knives and the rubber faces.
▪ The cutting angle of the knives.
▪ The alignment of the rubber faces.
▪ Knife slowdown points.
▪ Knife low speed duration time.
▪ Table slowdown point.
1.9.4.3 Knife current variance (high and low heat)

The knife is kept at a low heat in the rest position, during the approach and on return to the rear of the
machine. High heat is used during the cut. Typical values for butyl rubber innertubes are:
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▪ Low heat: 25-30 amps
▪ High heat: 55-65 amps
1.9.5 Guidelines on typical starting condition for universal innertube splicer are shown in the Table.
Table 1.9 : Guidelines for starting conditions for butyl innertube (universal innertube splicers)
Flat width cm 12-20 cm 20-25 cm 25-34 cm
Knives settings Amp 25-30 25-30 25-30
Low heat current Amp 55-65 55-65 55-65
High heat current Second 1.5-1.0 1.0-0.75 0.5
High heat transition Second 1 cm before fold 1 cm before fold 1 cm before fold
High-low speed transition Second 1 1 1
Low speed transition Second 0.5 0.5 0.5
Cutting low speed transition MPa (psi) 2.0-2.5 (300-360) 2.5-6.3 (360-430) 3.5-4.0 (500-570)
Clamping pressure:/Low
MPa (psi) 5.0-6.4 (640-910) 5.0-8.0 (850-1100) 8.0-10.0 (1100-1470)
(cutting)
High (butting)/Butting
MPa (psi) 5.0-6.4 (640-910) 5.0-8.0 (850-1100) 8.0-10.0 (1100-1470)
pressure
Butting time Second 4-7 6-9 8-12
1.9.6 Clearance between the rubber faces and the knives

The clearance between the rubber faces and the knife controls the overhang after the cut. This gap can
be adjusted to 1.0 mm to 1.2 mm. Excessive overhang can result in rind formation, resulting in insufficient
compound in the splice and potentially allowing a separation.
Rind can also refer to the formation of a hump at the splice which can be buffed off, flash which can be
shaved off, or lace strips at the splice which can be readily pulled or peeled off. Unequal overhang may
cause rind, as well as misalignment, or splice openings.
1.9.7 Knife cutting angle

The knife angle is normally 11º ±1º to the plane of the cut. However, the machine manufacturer’s
specifications should be consulted for the actual setup. The machine setup can also be checked by the
careful use of a protractor or by the use of a suitable jig from a factory workshop. Cutting angles greater
than 12º can result in a wavy cut while cutting angles less than 10º can cause smearing.
1.9.8 Alignment of rubber faces

Hardness of the rubber jaw faces for ECUISM type splicers should be approximately 60 Shore A.
Compounds based on passenger tire treads, containing N330 carbon black, may be suitable for this
application. The rubber clamp faces are to be aligned horizontally and vertically to eliminate the
possibility of a stepped splice. A test splice can be made with short pieces of innertube. The splice can be
opened after first marking the entry fold, and examined for step-off or misalignment.
If misalignment is evident, the clamps can be shimmed so that the step-off is eliminated. The table
approach slowdown must be properly adjusted before this test. Absence of slowdown may cause a step,
rolling, or splice hump even when the jaws are properly aligned.
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1.9.9 Knife slow down points

These are usually selected by moveable slotted fingers on the knife carriage, which operate appropriate
magnetic induction proximity switches. They are moved backwards or forwards to adjust the slow down
points which can be 1.0-1.5 cm before the fold entry or exit points. The upper finger usually adjusts entry
slowdown.
1.9.10 Knife low speed duration timer

The timer controls the duration of knife slow speed after the initial transition before entering the rear
fold. Normally it is set so that the slow speed is engaged for 1-1.25 cm after entry.
1.9.11 High-low heat transition timer

Control of the transition of current in the knife, from high to low prior to the exit fold is the function of
the timer. A setting of 0.5 seconds is typical.
1.9.12 Running adjustments

The running adjustments to the machine when in operation include:
▪ Clamp width (flat innertube width)
▪ Clamping pressure
▪ Butting pressure
▪ Butting time
▪ High heat initiation point
Table gives guidelines on starting conditions for butyl rubber innertubes, divided into three groups
according to flat width. These settings should only be viewed as a guide since
setup conditions may vary from factory to factory. The compound type, age of the stock, porosity level,
profile uniformity, and ambient temperature can all influence the conditions necessary to achieve good
splices. It should be noted that the machine could typically take about thirty minutes to reach operational
uniformity.
1.9.13 Butting time

Butting time should be minimum possible to ensure splice quality and minimize fold breakdown in the
splice area.
1.9.14 High heat initiation timer

This can be set to initiate the high heat about 1 cm before entry fold. The ‘switch on’ point can be
estimated by observing the knife movement and the ammeter. If the initiation is too early, the cut end
may be scorched at the entry fold (shiny appearance) and will open during subsequent handling. If
initiation is too late, the entry fold cut edge may be smeared and the splice may again be weakened at the
entry fold.
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1.9.15. Tuning the machine set-up
The following points regarding machine control settings should be monitored to assist in achieving the
desired output.
▪ Ensure that knife entry and cutting speeds are at the maximum level. These speeds can be varied on
many machines. Note that truck innertubes often accept higher cutting speed than passenger innertubes.
▪ Adjust the knife high-slow speed transition as close to the entry fold as possible, and, likewise the
cutting slow speed transition at the exit fold.
▪ Minimize the duration of the low speed at the entry fold consistent with splice quality.
▪ Adjust clamp descent slowdown as late as possible without permitting the clamps to meet at the high
speed.
▪ Set the table approach slowdown as late as possible without permitting the clamps to meet at high
speed.
▪ Check if one or two seconds can be reduced in the butting time by splicing, curing and checking a
few innertubes. With some compounds, increasing butting pressure may compensate for reduced butting
time.
▪ Careful attention to these points can sometimes reduce the total machine cycle time by up to 5 to
10%, with a corresponding output improvement.
1.9.16 Splice quality criteria

An uncured splice made on a well-adjusted universal splicing machine shows the following properties:
▪ Well consolidated fold region, internally and externally with minimal distortion and breakdown.
▪ Good overall alignment, internal and external (i.e. no stepping)
▪ No rind tails (flash) or cracks.
▪ If a 2.0 cm wide splice section is gripped with the fingers about 1.5 cm from the splice and elongated
25% for 2 minutes; the sample should stretch uniformly without undue thinning of the splice. A rapid
stretching of the splice to high extension is not a reliable indication of splice strength relative to forming
ring requirements.
▪ Knife entry and exit portions are generally the weakest spots of an innertube. To overcome this
problem, several innertube manufacturers add a small thin strip of unvulcanized innertube compound
on the knife entry and exit portions of the innertube. When the innertube is cured, these strips flow and
become cured, which reinforce the knife entry and exit portions of the innertube splice joints.
▪ Guidelines on trouble shooting of uncured splice defects have been summarized and are shown in
Figure:
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Fault Cause Remedy
Knife too cold

Tube slipping in jaws Raise high heat current
Knife angle incorrect Increase clamp pressure
Cutting speed too high Correct angle of knife
Uneven or wavy cut
Worn ball screw Reduce cutting speed
Bent screw Replace/repair knife
Excessive tube end overhang Reduce overhang
before cut
Retard high-low heat

High-low heat transition too early transition point
Tailed cut at exit fold Knife slowdown too late Advance knife slowdown
Slow speed too high point
Reduce knife slow speed
Deformed entry fold Reduce high heat delay.

Knife too cold at entry
cut Advance
Knife slowdown too late. Slow
slowdown timer. Reduce
speed too high. Knife
knife slow
too hot at entry scrap chute
speed. Increase high heat
touching tube
Opening at entry fold delay period
Talc ejected from fold by high
Reposition scrap chute
clamping pressure
Minimize talc
Adjust carefully
Jaws too tight
Pinched splice Flatten folds
Clamping pressure(s) too high
Reduce clamp pressures
Poor compound Improve compound

Fold break-down
Excessive porosity More careful extrusion
Tube thickness variation Improve extrusion control

Stepped splice Misaligned jaws Shim jaws in line
No slowdown on table closing Adjust slowdown
Excessive overhang after cut. Reduce knife clearance

Rind Excessive butting pressure. Lower butting pressure
Fatigued rubber faces Change jaw faces
1.9.17 Horizontal cut splicers with fixed clamps

Machines of this type are capable of producing an excellent splice. They are best suited for long runs of
single sizes as the clamp’s openings are not adjustable and the clamps must be changed for each flat width
of innertube to be spliced. They are relatively slow but it is possible for a single operator to operate two
machines, particularly if the machines have been completely automated. These machines require close
attention to innertube extrusion tolerances to obtained uniform splicing.
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1.9.18 Machine details
The machine is made in three sizes covering innertube flat widths of 65 to 156 mm, 130 to 414 mm and
360 to 600 mm.
1.9.18.1 Innertube dimensions

Any splicing machine, which does not have adjustable jaws, requires very close control on innertube flat
width and thickness. If the innertube is too wide for the clamps, pinching with fold breakdown may occur.
If the innertube is too narrow, misalignment of the folds is likely, resulting in a weak splice which is likely
to open during forming. Excessive thickness of the innertube results in crushing and breakdown of the
folds. It may also result in “stepping” due to the squeezing out of the innertube ends after cutting. An
innertube which is too thin may move in the clamps during cutting, producing a wavy edge, and during
butting, producing poor consolidation. It is recommended not to vary innertube dimensions by more than
± 5% from the clamp dimensions.
1.9.18.2 Lap splicing

The lap splicing technique is a very versatile method of joining. It can easily be set up as a secondary line
to a main butt splicing operation to handle low volume markets of special innertubes. Four operations
are involved in making a lap splice, namely, skiving, buffing, joining, and consolidation of the splice. After
the innertube has been cut to length, a beveled featheredge is made on the overlapping end of the
innertube using a suitable skiving machine. The surfaces to be joined may be freshened by very light
buffing with a rotary wire brush or grinding stone. The splice is consolidated in a pneumatic press, first
across the folds, then with the innertube in the normal position.
1.9.18.3 Guidelines for the storage of unvulcanized extruded innertubes

After splicing, green innertubes should be carefully stored on racks. Large size or heavy gauge innertubes
should have plastic cylinders or foam rubber “pillow” supports placed inside the folded ends to prevent
collapse and fold breakdown. Storage time should not be longer than 24 hours and the storage
environment should be clean.
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1.10 Chilling:
Majorly these factors affect to the Chilling Process in the Rubber Industries:
1. Chilling Temperature
2. Chilling Time
3. Chilling Method
4. Chilling Environment
5. Quality Control and Inspection
6. Validation and Testing
7. Process Optimization and Monitoring
1.10.1 Guidelines for splice chilling

Chilling of the crown area of the butt splice butyl innertube helps to increase its green strength and
minimize any splice opening during subsequent forming operations. The most common method of
chilling is by keeping the splice section over a pipe through which cooled brine at 0°C to 5°C is circulating.
Other methods include chilled air flow directed at the splice or a brief dip in a mixture of isopropanol or
acetone with solid carbon dioxide (“dry ice”). The innertube should be adequately supported during
chilling. If folded, the fold should be supported with foam pillows or similar devices. Splices should not
be over chilled, the chilling time being usually equivalent to the duration of the cure cycle. Chilling may
produce condensation on the splice. Thus, care should be taken to ensure that no moisture drops remain
on the innertube when it is placed in the press. The presence of moisture in the press may cause weak
splices and dimpling. The chilling operation can be avoided if the splice quality is adequate. Several
innertube producers, using ECUISM type splicers, which usually give good splice quality, omit this step
to increase productivity.
1.10.2 Guidelines for forming

Forming is the operation in which the uncured innertube is inflated to about 95% of its final cured volume
before placing the innertube in the press. Forming rings should be designed to minimize any expansion
of the base of the innertube, concentrating the expansion on the thickened crown section. Innertubes are
to be slowly inflated over about a 30 second interval or, alternatively, inflated in two stages with about a
20 second pause in between stages. It is advisable to use a limit switch cut off to control the degree of
inflation. Over formed innertubes are susceptible to thinning and may crease in the mould. If possible,
the forming rings should not be located close to presses as the heat from the press may cause splice
opening or thinning.
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1.11 Shaping, curing and vacuum:
Majorly these factors affect to the Shaping, curing and vacuum in the Rubber Industries:
1. Steam Temperature:
2. Steam Pressure:
3. Curing Time:
4. Curing Environment:
5. Tube Arrangement and Loading:
6. Quality Control and Inspection:
7. Validation and Testing:
8. Process Optimization and Monitoring:
1.11.1 Guidelines for curing of innertubes

Innertubes are vulcanized in simple presses, often with a hot block to increase the temperature in the
thicker valve region. Air pressure is applied internally to the innertube. The pressure can be up to 7 to 8
Bar. Low air pressure can result in the innertube wall flowing over the valve, whilst an excessively high
air pressure can force the innertube into the mold parting line, produce excessive flash, and cause a
localized deformation or gauge thinning around the innertube.
Innertubes are sometimes inflated internally with steam to gain a cure time reduction. Butyl rubber
innertube curing temperatures of 175°C to185°C are suggested and curing time will vary with size and
thickness. Typical passenger innertubes are cured for 3.5 to 5 minutes and truck innertubes 6 to 8
minutes including
blow down time.
Mold surfaces should
be smooth and clean,
both from the
standpoint of the
appearance of the
finished innertube
and from the ease
with which the stock
flows in the mold.
Dirty molds can lead
to poor stock flow
and buckles.
Sandpaper or steel
wool should be
avoided in cleaning
the molds, as these
cause scratches in
the mold which may
be quickly filled with
foreign deposits.
A combination wax-
abrasive material Figure 1.5 Shaping, curing and
applied with a cloth vacuum Machine
buffing wheel is
suggested. Molds should be well vented and the vents kept clear to prevent dimpling. An example of an
innertube vulcanization press is shown in Figure.
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1.12 Inspection:
1. Dimensional Measurements:
2. Visual Inspection:
3. Material Quality:
4. Functional Testing:
5. Leak Testing:
6. Appearance and Finish:
7. Documentation and Traceability:
8. Quality Control and Quality Management:
1.12.1 Guidelines for inspection

After curing, the innertubes should be inspected carefully for flaws that may affect serviceability using a
combination of visual and manual techniques. Particular attention should be given to the splice and to
the valve region, which are the most common source of defective innertubes.
The innertubes are then usually vacuum evacuated, folded and packaged for storage and shipment. After
the vacuum operation the innertubes should be inspected for any leakages.
Deflation of the innertube by vacuum is a good test to check innertube leaks. Leakage can be seen if air
flows into the innertube during the vacuum operation. In the event of a leak, the innertube should be
inflated and tested for any pinhole leaks and then sent for repair or scrap. Some manufacturers check all
of the inflated innertubes in a water bath to check for leaks following the vacuum operation. The
innertubes are then dried and packaged. High pressure vacuum evacuation of innertubes can cause high
degrees of stress at the fold area of the innertube and this may result in cracking during storage in
warehouses.
1.12.2 Guidelines for packaging
Following the quality assurance inspection, a good practice is to package the innertubes in sealed,
preferably black or colored polyethylene bags, printed with the innertube size for identification. This will
help maintain quality and prevent innertubes from potential degradation caused by ultra-violet light,
moisture, oxygen, or ozone during long storage. After packaging, the innertubes are usually stacked in
bulk in a cardboard box or polypropylene or polyethylene sack to prevent any damage during transit and
prevent moisture, water, or other foreign material contamination.
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1.13 Troubleshooting innertube processing and manufacturing
Factory compound processing difficulties tend to center around compound viscosity, milling operations,
and innertube gauge control. Potential challenges the factory engineer may encounter with possible
solutions are listed below.
1.13.1 Variations in compound viscosity

Mooney viscosity variation of compounds can cause problems in extrusion, splicing, and forming of
innertubes. For example, large variations in compound viscosity can occur as a result of cure system
variation. This variability can occur when the same internal mixer is used to prepare both the compound
masterbatch and final productive mix containing the curatives. Powdered curatives may collect at the
intake of the dust removal system of the internal mixer and later fall back into the mixer during
subsequent mixing operations. If this occurs during mixing of the innertube masterbatch, the
combination of curatives and high mixing temperatures can result in a condition of partial cure, pre-cure,
or scorching. Even at low curative levels, the effect will be to increase the Mooney viscosity of the
compound. The immediate solution to the problem is to prevent contamination of the masterbatch by the
curatives.
Variable viscosity can also result from poor filler dispersion, or from variations in the level of work-away,
rework (scrap), or stock being returned to the processing operations. In addition to causing variations in
the viscosity of the unvulcanized compound, accelerator contamination of the innertube masterbatch can
also result in differences in the cured modulus. To illustrate this, in a controlled experiment, 0.2 parts of
accelerator added to the masterbatch in a 175°C mixing operation caused an increase of 9 points in
Mooney viscosity and an increase of 1.5 MPa in 300% modulus value. The same number of additional
curatives added in a normal low temperature (i.e. less than 150°C) mixing operation showed no effect on
either the viscosity of the stock or the cured modulus.
1.13.2 Strainer screen plugging

Normal practice in innertube production plants is to change the strainer screen approximately once per
shift. At times, however it has been found necessary to make changes as frequently as every hour due to
plugging of the strainer screen. A common cause of such rapid plugging has been found to be poor
dispersion of some ingredient, usually the carbon black. Suggested steps that could be taken in
overcoming these problems are:
▪ Check the quality of the carbon black to ensure that the pellet hardness or other properties like grit
content of the black have the proper specified values,
▪ Increase the length of the mixing cycle
▪ Delay oil addition until the carbon black has been dispersed in the rubber, or,
▪ Change the black type to one that is more readily dispersed.
1.13.3 Mill bagging

The bagging of butyl rubber innertube stocks on the mill is frequently associated with the use of a
compound having excessively high carbon black and oil. Should this condition be a problem, the
suggested solution is to increase the viscosity or the nerve of the compound. This is most easily done by
adjusting the amount of carbon black, reducing the quantity of oil, or both.
An alternative approach may be to reduce the temperature of the compound on the mill. This might be
accomplished through the use of more cooling water, or the use of cooling water at a lower temperature.
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If feasible, a change in the mill roll ratio or speed may also be helpful. Another approach would be the use
of rework added to the internal mixer. This should be carefully controlled in order to avoid variations in
viscosity that can cause other concerns.
1.13.4 Die plating

A build-up of material on the extruder die can cause a gradual change in the dimensions of the extruder
innertube, eventually requiring that the extrusion line be shut down while the die is either cleaned or
adjusted in order to return to the proper innertube dimensions and weight. Analysis of such die build-up
material usually shows it to be high in inorganic materials. Spectrographic analysis of these materials
frequently shows a high percentage of clay, which apparently tends to accumulate on the extruder die.
Under typical conditions, clay is not a component of the innertube compound nor is it used during the
processing of innertubes. However, occasionally the talc, which is used to dust the extruded innertubes,
may contain minor amounts of clay. The practice of including reworked material with fresh stock during
extrusion of innertubes provides a route for such clay to reach the extruder. To help prevent this problem,
clay-free talc could be used. Die plating will also occur if calcium carbonate fillers are used in the
compound.
1.13.5 Variable innertube width

Variations in extruded innertube width have frequently been due to excessive stretching of the innertube
during the extrusion operation. This can occur when the innertube is passed over a succession of
conveyor belts not operating at synchronized speed. It is necessary to minimize the amount of stretch
needed to properly control the innertube dimensions. Mooney variance and extruder starvation may also
lead to excess stretch-down even when the take-off conveyors are operating satisfactorily.
Dimension or gauge variation has been observed when some aromatic process oils have been used in
butyl innertube compounds. Therefore, aromatic process oils are not used to any great extent in butyl
rubber innertube compounds. Paraffinic and naphthenic oils tend to be preferred. Adequate attention to
masterbatch mix quality can help minimize problems. Another possible cause of variation is addition of
rework which has variable viscosity.
1.13.6 Uncured innertube blisters

The most common cause of blisters in the uncured extruded innertube is trapped air. This trapped air is
frequently the result of an excessively soft compound. This compound softness can be due to either the
formulation being employed or to the processing temperatures, particularly on the mills feeding the
extruder. It is suggested that the stock temperature leaving the final mill prior to the extruder be
approximately 90°C. Temperatures substantially above this level have been found to contribute to an
excessive amount of air being trapped by the stock on the mill and carried into the extruder from which
it emerges as blisters in the innertube.
In order to control the stock temperature on the mills within the desired range, in some cases it may be
necessary to consider equipment setup adjustments. That is, either the friction ratio between the front
and rear rolls of the mills may need to be changed or the overall roll speeds may need adjustment.
Alternatively, consideration can be given to compound formulation changes enabling an increase in the
green strength of the compound.
Another known cause of blisters in uncured innertubes is moisture in the stock being fed to the extruder.
This moisture is most often traceable to wet slabs of compound being used to load the warm-up mill on
the extruder line. It is suggested that care is taken to use only dry stock in feeding the extruder.
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1.13.7 Cold flow and bruising

Unvulcanized butyl rubber is subject to flow under load. Therefore, in all operations subsequent to
extrusion, unvulcanized innertubes should be handled with care. Excessive stacking or prolonged storage
should be avoided in order to minimize the effects of cold flow and bruising which can lead to thin spots
in the cured innertube or even failure of the green innertube during forming. Green strength promoters
such as poly-para-dinitroso benzene (DNB) on an inert carrier can be used to increase the green strength
of the innertube stock to improve its resistance to cold flow and bruising. It is added to the compound
early in the mix. DNB partially crosslinks the polymer, giving an effect similar to increasing the molecular
weight of the polymer. This increases the tolerance of the compound for high carbon black and oil loading
without excessive cold flow or bruising of the uncured innertube stock.
1.13.8 Fold breakdown

Fold breakdown, a condition caused by creasing of the innertube under its own weight, is related to cold
flow and bruising. An effective means of controlling this condition is to limit the storage times after
innertube extrusion and splicing. This limit in storage time should be balanced against improvements in
splice strength, which may be realized by a longer storage period between splicing and curing. If
modifications in the factory operations are not sufficient to overcome the fold breakdown or related
problems, then compound modifications may be required. Potentially helpful modifications include
reductions in the loading of carbon black and oil, or a partial or full replacement of the carbon black type
to a lower structure filler.
1.13.9 Splice defects

A frequent cause of defective splices is misalignment of the clamps and dies holding the innertube during
the splicing operation. This type of splice defect is usually visible in the uncured innertube as a step or
offset area at the splice. The solution to this problem is to maintain the splicing machine in proper
settings. The settings should be checked periodically during innertube production and adjustments made
as needed.
1.13.10 Buckle and mold pinching

Buckles in a cured innertube are generally caused by the uncured innertube being too large for the mold.
The oversized green innertube can be due to oversized innertube extrusion or due to forming under high
pressure causing the rubber to stretch more than the normal. In addition, the use of a compound that is
excessively soft can result in innertubes being stretched too much even under normal pressures. The
presence of these conditions will indicate a need to check the uncured innertube dimensions, and if
necessary, adjust the formulation in order to avoid excessive softness. The use of limit switches during
forming operations may also help to overcome this problem.
In addition to buckles, an oversized green innertube can result in the innertube being pinched between
the two halves of the mold as it closes. This pinching causes a loss in gauge of the innertube along the
mold parting line. In the most severe case, the thinning can be such that the innertube will fail under very
low internal pressure. In some cases, buckles and pinches in cured innertubes can also be the result of
excessive stiffness which prevents the extruded innertube from forming into the proper shape for curing.
If this problem is encountered, Mooney viscosity of the compound should be checked to ensure that the
compound has not scorched. In some cases, it may be necessary to reformulate to overcome the problem.
3714007 Practical-1
1.13.11 Dimpling
Dimpling, or the presence of cavities in the surface of cured innertubes, is thought to be due to localized
areas of trapped vapor or air between the innertube and the mold. To avoid this problem, the mold should
be sufficiently well vented to allow gases to escape and the vents kept open. Periodic inspection of molds
for plugged vents is suggested. In addition, the dusting agents used on the surface of the innertube can
have an influence on the problem. Large particle size, coarse dusting agents aid the escape of gases from
between the innertube and the mold.
1.13.12 Ghosting
“Ghosting” is a condition in which a label printed on an uncured innertube transfers from the innertube
to the mold during curing and then back to other innertubes cured subsequently. In order to avoid this
problem, a common practice is to label innertubes after vulcanization.
1.13.13 Splice rind cracking

Rind formation is a characteristic of steel clamp splicers and has been discussed earlier. The most
common cause of cracked rind is excessive overhang at the time the ends of the innertube are trimmed
prior to splicing. The most direct means of avoiding this situation is either to reduce the amount of
overhang or to trim the rind with a hot knife after the innertube has been spliced. There is evidence that
trimming the rind will also result in improved splice durability, perhaps because any weak spot resulting
from a cracked rind is eliminated. An additional procedure, which can be used, is to paint the rind area
with cement prior to curing. However, there is some hazard involved in doing this since the solvent used
in the cement can weaken the uncured splice and may cause it to partially or completely open during the
forming step.
Another common cause of rind cracking is contamination, which may prevent the surface of the rubber
from curing. The use of zinc stearate for exterior dusting usually eliminates rind cracking. Condensation
on the innertube during and immediately following the chilling of the splice area is another source of
contamination and potential source of final product defect.
1.13.14 Under valve porosity

There are two varieties of porosity beneath the valve. The first manifests itself predominantly at the valve
pad/innertube wall interface and is associated with trapped air, freshener, cement volatiles, or less
frequently with uncured cement solids. The second type of porosity extends throughout the innertube
wall and is caused by under-cure of the innertube itself.
Air entrapment is sometimes caused by the use of a high viscosity valve cement, particularly when it is
applied to the valve base by brushing. This problem can be avoided by applying the cement as a spray. If
it is necessary to apply the cement by brushing, care should be taken to avoid excessive application of
cement. Adjusting the viscosity of the cement may be helpful in this respect. Brushes can be cleaned at
each shift change and replaced as needed. Increasing the applied pressure dwell time during valve
attachment to the innertube may help reduce air entrapment and subsequent porosity under the valve.
Solvent is frequently used to freshen the innertube valve area prior to attachment of the valve. If the
solvent is not given sufficient time to evaporate before applying the valve, porosity can develop at the
interface during the cure. Solvent can also be present as a result of insufficient drying of cemented valves.
Both problems can be overcome by increasing the drying time for the solvent or cement. An alternative
to the solvent freshening is to place a small square of plastic over the valve area after the innertube has
been extruded. When the plastic is removed, a clean, fresh surface is available for attaching the valve.
3714007 Practical-1
Porosity due to low state of cure has several solutions. The simplest way is to increase the cure time or
increase the hot block temperature if it is possible.
1.13.15 Ozone resistance

The amount of carbon black and oil in butyl innertubes has increased over the years leading to a decrease
in the cross-link density of innertubes cured under constant temperature and time conditions. This
decrease in cross-link density can have a detrimental effect on properties such as ozone resistance and
this can lead to defective innertubes during storage in high ozone environments. When production
limitations prohibit increasing the cross-link density by the use of a longer cure cycle or a higher cure
temperature, an increase of 15 phr of EPDM, such as VistalonTM 2504, may substantially improve the
ozone resistance of innertubes. However, aged modulus may increase and splice life may be reduced.
Hence this approach is not suggested for low modulus innertubes without adjustments to the compound
composition.
A possible source of variation in the ozone resistance of innertubes is a mold that is operating at a lower
temperature than other molds in the same line, thereby causing a lower state of cure. The lower press
mold temperature sometimes occurs when the mold is located at the end of the curing line and where it
receives only a portion of the steam required to maintain full curing temperature. A reduced flow of steam
may also be related to the mold being blocked or filled with water. Another source of lower mold
temperature can be the practice of leaving the mold open for an extended period of time. This can permit
parts of the mold to cool off with the result that the first innertube cured after this period may have a
lower state of cure.
An additional cause of poor ozone resistance in butyl innertubes can be the use of butyl rubber innertube
reclaim. This is thought to be due to some reclaiming oils used in the production of reclaim which may
vary in unsaturation. The scrap innertubes from which butyl rubber reclaim is made can also contain
repair patches made of highly unsaturated general-purpose rubber. If these patches are not removed
from the innertube prior to the reclaiming process, they can contaminate the butyl rubber reclaim. This
in turns affects the ozone resistance of the butyl rubber innertubes in which the reclaim is used.
1.13.16 Cured innertube faults

Quality control inspection of finished innertubes and laboratory testing can reveal a wide range of faults,
such as thin spots, stepped splices, weak splices, foreign matter, hard lumps, punctures, variable physical
properties, blisters, blemishes, poor valve adhesion, under valve porosity, creases or folds, valve
overflow, high set, poor ozone resistance, poor heat resistance, poor appearance, weak spots, mold
sticking and dimpling. An analysis of these faults, relating them to uncured innertubes and compound
faults and indicating the basic cause, is given earlier. It should therefore be noted that many of the cured
innertube faults and defects can arise from more than one cause.
3714007 Practical-1
Uncured
Cured
Innertube
innertube Basic Cause Operation
or Compound
Fault
Fault
Thin spots
Stepped splice
Weak splice
Uneven thinning Black/Polymer Unsuitable cycle
Foreign
Dimensional lumps, poor Incorrect loading
matter
variation dispersion Insufficient time
Hard lumps Mixing
Fold breakdown
Punctures
Scorch Undispersed Low dump
Variable
Porosity Polyethylene Temperature
physicals
Blisters
Blemishes
Thin spots
Splice faults Uneven thinning
Poor curative Batch size too
Variable High viscosity
dispersion large
physicals Scorch Finalizing
Excessive Overlong mixing
Punctures Dimensional
heat history time
Blisters variation
Blemishes
Porosity
Overload feed mill
Fold breakdown
Thin spots Irregular feed
Dimensional Extrusion
Splice faults Starved extruder
variation
Take-off speeds differential
Uneven thinning
Blisters
Scorch Unsuitable extruder head design
Porosity
Viscosity increase
Thin spots
Scorch
Splice faults
Dimensional Excessive rework
Hard lumps Reworking
variation Contaminated rework
Poor valve
Porosity
adhesion
Mill sticking
Blisters PE patches in rework grease oil

Porosity or dirt in rework
Rind
Thin spots
Poor green splice Imperfect machine adjustment Splicing
Splice faults
Fold breakdown
Short adhesive drying time

Under valve Residual solvent in
High solids content Valving
Porosity adhesive
Thick or uneven coat
Low valve Low uncured Dirt or talc on valve,

adhesion adhesion tube or operators’ hand
3714007 Practical-1
Thin or open
Condensation in
splice Excessive chilling Chilling
splice
Blistered
Partial or
complete splice
Insufficient chilling
openingon
forming ring
Wrinkled or Over size green Excessive inflation on forming

Forming
folded tube tube ring
Variability
high set
Low cure temperature
Poor ozone Under cure
Too short cure time
and heat
resistance
Overcure Cure temperature too high

Curing
Reversion Excessive cure time
Poor
appearance
Dirty moulds
Weak spots
Blocked vents
Sticking
Air trapping
Porosity
Excessive blowdown time
Blisters
3714007 Practical-2
Practical - 02
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3714007 Practical-3
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3714007 Practical-3
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3714007 Practical-3
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3714007 Practical-3
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3714007 Practical-4
Practical - 04
AIM: To create the geometry of K-Frame mount and generate mesh in GMSH software.
#10=MECHANICAL_DESIGN_GEOMETRIC_PRESENTATION_RE #20=NEXT_ASSEMBLY_USAGE_OCCURRENCE('Revised
PRESENTATION('',(#27,#28), Mount:1','Revised Mount:1',
#1528); 'Revised Mount:1',#1550,#1551,'Revised Mount:1');
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Mount Bracket v16:1',
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'Front Motor Mount Bracket v16:1','Front Motor Mount Bracket
#13=ITEM_DEFINED_TRANSFORMATION($,$,#951,#996); v16:1',#1549,
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(#11) Mount v5:1',
SHAPE_REPRESENTATION_RELATIONSHIP() ); 'Rear Motor Mount v5:1','Rear Motor Mount
v5:1',#1549,#1552,
#15=( REPRESENTATION_RELATIONSHIP($,$,#1545,#1544)
'Rear Motor Mount v5:1');
REPRESENTATION_RELATIONSHIP_WITH_TRANSFORMATION
(#12) #23=SHAPE_REPRESENTATION_RELATIONSHIP('SRR','None',
#1546,#25);
SHAPE_REPRESENTATION_RELATIONSHIP() );
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#1547,#26);
REPRESENTATION_RELATIONSHIP_WITH_TRANSFORMATION
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(#13)
526);
SHAPE_REPRESENTATION_RELATIONSHIP() );
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#1543); #30=MANIFOLD_SOLID_BREP('Body1',#863);
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3714007 Practical-4
#32=FACE_BOUND('',#200,.T.); #1484=CARTESIAN_POINT('Origin',(80.,0.,0.));
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3714007 Practical-4
#1518=CARTESIAN_POINT('',(0.,300.,0.)); 'Jumbuck K-Frame Mounts v2',(#1564));
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URE(0.01),#1529, Motor Mount Bracket v16',
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Mount','Revised Mount',
#1539=PRODUCT_DEFINITION_SHAPE('',$,#1551);
(#1566));
#1540=PRODUCT_DEFINITION_SHAPE($,$,#20);
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#1541=PRODUCT_DEFINITION_SHAPE('',$,#1552); Motor Mount v5',
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standard',
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#1546=SHAPE_REPRESENTATION('',(#889),#1526); 'Core Data for Automotive Mechanical Design Process');
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definition',#1562,'mechanical');
#1548=PRODUCT_DEFINITION_CONTEXT('part
definition',#1562,'design'); #1564=PRODUCT('Jumbuck K-Frame Mounts','Jumbuck K-
Frame Mounts v2',$,(#1563));
#1549=PRODUCT_DEFINITION('Jumbuck K-Frame Mounts',
#1565=PRODUCT('Front Motor Mount Bracket v16',
'Jumbuck K-Frame Mounts v2',#1553,#1548);
'Front Motor Mount Bracket v16',$,(#1563));
#1550=PRODUCT_DEFINITION('Front Motor Mount Bracket
v16', #1566=PRODUCT('Revised Mount','Revised
Mount',$,(#1563));
'Front Motor Mount Bracket v16',#1554,#1548);
#1567=PRODUCT('Rear Motor Mount v5','Rear Motor Mount
#1551=PRODUCT_DEFINITION('Revised Mount','Revised
v5',$,(#1563));
Mount',#1555,#1548);
#1568=PRESENTATION_STYLE_ASSIGNMENT((#1569));
#1552=PRODUCT_DEFINITION('Rear Motor Mount v5','Rear
Motor Mount v5',#1556, #1569=SURFACE_STYLE_USAGE(.BOTH.,#1570);
#1548); #1570=SURFACE_SIDE_STYLE('',(#1571));
#1553=PRODUCT_DEFINITION_FORMATION('',$,#1564); #1571=SURFACE_STYLE_FILL_AREA(#1572);
#1554=PRODUCT_DEFINITION_FORMATION('',$,#1565); #1572=FILL_AREA_STYLE('Steel - Satin',(#1573));
#1555=PRODUCT_DEFINITION_FORMATION('',$,#1566); #1573=FILL_AREA_STYLE_COLOUR('Steel - Satin',#1574);
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Satin',0.627450980392157,0.627450980392157,0.627450980
#1557=PRODUCT_RELATED_PRODUCT_CATEGORY('Jumbuck
392157);
K-Frame Mounts v2',
3714007 Practical-5
Practical - 05
AIM: To create the geometry of O-ring and generate mesh in GMSH software.
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3714007 Practical-6
#32=ORIENTED_EDGE('',*,*,#50,.T.);
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3714007 Practical-6
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3714007 Practical-6
#118=FACE_BOUND('',#94,.T.);
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3714007 Practical-6
#160=AXIS2_PLACEMENT_3D('',#237,#189,#190);
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3714007 Practical-6
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3714007 Practical-6
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3714007 Practical-6
LENGTH_UNIT()
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3714007 Practical-6
Practical - 06
AIM: To create the geometry of Rubberized Bumper and generate mesh in GMSH software.
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3714007 Practical-6
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3714007 Practical-6
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1.193211549122742600, 0.7841039952627273400,
2.209774058222675900 ) ) ;
3.186888101828253500 ) ) ;
1.104589124324470300, 0.8419021737929596200, #20778 = CARTESIAN_POINT ( 'NONE', (
1.182781916681464800, 0.7881530980994355700,
2.217589540770062300 ) ) ;
3.186879040901201300 ) ) ;
1.101472425822471100, 0.8415639055541991300,
1.172320900806608700, 0.7942581991602074600,
2.233689585877074900 ) ) ;
3.186865599240830300 ) ) ;
3714007 Practical-6
1.161834137856524700, 0.8020500481293393300, 1.327186178532851100, 0.8369727087574284600,
3.186848563612005400 ) ) ; 3.197322870322244700 ) ) ;
1.151347374906440500, 0.8098418970984713200, 1.316990178119470600, 0.8257160601297580700,
3.186831527983180000 ) ) ; 3.197346421493107500 ) ) ;
1.140834865757871300, 0.8193204365386064200, 1.306794177706090300, 0.8144594115020877800, 3.
3.186810898508281900 ) ) ;
1.130305977873641300, 0.8298719832182428500, 3.197439814506941600 ) ) ;
3.186787982767515200 ) ) ;
1.119777089989411300, 0.8404235298978791600, 3.197425926160571300 ) ) ;
3.186765067026748900 ) ) ;
1.109231824246263800, 0.8520480263796596000, 3.197408339397718600 ) ) ;
3.186739865142496500 ) ) ;
1.098683266060360500, 0.8638882180766431800, 3.197390752634865900 ) ) ;
3.186714203674570800 ) ) ;
1.347542197284805000, 0.8618432714062283000, 3.197369467580546000 ) ) ;
3.197270745334620700 ) ) ;
`#20788 = CARTESIAN_POINT ( 'NONE', (
1.337365554933002800, 0.8493184333012163700,
3.197296998647844600 ) ) ;
3714007 Practical-7
Practical - 07
AIM: To create the geometry of Tire and generate mesh in GMSH software.
#10=CONSTRUCTIVE_GEOMETRY_REPRESENTATION_RELATI 'relationship between tire-None and tire-None',#36,#12);

ONSHIP(
#25=ADVANCED_BREP_SHAPE_REPRESENTATION('tire-
'supplemental geometry','',#36,#11); None',(#50),#20026);
#11=CONSTRUCTIVE_GEOMETRY_REPRESENTATION('supple #26=SHAPE_DEFINITION_REPRESENTATION(#27,#36);
mental geometry',(#9022),
#27=PRODUCT_DEFINITION_SHAPE('','',#28);
#20026);
#28=PRODUCT_DEFINITION(' ','',#30,#29);
#12=GEOMETRICALLY_BOUNDED_WIREFRAME_SHAPE_REPR
#29=PRODUCT_DEFINITION_CONTEXT('part
ESENTATION('tire-None',(#37),
definition',#35,'design');
#20026);
#30=PRODUCT_DEFINITION_FORMATION_WITH_SPECIFIED_S
#13=MANIFOLD_SURFACE_SHAPE_REPRESENTATION('tire- OURCE(' ',' ',#32,
None',(#38),#20026);
.NOT_KNOWN.);
#14=PROPERTY_DEFINITION_REPRESENTATION(#18,#16);
#31=PRODUCT_RELATED_PRODUCT_CATEGORY('part','',(#32)
#15=PROPERTY_DEFINITION_REPRESENTATION(#19,#17); );
#16=REPRESENTATION('',(#20),#20026); #32=PRODUCT('tire','tire',' ',(#33));
#17=REPRESENTATION('',(#21),#20026); #33=PRODUCT_CONTEXT(' ',#35,'mechanical');
#18=PROPERTY_DEFINITION('pmi validation property','',#27); #34=APPLICATION_PROTOCOL_DEFINITION('international
standard',
#19=PROPERTY_DEFINITION('pmi validation property','',#27);
'automotive_design',2010,#35);
#20=VALUE_REPRESENTATION_ITEM('number of
annotations',COUNT_MEASURE(0.)); #35=APPLICATION_CONTEXT(
#21=VALUE_REPRESENTATION_ITEM('number of 'core data for automotive mechanical design processes');
views',COUNT_MEASURE(0.));
#36=SHAPE_REPRESENTATION('tire-None',(#9013),#20026);
#22=SHAPE_REPRESENTATION_RELATIONSHIP('None',
#37=GEOMETRIC_CURVE_SET('None',(#11092,#8302,#8303,#
'relationship between tire-None and tire-None',#36,#25); 8304,#8305,#8306,#8307,
#23=SHAPE_REPRESENTATION_RELATIONSHIP('None', #8308,#8309,#8310,#8311,#8312,#8313,#8314,#8315,#831
6,#8317,#8318,#8319,
'relationship between tire-None and tire-None',#36,#13);
#8320,#8321,#8322,#8323,#8324,#8325,#8326,#8327,#832
#24=SHAPE_REPRESENTATION_RELATIONSHIP('None',
8,#8329,#8330,#8331,
3714007 Practical-7
#8332,#8333,#8334,#8335)); #876,#877,#878,#879,#880,#881,#882,#883,#884,#885,#88
6,#887,#888,#889,#890,
#38=SHELL_BASED_SURFACE_MODEL('',(#39));
#891,#892,#893,#894,#895,#896,#897,#898,#899,#900,#90
#39=OPEN_SHELL('',(#1098));
1,#902,#903,#904,#905,
#40=SURFACE_STYLE_USAGE(.BOTH.,#42);
#906,#907,#908,#909,#910,#911,#912,#913,#914,#915,#91
#41=SURFACE_STYLE_USAGE(.BOTH.,#43); 6,#917,#918,#919,#920,
#42=SURFACE_SIDE_STYLE('',(#44)); #921,#922,#923,#924,#925,#926,#927,#928,#929,#930,#93
1,#932,#933,#934,#935,
#43=SURFACE_SIDE_STYLE('',(#45));
#936,#937,#938,#939,#940,#941,#942,#943,#944,#945,#94
6,#947,#948,#949,#950,
#951,#952,#953,#954,#955,#956,#957,#958,#959,#960,#96
#46=FILL_AREA_STYLE('',(#48)); 1,#962,#963,#964,#965,
#47=FILL_AREA_STYLE('',(#49)); #966,#967,#968,#969,#970,#971,#972,#973,#974,#975,#97
6,#977,#978,#979,#980,
#48=FILL_AREA_STYLE_COLOUR('',#9011);
#981,#982,#983,#984,#985,#986,#987,#988,#989,#990,#99
#49=FILL_AREA_STYLE_COLOUR('',#9012); 1,#992,#993,#994,#995,
#50=MANIFOLD_SOLID_BREP('',#51); #996,#997,#998,#999,#1000,#1001,#1002,#1003,#1004,#10
#51=CLOSED_SHELL('',(#611,#612,#613,#614,#615,#616,#61 05,#1006,#1007,#1008,
7,#618,#619,#620, #1009,#1010,#1011,#1012,#1013,#1014,#1015,#1016,#101
#621,#622,#623,#624,#625,#626,#627,#628,#629,#630,#63 7,#1018,#1019,#1020,
1,#632,#633,#634,#635, #1021,#1022,#1023,#1024,#1025,#1026,#1027,#1028,#102
#636,#637,#638,#639,#640,#641,#642,#643,#644,#645,#64 9,#1030,#1031,#1032,
6,#647,#648,#649,#650, #1033,#1034,#1035,#1036,#1037,#1038,#1039,#1040,#104
#651,#652,#653,#654,#655,#656,#657,#658,#659,#660,#66 1,#1042,#1043,#1044,
1,#662,#663,#664,#665, #1045,#1046,#1047,#1048,#1049,#1050,#1051,#1052,#105
#666,#667,#668,#669,#670,#671,#672,#673,#674,#675,#67 3,#1054,#1055,#1056,
6,#677,#678,#679,#680, #1057,#1058,#1059,#1060,#1061,#1062,#1063,#1064,#106
#681,#682,#683,#684,#685,#686,#687,#688,#689,#690,#69 5,#1066,#1067,#1068,
1,#692,#693,#694,#695, #1069,#1070,#1071,#1072,#1073,#1074,#1075,#1076,#107
#696,#697,#698,#699,#700,#701,#702,#703,#704,#705,#70 7,#1078,#1079,#1080,
6,#707,#708,#709,#710, #1081,#1082,#1083,#1084,#1085,#1086,#1087,#1088,#108
#711,#712,#713,#714,#715,#716,#717,#718,#719,#720,#72 9,#1090,#1091,#1092,
1,#722,#723,#724,#725, #1093,#1094,#1095,#1096,#1097));
#726,#727,#728,#729,#730,#731,#732,#733,#734,#735,#73 #52=PLANE('',#9069);
6,#737,#738,#739,#740,
#53=PLANE('',#9074);
#741,#742,#743,#744,#745,#746,#747,#748,#749,#750,#75
1,#752,#753,#754,#755, #54=PLANE('',#9085);
#756,#757,#758,#759,#760,#761,#762,#763,#764,#765,#76 #55=PLANE('',#9088);
6,#767,#768,#769,#770,
#56=PLANE('',#9099);
#771,#772,#773,#774,#775,#776,#777,#778,#779,#780,#78
#57=PLANE('',#9102);
1,#782,#783,#784,#785,
#58=PLANE('',#9113);
#786,#787,#788,#789,#790,#791,#792,#793,#794,#795,#79
6,#797,#798,#799,#800, #59=PLANE('',#9116);
#801,#802,#803,#804,#805,#806,#807,#808,#809,#810,#81 #60=PLANE('',#9127);
1,#812,#813,#814,#815,
#61=PLANE('',#9130);
#816,#817,#818,#819,#820,#821,#822,#823,#824,#825,#82
#62=PLANE('',#9141);
6,#827,#828,#829,#830,
#63=PLANE('',#9144);
#831,#832,#833,#834,#835,#836,#837,#838,#839,#840,#84
1,#842,#843,#844,#845, #64=PLANE('',#9155);
#846,#847,#848,#849,#850,#851,#852,#853,#854,#855,#85 #65=PLANE('',#9158);
6,#857,#858,#859,#860,
#66=PLANE('',#9169);
#861,#862,#863,#864,#865,#866,#867,#868,#869,#870,#87
#67=PLANE('',#9172);
1,#872,#873,#874,#875,
3714007 Practical-7
#68=PLANE('',#9183); #8632=VECTOR('',#9609,0.195712505360579);
#69=PLANE('',#9186); #8633=VECTOR('',#9610,0.0699999999999996);
#70=PLANE('',#9197); #8634=VECTOR('',#9611,0.0790000000000002);
#71=PLANE('',#9200); #8635=VECTOR('',#9612,0.160000000000001);
#72=PLANE('',#9211); #8636=VECTOR('',#9613,0.160000000000001);
#73=PLANE('',#9214); #8637=VECTOR('',#9614,0.0790000000000002);
#74=PLANE('',#9225); #8638=VECTOR('',#9615,0.0699999999999996);
#75=PLANE('',#9228); #8639=VECTOR('',#9616,0.195712505360579);
#76=PLANE('',#9239); #8640=VECTOR('',#9617,0.110000000000001);
#77=PLANE('',#9242); #8641=VECTOR('',#9618,0.0790000000000002);
#78=PLANE('',#9253); #8642=VECTOR('',#9619,0.0699999999999997);
#79=PLANE('',#9256); #8643=VECTOR('',#9620,0.108899664747893);
#80=PLANE('',#9258); #8644=VECTOR('',#9621,0.108899664747893);
#81=PLANE('',#9260); #8645=VECTOR('',#9622,0.0699999999999997);
#82=PLANE('',#9280); #8646=VECTOR('',#9623,0.0790000000000002);
#83=PLANE('',#9284); #8647=VECTOR('',#9624,0.110000000000001);
#84=PLANE('',#9288); #8717=VECTOR('',#10010,1.);
#85=PLANE('',#9292); #8718=VECTOR('',#10017,1.);
#86=PLANE('',#9296); #8719=VECTOR('',#10022,1.);
#87=PLANE('',#9299); #8720=VECTOR('',#10029,1.);
#88=PLANE('',#9303); #8721=VECTOR('',#10032,1.);
#89=PLANE('',#9307); #8722=VECTOR('',#10037,1.);
#90=PLANE('',#9311); #8723=VECTOR('',#10040,1.);
#91=PLANE('',#9314); #8724=VECTOR('',#10045,1.);
#92=PLANE('',#9317); #8725=VECTOR('',#10052,1.);
#8552=LINE('',#19762,#8848); #8726=VECTOR('',#10057,1.);
#8553=LINE('',#19764,#8849); #8727=VECTOR('',#10064,1.);
#8554=LINE('',#19767,#8850); #8728=VECTOR('',#10067,1.);
#8555=LINE('',#19776,#8851); #8729=VECTOR('',#10072,1.);
#8556=LINE('',#19778,#8852); #8730=VECTOR('',#10075,1.);
#8557=LINE('',#19780,#8853); #8731=VECTOR('',#10080,1.);
#8558=LINE('',#19782,#8854); #8732=VECTOR('',#10087,1.);
#8559=LINE('',#19783,#8855); #8733=VECTOR('',#10092,1.);
#8560=LINE('',#19785,#8856); #8734=VECTOR('',#10099,1.);
#8561=LINE('',#19788,#8857); #8735=VECTOR('',#10102,1.);
#8624=LINE('',#19977,#8920); #8736=VECTOR('',#10107,1.);
#8625=LINE('',#19986,#8921); #8737=VECTOR('',#10110,1.);
#8626=LINE('',#19988,#8922); #8738=VECTOR('',#10115,1.);
#8627=LINE('',#19990,#8923); #8739=VECTOR('',#10122,1.);
#8628=LINE('',#19992,#8924); #8740=VECTOR('',#10127,1.);
#8629=LINE('',#19993,#8925); #8741=VECTOR('',#10134,1.);
#8630=LINE('',#19995,#8926); #8742=VECTOR('',#10137,1.);
#8631=LINE('',#19998,#8927); #8743=VECTOR('',#10142,1.);
3714007 Practical-7
#8744=VECTOR('',#10145,1.); #14981=CARTESIAN_POINT('',(0.572981885783868,-
0.105672325611679,3.87650571102262));
#8745=VECTOR('',#10150,1.);
#14982=CARTESIAN_POINT('',(-0.487393163802832,-
#8746=VECTOR('',#10157,1.);
0.146275295381206,-1.16612493952387));
#8747=VECTOR('',#10162,1.);
#14983=CARTESIAN_POINT('',(-0.489690927655861,-
112871,-0.140639637467006,-0.916105458685864)); 0.146524265129597,-1.16514084467708));
#14958=CARTESIAN_POINT('',(-0.891509175597122,- #14984=CARTESIAN_POINT('',(-0.491988416678765,-
0.140080761889501,-0.910594809437562)); 0.146763356113684,-1.1641497086312));
0.139502567853533,-0.905068397572259)); 0.146992562469133,-1.16315150067248));
#14960=CARTESIAN_POINT('',(2.03438883719217,0.76496,3. #14986=CARTESIAN_POINT('',(-0.487393163802841,-
35609839607472)); 0.146275295381164,-1.16612493952387));
#14961=CARTESIAN_POINT('',(-0.63962138895441,0.,- #14987=CARTESIAN_POINT('',(-0.494285621441555,-
1.0450515265278)); 0.146992562469121,-1.16315150067247));
3.10101841209446E-13,-1.08160442450773)); 0.146275295381164,-1.16612493952387));
0.102962468037701,-0.879942921844345)); 0.146523486975109,-1.17158473793571));
0.0894575926040294,-0.961122009613437)); 0.146762637760939,-1.17703961338145));
0.0540699202490988,-1.03025022597051)); 0.146992562469121,-1.18248944018726));
#14966=CARTESIAN_POINT('',(- #14992=CARTESIAN_POINT('',(-0.498396027374602,-
0.666178623858205,1.61147628046556E-13,- 0.146992562469121,-1.18248944018726));
1.08160442450759));
#14993=CARTESIAN_POINT('',(0.576756068782308,-
#14967=CARTESIAN_POINT('',(-0.911757896074227,- 0.146992562469121,3.87570348366136));
0.102962468037701,-0.879942921844345));
#14994=CARTESIAN_POINT('',(0.493458485844209,0.76496,
#14968=CARTESIAN_POINT('',(-0.911757896074227,- 3.8934089314861));
0.102962468037701,-0.879942921844345));
#14995=CARTESIAN_POINT('',(-9.74562485562373,-
#14969=CARTESIAN_POINT('',(-0.920249053158942,- 0.76496,-12.8576994736199));
0.103412219555653,-0.885388426009632));
#14996=CARTESIAN_POINT('',(0.475118756947195,-
#14970=CARTESIAN_POINT('',(-0.928753440776994,- 0.15669552900694,3.89730716120241));
0.103841030117327,-0.890815122812416));
#14997=CARTESIAN_POINT('',(-0.590566538054619,-
#14971=CARTESIAN_POINT('',(-0.937271077148468,- 0.15669552900694,-1.1163479648915));
0.104248193373611,-0.896222490878808));
#14998=CARTESIAN_POINT('',(-0.494285621441555,-
#14972=CARTESIAN_POINT('',(2.03438883719217,0.76496,3. 0.146992562469121,-1.16315150067247));
35609839607472));
#14999=CARTESIAN_POINT('',(-0.527011419111222,-
#14973=CARTESIAN_POINT('',(-10.3906594672022,- 0.150257818111335,-1.14893110890821));
0.76496,-13.7455134510747));
#15000=CARTESIAN_POINT('',(-0.559162760710377,-
#14974=CARTESIAN_POINT('',(-0.52691026152698,- 0.153497954115177,-1.13330194828122));
0.108508685662637,-1.15198791581449));
#15001=CARTESIAN_POINT('',(-0.590566538054619,-
#14975=CARTESIAN_POINT('',(-0.59484163533429,- 0.15669552900694,-1.1163479648915));
0.115375292149498,-1.11790235393998));
#15002=CARTESIAN_POINT('',(0.475118756947195,-
#14976=CARTESIAN_POINT('',(-0.572549095389489,- 0.15669552900694,3.89730716120241));
0.113105340180791,-1.12994236680504));
#15003=CARTESIAN_POINT('',(-1.20482846064584,-
#14977=CARTESIAN_POINT('',(-0.549884870640388,- 0.14117864583496,-0.47239266276861));
0.110814406402434,-1.14131444792079));
#15004=CARTESIAN_POINT('',(-1.16361841816066,-
#14978=CARTESIAN_POINT('',(-0.52691026152698,- 0.12423912505817,-0.581365300709115));
0.108508685662637,-1.15198791581449));
#15005=CARTESIAN_POINT('',(-1.10986514562836,-
#14979=CARTESIAN_POINT('',(-0.59484163533429,- 0.084182788742997,-0.682620709152814));
0.115375292149498,-1.11790235393998));
#15006=CARTESIAN_POINT('',(-1.05034738675974,-
#14980=CARTESIAN_POINT('',(0.471344573948755,- 0.0242820245503036,-0.765715019333259));
0.115375292149498,3.89810938856367));
3714007 Practical-7
0.141178645834959,-0.47239266276861)); 0.154301006112031,-0.758254079149657));
0.0242820245503036,-0.765715019333259)); 0.238329143798608,-0.780226687559184));
0.0242820245503036,-0.765715019333259)); 0.321950921366145,-0.795721421049427));
0.0497023002883681,-0.798454236609707)); 0.405171363863069,-0.804818385008821));
0.0784963864999229,-0.828181178710105)); 0.405171363863069,-0.804818385008821));
0.109549226982811,-0.854125465788656)); 0.405171363863069,-0.804818385008821));
0.109549226982808,-0.854125465788643)); 0.406506295094088,-0.804964308545544));
0.109549226982808,-0.854125465788643)); 0.407799474890006,-0.80523233592747));
0.111503144252564,-0.837878700073167)); 0.409003925114974,-0.805615494605037));
0.113446369154564,-0.821274669038937)); 0.410878748863208,-0.806211911935661));
0.115375292149498,-0.804344181977493)); 0.412578667572487,-0.807107043865251));
0.115375292149498,-0.804344181977493)); 0.413954201861842,-0.808224121483401));
0.115375292149498,-0.804344181977493)); 0.415295434484247,-0.809313342562669));
0.115634325362555,-0.802070603159848)); 0.416365534822069,-0.810642405279787));
0.116079616933784,-0.799791672682413)); 0.417086012764905,-0.812098357663166));
0.116704121271297,-0.797535519428603)); 0.417814119223906,-0.813569725863782));
0.118320392820996,-0.791696398550085)); 0.418205612994927,-0.815208497451668));
0.12119253186052,-0.785902869872296)); 0.418246345791982,-0.816884162522023));
0.125088970644906,-0.78062231896021)); 0.418288683128129,-0.818625835092594));
0.129050367726539,-0.7752537349454)); 0.41795450386875,-0.820451956542368));
0.134184932658243,-0.770265135915705)); 0.417285797908308,-0.822225012643934));
0.14008391988569,-0.766104559312265)); 0.416582674806997,-0.824089324880819));
0.144410515210234,-0.763052996292074)); 0.415492117711406,-0.825943579216351));
0.149224533499927,-0.760386148506632)); 0.41410765618078,-0.827649332296409));
0.154301006112031,-0.758254079149656)); 0.412663305251094,-0.82942887328942));
0.154301006112031,-0.758254079149656)); 0.410859944391635,-0.83109481358004));
3714007 Practical-7
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#15062=CARTESIAN_POINT('',(-0.931613788852708,-
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0.402035691977432,-0.836086981111298));
#19997=CARTESIAN_POINT('',(-
#15063=CARTESIAN_POINT('',(-0.93159784727685,-
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3714007 Practical-7
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3714007 Practical-8
Practical - 08
AIM: To simulate the geometry of O-ring considering the temperature distribution parameter in Elmer Software.

Header End
CHECK KEYWORDS Warn
Mesh DB "." "." Body 1
Include Path "" Target Bodies(1) = 1
Results Directory "" Name = "Body 1"
End Equation = 1
Material = 1
Simulation Body Force = 1
Max Output Level = 5 End
Coordinate System = Cartesian
Coordinate Mapping(3) = 1 2 3 Solver 1
Simulation Type = Steady state Equation = Heat Equation
Steady State Max Iterations = 1 Variable = Temperature
Output Intervals(1) = 1 Procedure = "HeatSolve" "HeatSolver"
Solver Input File = case.sif Exec Solver = Always
Post File = case.vtu Stabilize = True
End Optimize Bandwidth = True
Steady State Convergence Tolerance = 1.0e-5
Constants Nonlinear System Convergence Tolerance = 1.0e-7
Gravity(4) = 0 -1 0 9.82 Nonlinear System Max Iterations = 20
Stefan Boltzmann = 5.670374419e-08 Nonlinear System Newton After Iterations = 3
Permittivity of Vacuum = 8.85418781e-12 Nonlinear System Newton After Tolerance = 1.0e-3
Permeability of Vacuum = 1.25663706e-6 Nonlinear System Relaxation Factor = 1
Boltzmann Constant = 1.380649e-23 Linear System Solver = Iterative
Unit Charge = 1.6021766e-19 Linear System Iterative Method = BiCGStab
3714007 Practical-8
Linear System Max Iterations = 500 Poisson ratio = 0.28
Linear System Convergence Tolerance = 1.0e-10 Emissivity = 0.7
BiCGstabl polynomial degree = 2 Density = 2330.0
Linear System Preconditioning = ILU0 End
Linear System ILUT Tolerance = 1.0e-3
Linear System Abort Not Converged = False Body Force 1
Linear System Residual Output = 10 Name = "heating"
Linear System Precondition Recompute = 1 Heat Source = 0.1
End End
Equation 1 Initial Condition 1

Name = "Heat equation" Name = "InitialCondition 1"
Active Solvers(1) = 1 Temperature = 293
End End
Material 1 Boundary Condition 1

Name = "Silicon (solid)" Target Boundaries(1) = 4
Youngs modulus = 185.0e9 Name = "Room Temp"
Heat Conductivity = Variable Temperature; Real; 0 156; 300 Temperature = 293
156; 550 72; 800 43; 1050 29; 1300 25; 1550 23; 1800 21;
Radiation = Diffuse Gray
3000 21; End
End
Heat Capacity = 555.8
Heat expansion Coefficient = 4.68e-6
Sound speed = 8433.0
3714007 Practical-9
Practical - 09
AIM: To simulate the geometry of Diaphragm considering the temperature distribution parameter in Elmer Software.
Header Unit Charge = 1.6021766e-19

CHECK KEYWORDS Warn End
Mesh DB "." "."
Include Path "" Body 1
Results Directory "" Target Bodies(1) = 1
End Name = "Body 1"
Equation = 1
Simulation Material = 1
Max Output Level = 5 Body Force = 1
Coordinate System = Cartesian End
Coordinate Mapping(3) = 1 2 3
Simulation Type = Steady state Solver 1
Steady State Max Iterations = 1 Equation = Heat Equation
Output Intervals(1) = 1 Procedure = "HeatSolve" "HeatSolver"
Solver Input File = case.sif Variable = Temperature
Post File = case.vtu Exec Solver = Always
End Stabilize = True
Optimize Bandwidth = True
Constants Steady State Convergence Tolerance = 1.0e-5
Gravity(4) = 0 -1 0 9.82 Nonlinear System Convergence Tolerance = 1.0e-7
Stefan Boltzmann = 5.670374419e-08 Nonlinear System Max Iterations = 20
Permittivity of Vacuum = 8.85418781e-12 Nonlinear System Newton After Iterations = 3
Permeability of Vacuum = 1.25663706e-6 Nonlinear System Newton After Tolerance = 1.0e-3
Boltzmann Constant = 1.380649e-23 Nonlinear System Relaxation Factor = 1
3714007 Practical-9
Linear System Solver = Iterative Sound speed = 8433.0
Linear System Iterative Method = BiCGStab Youngs modulus = 185.0e9
Linear System Max Iterations = 500 Mesh Poisson ratio = 0.28
Linear System Convergence Tolerance = 1.0e-10 Heat Conductivity = Variable Temperature; Real; 0 156; 300
156; 550 72; 800 43; 1050 29; 1300 25; 1550 23; 1800 21;
BiCGstabl polynomial degree = 2
3000 21; End
Linear System Preconditioning = ILU0
Density = 2330.0
Linear System ILUT Tolerance = 1.0e-3
Heat Capacity = 555.8
Linear System Abort Not Converged = False
Emissivity = 0.7
Linear System Residual Output = 10
End
Linear System Precondition Recompute = 1
End
Body Force 1
Name = "Heating"
Equation 1
Heat Source = 0.01
Name = "Heat Equation" End
Active Solvers(1) = 1
End
Boundary Condition 1
Target Boundaries(2) = 8 18
Material 1
Name = "Room Temp"
Name = "Silicon (solid)"
Temperature = 293
End
3714007 Practical-10
Practical - 10
AIM: To simulate the geometry of O-ring considering the pressure distribution & compression parameter
in Elmer Software.
Header Unit Charge = 1.6021766e-19

CHECK KEYWORDS Warn End
Mesh DB "." "."
Include Path "" Body 1
Results Directory "" Target Bodies(1) = 1
End Name = "Body 1"
Equation = 1
Simulation Material = 1
Max Output Level = 5 End
Coordinate System = Cartesian
Coordinate Mapping(3) = 1 2 3 Solver 1
Simulation Type = Steady state Equation = Linear elasticity
Steady State Max Iterations = 1 Procedure = "StressSolve" "StressSolver"
Output Intervals(1) = 1 Exec Solver = Always
Solver Input File = case.sif Stabilize = True
Post File = case.vtu Optimize Bandwidth = True
End Steady State Convergence Tolerance = 1.0e-5
Nonlinear System Convergence Tolerance = 1.0e-7
Constants Nonlinear System Max Iterations = 1
Gravity(4) = 0 -1 0 9.82 Nonlinear System Newton After Iterations = 3
Stefan Boltzmann = 5.670374419e-08 Nonlinear System Newton After Tolerance = 1.0e-3
Permittivity of Vacuum = 8.85418781e-12 Nonlinear System Relaxation Factor = 1
Permeability of Vacuum = 1.25663706e-6 Linear System Solver = Direct
Boltzmann Constant = 1.380649e-23 Linear System Direct Method = Banded
3714007 Practical-10
End Sound speed = 8433.0
Equation 1 End
Name = "Compression"
Calculate Stresses = True Boundary Condition 1
Active Solvers(1) = 1 Target Boundaries(1) = 6
End Name = "Fixed"
Displacement 3 = 0
Material 1 Displacement 1 = 0
Name = "Silicon (solid)" Displacement 2 = 0
Mesh Poisson ratio = 0.28 End
Density = 2330.0
Emissivity = 0.7 Boundary Condition 2
Heat Capacity = 555.8 Target Boundaries(2) = 8 10
Youngs modulus = 185.0e9 Name = "pressure"
Heat Conductivity = Variable Temperature; Real; 0 156; 300 Force 2 = 100
156; 550 72; 800 43; 1050 29; 1300 25; 1550 23; 1800 21;
End
3000 21; End

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3714007 Index

1.1 Plant Layout:

Figure 1.1 Current Plant Layout

Splicing and Valve Jamming Curing Area

Quality Control & Tool Design;

Mixing Area Admin

Parking Area Security Security

Figure 1.2 Simulated Plant Layout

Table 1.1 : Current Formulation Table 1.2 : Simulated Formulation

Compounding Ingredients PHR Compounding Ingredients PHR

Cure temperature: 160-165 °C.

Table 1.3 : Various Properties

Properties Units and Conditions Typical Value

Rheometer (ODR) (ASTM D2048) 160°C, 60 min., 3.0 deg.arc

Rheometer (ODR) (ASTM D2048) 180°C, 30 min., 3.0 deg.arc

Rheometer (ODR) (ASTM D2048) 180°C, 30 min., 0.5 deg.arc

Tensile Strength MPa 11.2

Tear Strength (Die B) Mean KN/m 30.8

Rheometer (ODR) (ASTM D412) Aged 125 deg C, 72 hours

Tear Strength (Die B) Mean (ASTM D624) KN/m 22.8

De’Mattia Flex Resistance Kilocycles KC >80 No Cracks

1.3.1 Overall Process Flow Chart

Incoming Inspection Raw Material Inward Order Booked by Sales

Raw Material Storage

Material Weighing in Mixing

Master Batch Mixing Cleaning & Cooling of Mill

In Process Inspection by Q.C.

Corrections & Modification Q.C. Not Passed Q. C. Passed

Cutting and Dusting

Packaging Re-Work Not Ok Forming / Shaping

Final Inspection by Q. C. Curing

Product Requirement from Marketing/Sales

Production Planning Control (P.P.C.) Department

Product Stock Available Product Stock Not Available

Partially Stock Fully Stock Die/Mould Not

Send to Dispatch Ok Apply for New Die/Mould

Generate Validation Report Validation Report Not

Make Validation Report

Handover to Production Department Not Ok

Production Planning Control (P. P. C.) Department

Raw Material Raw Material

Weight the compound as Collect Raw

Send to Cutting (If Required)

Send to Quality Control Department

1.3.4 Production Department Process Flow Chart

Get Job Card from P. P. C. Department

Collect Uncure Rubber Sheet from Mixing Department

Set Parameters as per Validation Report

After Extruder Machine, Place Beta Tester

Place D. C. Oven/Heat Box/C. V. (If Required)

Continues Quality Checking

Product Ok Product Not Ok

Stop the Process and

Ok Check Defects Not Ok

1.3.6 Testing Department Process Flow Chart

Head Scrap In Process Scrap Cutting Scrap

1.3.8 Tools and Design Department Process Flow Chart

Get Order from Sales Department

Old Product New Product