Presentation - Tyre Manufacturing[1] 4y1m2z

MOHAMAD REDZUAN BIN ABDULLAH ZAWAWI ISWANDI BIN WI

HILMI BIN NANDAN MOHD HIZAR MANSHID @ SHAHEMANJA

DEFINITION  A tyre is a ring-shaped covering that fits around a wheel rim to protect it and enable better vehicle performance by providing a flexible cushion that absorbs shock while keeping the wheel in close with the ground. BACKGROUND  The fundamental materials of modern tires are rubber and fabric along with other compound chemicals. They consist of a tread and a body. The tread provides traction while the body ensures .

APPLICATION  Before rubber was invented, the first versions of tires were simply bands of metal that fitted around wooden wheels in order to prevent wear and tear. Today, the vast majority of tires are pneumatic, comprising a doughnut-shaped body of cords and wires encased in rubber and generally filled with compressed air to form an inflatable cushion. Pneumatic tires are used on many types of vehicles, such as bicycles, motorcycles, cars, trucks, earthmovers and sircraft.

 14% NATURAL RUBBER

 27% SYNTHETIC POLYMERS  28% CARBON BLACK  10% OIL

 4% OTHER PETROCHEM  4% FABRIC  10% WIRE

 3% OTHERS

1) Natural rubber/polyisoprene  The basic elastomeric used in tyre making.

 It was derived from latex, a milky colloid found in the sap of some

plants. Rubber's stress-strain behaviour is often modelled as hyper elastic. Rubber strain crystallizes. Natural rubber is sensitive to ozone cracking.

2) Styrene-Butadiene-Rubber (SBR)  a synthetic rubber copolymer consisting of styrene and butadiene.  has good abrasion resistance and good aging stability when protected

by additives  can be produced from solution or as emulsion. Pressure reaction vessels are required and usually charged with the two monomers, a free radical acid and a chain transfer agent such as an alkyl mercaptan.  The latter prevents high molecular weight and high viscosity product from forming

3) Polybutadiene  a synthetic rubber that is a polymer formed from the polymerization of

the monomer 1,3-butadiene.  has a high resistance to wear It is a highly resilient synthetic rubber. Heat build-up is subjected to repeat flexing during serviceLow rolling resistance of this rubber also leads to its use in the tread portion of tires

4) Butyl rubber  a synthetic rubber, a copolymer of isobutylene with isoprene.

 Butyl rubber is produced by polymerization of about 98% of

isobutylene with about 2% of isoprene.  Butyl rubber is used for the tubeless inner liner compounds, because of its low air permeability.  The halogen atoms provide a bond with the carcass compounds which are mainly natural rubber.

5) Carbon black  a material produced by the incomplete combustion of heavy petroleum

products such as FCC tar, coal tar, ethylene cracking tar, and a small amount from vegetable oil.  a form of amorphous carbon that has a high surface-area-to-volume ratio.  the most common use [70%] is as a pigment and reinforcing phase in automobile tires.  helps conduct heat away from the tread and belt area of the tire, reducing thermal damage and increasing tire life.

6) Silica  the chemical compound silicon dioxide with a chemical formula of

SiO2 and has been known for its hardness since antiquity.  is most commonly found in nature as sand or quartz, as well as in the cell walls of diatoms. It used together with carbon black in high performance tires, as a low heat build up reinforcement.

7) Sulphur  is the chemical element that has the atomic number 16.  it crosslink the rubber molecules in the vulcanization process.

8)Vulcanizing Accelerators  are complex organic compounds that speed up the vulcanization.  these additives modify the polymer by forming crosslink (bridges)

between individual polymer chains.  The vulcanized material is less sticky and has superior mechanical properties.

9) Activators  assist the vulcanization.  the main one is zinc oxide.

10) Antioxidants and antiozonants  prevent sidewall cracking due to the action of sunlight and ozone.

11) Textile fabric and steel wire  reinforces the carcass of the tire.

TYRE CONSTRUCTION

CASING or CARCASS  The casing is the framework of the tyre. It must be strong enough to withstand high inflation pressure, yet flexible enough to absorb load changes and impact.  It consists of tyre cords coated with compounded rubber. Generally, tyres are classified into Bias or Radial ply construction.

PLY  This is a layer tyre cord (textile or

steel) extending from bead to bead makes up the carcass of the tyre.  Plies are turned up and around the beads which lock the bead into the carcass.

BEAD  This is part of tyre which is

shaped to fit on the rim.  is made of continuous high tensile wire wound to form a high strength unit, the bead wire core is the anchor foundation of the casing which maintain the required tyre diameter on the rim.

TREAD  Tread rubber provides the interface between the

tyre structure and road.  Primary purpose is to provide traction and wear.

BREAKER  This is the layers of tyre cord

(textile or steel) directly under the tread,run circumferentially around the tyre.  Breaker plies provide strength to the tyre stabilize the tread and protect external damage to the casing.

SIDEWALL

SIDEWALL  This is the part between tread and bead and is directly related to the ride characteristics of the tyre. It is specially compounded to withstand flexing and weathering while providing protection for the casing.

APEX

APEX  Triangle rubber piece with selected characteristics are used to fill in the bead and lower sidewall area to provide a smooth transition from the stiff bead area to the flexible sidewall.

CHAFER

CHAFER  It consists of narrow strips of specially compounded rubber or ply material around the outside of the bead that reinforces and stabilizes the bead to sidewall' transition zone. It protects the bead area from chafing or cutting by the rim.

LINER

LINER  A layer of non-porous rubber incorporated at the internal part of the casing. Its purpose is to provide a complete seal which retain the inflation pressure.

MIXING PROCESS  Equipment = Banbury Mixer  Input Material = natural rubber, synthetic rubber, carbon black & chemicals  Output = slab compound

EXTRUSION PROCESS  Equipment = Extruder  Input Material = slab compound  Output = tread, sidewall & apex

CALENDERING PROCESS  Equipment = 4 Roll Calender  Input Material = fabric, steel wire & slab compound  Output = calendered fabric/steel ply & liner

PLY/BREAKER CUTTING PROCESS  Equipment = ply/breaker cutter  Input Material = fabric & steel plies  Output = ply & breaker

BEAD PROCESS  Equipment = bead insulation  Input Material = steel wire & slab compound  Output = bead

TYRE BUILDING PROCESS  Equipment = tyre building machine  Input Material = liner, chafer, ply, breaker, bead, apex, sidewall & tread  Output = green tyre

CURING PROCESS  Equipment = curing press  Input Material = green tyre  Output = finish tyre

FINAL FINISHING • After the tire has been cured, there are several additional operations. • Tire uniformity measurement is a test where the tire is automatically mounted on wheel halves, inflated, run against a simulated road surface, and measured for force variation. • Tire balance measurement is a test where the tire is automatically placed on wheel halves, rotated at a high speed and measured for imbalance.

TWEEL  an experimental tyre design developed by the French tyre company Michelin.  uses no air, cannot burst or become flat.  the Tweel's hub connects to flexible polyurethane spokes which are used to an outer rim and assume the shock-absorbing role of a traditional tyre's pneumatic properties.

AIRLESS TYRE  Non-pneumatic tires or Airless tires, are tires that are not ed by air pressure  used on some small vehicles such as riding lawn mowers and motorized golf carts, heavy equipment such as backhoes  have higher rolling friction and provide much less suspension than similarly shaped and sized pneumatic tires.  cannot go flat, but they are far less common than air filled tires.

RUN FLAT TYRE  Non-pneumatic tires or Airless tires, are tires that are not ed by air pressure  used on some small vehicles such as riding lawn mowers and motorized golf carts, heavy equipment such as backhoes  have higher rolling friction and provide much less suspension than similarly shaped and sized pneumatic tires.  cannot go flat, but they are far less common than air filled tires.

 Pneumatic tires are used on many types of vehicles,

such as bicycles, motorcycles, cars, trucks, earthmovers and aircraft.  Tires enable better vehicle performance by providing traction, braking, steering and load .  Tires form a flexible cushion between the vehicle and the road, which smoothes out shock and makes for a comfortable ride.