Tire Materials
Radial vs Bias
TIRE MANUFACTURING PROCESS FLOW
Raw Materials % In Tyre
Note: Raw materials percentage will be varied with respect to applications.
Classification of Compounding Ingredients
1. Rubbers
2. Vulcanizing Agents (curatives)
3. Accelerators.
4. Activators and Retarders.
5. Anti-degradants (Anti-oxidants, Anti-
ozonants, Protective waxes).
6. Processing aids (Peptizers, Lubricants,
Release Agents).
7. Fillers (carbon black, Non-Black
materials).
8. Plasticizers, Softeners and Tackifiers.
9. Colour pigments.
10. Special Purpose Materials
What is Mixing?
Mixing is a process of incorporating different ingredients such
as chemicals,fillers,oils and processing aids in to
polymers(Natural & synthetic rubbers) to prepare a compound
which is designed to achieve final physical properties which
are required by different components of tire to meet service
conditions of tires based on tire application.
Mixing is carried out using highly engineered machine called
Bunbury/Inter mix and generally consists of 2-3 stages of
mixing. Some special compounds have more than 3 stages
depending upon filler & oil loading.
Mixing Process layout
Mixing Process Flow
Weighing of
Mixing of
Receipt of Raw Polymer, Carbon,
Bale Cutting Master,Remill and
Materials from Stores Chemicals and Oils
Final Batch
and Loading
Storage of Sheeting and
compound Cooling Sample collection of
compound
Lab
Testing
Mixing Stages
Master batch: Master batches are generally consists of major raw materials
like rubbers,fillers,oils and other chemicals except accelerators and vulcanizing
agents.
Repass Stage: Repass stage is process of remixing the previously mixed master batch
compound without addition of any ingredients to further improve homogeneity of
compound and also reduce viscosity of compound to take care of further processing
requirements.
Final batch: Final batch mixing is a process in which accelerators, vulcanizing
agents & retarders are added in to master batch which are essential for compound
vulcanization.
CALENDER
LAYOUT:-
4-ROLL CALENDER
PROCESS FLOW DIAGRAM:-
COMPOUND TRANFER TO LET OFF STATION
MILL
SPLICING PRESS
ACCUMULATOR
CRACKER MILL
HOT DRUM
CENTERING
WARM UP MILL
EXPANDER
FEED MILL TRIO CANTER
CALENDERING
COOLING DRUM
ACCUMULATOR
WINDING
GENERAL CREEL ROOM
CREEL ROOM:-
1)Inside Temp. should be greater than
Outside Temp. by 2⁰C(Approx.)
2)Humidity< 55%
3)Conditioning of wires= 24 hours
HOT FEED EXTRUDERS
TYPES OF EXTRUDERS
COLD FEED EXTRUDERS HOT FEED EXTRUDERS
SMOOTH BARREL EXTRUDERS
PIN BARREL EXTRUDERS
Compounds are preheated in the upstream Cold compounds which are not been preheated in the
mills before feeding to extruder in strip mills are fed to extruder
form.
ADVANTAGES OF HOT FEED EXTRUDERS ADVANTAGES OF COLD FEED EXTRUDERS
• High output with larger screw diameters Saves Energy, Space & Labour
• Larger profiles - Tubes • Lower thermal stress for polymer
• Smooth extrusion of Highly loaded compounds • Consistent output at low temperatures
• High dimensional stability for extrudate
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Extrusion Line - Equipment
Extrude Evaluate Convey
Contour
Feed Temp measurement
Masticate measurement
M
Converge Width Reject marker
monitoring
Form
Weight
monitoring ABC Cool
M
mp
Pu
Mark
Relax Online Color line
recognition system
Store - Booking Length control
Profiler
Temp measurement Running weight scale
4 MAJOR SECTIONS:
EXTRUDE, EVALUATE, CONVEY,
Dr y
Cut STORE )
Store
PURPOSE: HEAT, SOFTEN, FLOW & SHAPE
FLOW CHANNEL, PREFORMER & DIE
DIE
Opening in a piece of metal to achieve shape of the extrudate.
Die can be single piece or double piece
In double split die bottom plate is called as “Base Plate”
Back chafer is provided to achieve uniform pressure
FLOW CHANNEL, PREFORMER & DIE
Preformer
Casette
or Preformer/ die holder
Die plate
Cap plate
Base plate
Die opening
15
Extrusion Process Flow Diagram - Details
Contour
Weight Control Width Control
Measurement
Metal detectors Hot Hot
Hot
Slab Rubber Closed Loop
Feed Measure Control
Identification
Pin
Mark Rejection
Configuration
Masticate
Screw & Barrel
Water Quality
Temperature Control
Cool Control
Pressure
Pump
Speed Cut
Splice Bar
Design Converge Dry
Die Design Form Mark Rejection
Width / Contour Weight
Measurement Control
Tension Relax Measure Cold Cold
Temperature
Control
Store Store
Cut to Extruded Components
Spooling
length
3 Roll Calender Machine
3 Roll Calender for ROTR & TBR Tire
Compound feeding to extruder Extruder for compound feeding Compound feeding from extruder to
3 roll calender
Pass through the cooling drum Generation of inner liner / squeezee
3 roll calender Machine
Role of Bead In Tire-Wheel Assembly
Role of bead is to hold the tire on rim and bead is the main contact part of tire with rim
Bead is the contact area of tire with rim
Cross –section of tire
Steps of Bead Winding
Confirm the availability of
Place the compound near the extruder
bead wire
Set the correct size Switch ON The Main Panel
Steps of Bead Winding
Ensure the die assembly for specified die and buffle
Observe specified temperature reached
Cooling Drum Pre-heating Unit
Feed the specified compound to extruder barrel Ensure the temp. of cooling drum and pre-heating unit
Steps of Bead Winding
Load the bead wire spools Draw the specified no of wires
Confirm the Wound bead perimeter Take a specified Bead building former
Steps of Bead Winding
Ensure the WBP as per specification
Keep the complete wound bead in trolley Put proper identification
tag
Hexagonal Bead for ROTR & TBR Tire
Bead Winding Machine Whole Bead Auto Wrapping Machine Bead Fillering Machine
Filler Joint stitching on Machine Filler Joint on Machine
Filler Kept on Machine
Bias Cutter Machine
Steps of Slitting at Bias Cutter
Switch ON The Main Panel
Ensure the specific calendered fabric as per requirement
Load the calender roll at
Check the liner and shell condition and take only
let-off unit
same width liner and shell
Band Building Process
• Band building process involves making an assembly of cut ply fabric with
specified width and specified angle, which eases tire building process and
increases the productivity of tire building
Steps of Band Building
Switch ON The Main Panel Ensure the specific cut ply roll and inner liner
roll as per requirement
Check the inner liner, squeezee and shoulder strip Load the cut ply roll and
width as per requirement inner liner roll at let-off unit
Steps of Band Building
Ensure the cut ply width and angle as per
Ensure Fabric Thread ID requirement
Ensure the canvass perimeter as per specification Select the canvass as per specification.
Steps of Band Building
Apply the second and third ply over the 1st ply and
stitch the band
Apply the rubber roller stitcher to bleed out the air
and to ensure the appropriate stitching
Check the band for any visual defects Ensure the ply to ply step off as per specification
Steps of Band Building
Store bands in appropriate trolley and ensure the appropriate storage
Measure the total width of the band
Identify the band properly with code identification and centre line marking
TIRE BUILDING PROCESS
Tire building is the process of assembling all the
individual components of the tire to produce green
tire.
It is the section where different components of the
tire such as bead, plies, tread, sidewall etc are
assembled together to form the green tire .
Tire building is said to be the heart of tire
manufacturing process.
Type of tire building machines for OHT
Tire building
machine
Bias Radial
Band and Ply
method with Band method Two stage Uni stage
servicers
Attached Strip Separate strip
Tool turn up Bladder turn up
winding system winding System
Single B&T
Drum
Multiple B&T
Station
Types of tire Strip winding machines for OHT
Strip winder
Bias (without Radial (with
servicer) belt servicers)
Hot strip Cold strip Hot strip Cold strip
winding winding winding winding
system system system system
Flange type Spin Drum
Multiple
Dual stations
stations
Yantai TBM are Equipped with following parts
1.Drum
2.Triaxial back stitcher
3.Under stitcher
4.Ply cuff and BPR both side
5.Panel board with HMI display
6.Electrical and Pneumatic controls
7.Ply servicer (shuttle or single station tray servicer or turret
servicer.
8. Tread servicer (optional)
9. Breaker and chafer stand.
10.Guide lights
11.Foot pedals
The process
Tire building is the process of assembling various components on collapsible cylindrical drum
The performance of tires depend on the perfection of assembling process.
Perfection Factors
1.Centering of components
2.No air trap
3.No contamination
4.No wrinkles
Important quality parameters
Centering of components
Machine setting for tool positions and tool movement
Stitching pressure
Bead tool difference
Turret tension of liners (line tension in tray type)
Drum lateral and radial run out
Bead placing square and concentricity
Tyre curing press diagram
Tyre curing press diagram
Types of curing-based on internal heating
Conventional curing:
In case of conventional curing, high-pressure steam , hot water and cold water is used. In
conventional curing first HPS is supplied to get the maximum heat input. Then HW supplied to get the
best consolidation of the materials. Cooling will be done with circulating cold water
All steam cure:
In case of all steam cure high-pressure steam, Medium pressure steam and vacuum is used.
Hot water cure:
In case of hot water cure high-pressure hot water will be circulated.
Types of curing-based on external heating
Dome type:
Mould is fixed inside the shell and directly heated by steam. This is called as dome. The heat transfer in this case is good. Dome is well
insulated. This press is used for large size tyre for better heat transfer
Platen type:
Platens are kept continuously heated by circulating high-pressure steam through channel. Mold is fixed on platen and indirectly heated
so heat transfer takes place. It is used for passenger and light truck sizes tyre.
Bladder assembly
Tyre PCI operation
Tyre Curing PCI Treatment :
Tyre curing is the process of moulding
and vulcanization of green tires where
the tire gets its final shape as per the
mould design.
The raw green tire is converted to its
final shape and get vulcanized in to
elastic composite in presence of high
pressure and temperature and all
assembled components gets integrated
to form a high performance product
called tire.
FID-INSPECTION CURED TIRES
Content
• Tire trimming
• On line inspection
• Second line inspection
• Tire appearance
• OTR Tires awling process
• Repair Standard
• X-Ray Inspection & Quality parameters check
• Run out Testing
• PDI Inspection & Dispatch tires
FID-INSPECTION PROCESS
X-ray Inspection Run out
Tire Repair
Repair Tires
OK TIRES
As per SOP Send tires
Steel belted +Sample tires
Curing 1st Inspection 2nd Inspection Stocking Dispatch
OK OK OK
Tire
Trimming
Repair Tires
Major defect Tires
Major defect Tires
OK TIRES
Scrap
NCMR AREA Tires
Classification Area
FID INSPECTION
FID INSPECTION :
Defect code and Photo
Defect code and Photo
Defect code and Photo
Defect code and Photo
FID INSPECTION
Reaction Mechanism:
1-After inspection, if found any types of defects/abnormality inside and outside of the cured tyres, mark that
portion by colour crayon/chalk with defect code and kept separately as per defined area.
2-No good tires to be send to repair/classification area for further action.
3-Major defective repairable tyres send to Repair station and Scrap tyres send to NCMR area.
4-Isolate The nonconforming material and Place in NCMR area.
5-Raise defect alert for common defects more than 3 in no's (Same size & Same defect).
6-Inform Shift Quality In charge for immediate corrective actions .If problem persists and not solved, Informed
shift manager & Plant quality manager for next course of action.
CURE TIRE AWLING
Fid Cure Tire Awling:
1-All OTR Tires Location to be awled is identified with small oval marking at bead , Tread and shoulder area.
2- As per the Size wise Specification pick up the correct Gun, Dip into the Respective Paint and do awling on the era marked
location on tire.
3-Tolerance for needle length is ±2 mm.
Identification of Gun and Needle by Color Marking
CURE TIRE AWLING
Photographs of Stopper Provision over the Needle Location of Awling
Awling at shoulder area:
Awling to be performed at shoulder region as shown in the
photobelow.
Awling at Bead
Awling to be performed at bead region as shown in the photo
area:
below
X-Ray Inspection &Quality Check Parameter
X-Ray inspection:
All TBR and R-OTR tires have to undergo X-Ray inspection
X-Ray inspection is done for tires with All steel/Steel belted
tires to check placement of steel belts, spacing of body
plies/belts and any other abnormality as per the test
standards. If the tire is not as per the specified standards,
such tires are held and sent to classification area for further
disposal.
Important Quality Check parameters:
1-All tires tested for X-Ray should have inspector stamp.
2-Held up tires details are recorded in held register for further
reference & records.
3-Defective tires are sent to classification area to avoid mix up
with OK tires.
Run out testing & Quality Check Parameter
Run out testing:
Run out test is done for all TBR & specified Farm tires to check
the tires for Radial Run out and Lateral Run out test to ensure
that tire run out valves are within the specified limits for the
tested size tire.
Excessive run out can cause wobbling of tires when fitted on to
the vehicle which causes riding comforts of the vehicle.
Important Quality Check parameters:
1-All tires tested for Run out should have inspector stamp.
2-Held up tires details are recorded in held register for further
reference & records.
3-Defective tires are sent to classification area to avoid mix up
with OK tires.
Warehousing of tires PDI Inspection Dispatch of tires
Warehousing of tires:
All OK tires after primary & secondary inspections are
transferred to FGS and stored in racks size wise to ensure that
FIFO is followed during dispatch of tires.
PDI Inspection:
PDI inspection of tires is done just before the dispatch tires as
per dispatch plan by inspecting the tires as per inspection plan
to ensure that tires are clean and free from any visual defects
and PDI report is prepared and given FGS personnel to send
along with the inspected lot for dispatching to the customers.
PDI inspection
Dispatch of tires:
After the tires are cleared from QA the inspected lot along with
PDI report is dispatched in specified containers by loading tires
as per specified pattern to avoid any damage during transit.
Thankyou
