11/18/2010

TYRE & TUBE MANUFACTURING

LEADING MANUFACTURERS

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TYRES
INTRODUCTION:

Tyres are ring-

ring-shaped parts, either pneumatic or solid that fit
around wheels to protect them and enhance their function.

Used almost in all road using vehicles like bicycles , motor

cycles , cars , trucks , heavy engineering and heavy duty
vehicles , agricultural vehicles , aircrafts.

Components of tyre

Tread

Wear bar

Bead

chafer

Sidewall

Inner liner

Belt package

Body ply

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Brief explanations of tyre components

Tread-
Tread- thick rubber, or rubber/composite compound
provides an appropriate level of traction for vehicle. It
has grooves , voids ,lugs , sipes.

Bead – rubber reinforced with steel wire to ensure that

tyre does not shift circumferentially as the wheel rotates.

Sidewall - reinforced with rubber and fabric plies ,that

transmits the torque applied by the drive axle to the tread
in order to create traction. It gives flexibility .

Continues…..

Belts - calendered sheets consisting of a layer of
rubber, a layer of closely-spaced steel cords which give
the tyre strength and dent resistance.

Body ply -calendered sheet consisting of one layer of
rubber, one layer of reinforcing fabric includes
rayon,nylon highly flexible but relatively inelastic.

Wear bars -( wear indicators) raised features located
at the bottom of the tread grooves that indicate the
tyre has reached its wear limit.

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Classification of tyres

Based on tube :
Based on construction:
• Tube tyre
Bias
• Tubeless
Belted bias

Radial

Solid

Semi-pneumatic

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Classification of tyres

Based on meteoroliogical
Based on geographical
conditions: conditions:
• summer • Terrain.
• Winter • Muddy
• all-weather • snowy
• Wet weather

Materials in tyre making

Natural rubber or Polyisoprene - the basic elastomer of tyre
making .

Styrene-
Styrene-butadiene co-polymer (SBR) is a synthetic rubber.

Halobutyl rubber is used for the tubeless inner liner
compounds, because of its low air permeability.

Carbon black gives reinforcement and abrasion resistance.

Sulphur cross-links the rubber molecules in the vulcanization
process .

Antioxidants and Antiozonants for preventing from
sunlight effect.

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Compound manufacturing
(mixing and compounding)
Component preparation
1.Extrusion
2. Calendering.
3. Bead building.

Tyre building

Curing or vulcanisation

Finishing & testing

1.compound manufacturing

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2.Component preparation
EXRTUSION:

CALENDERING

steel calendering

Textile calendering.
calendering machine has
wire room that houses
hundreds of fabric or wire
spools that are fed into the
calender to produce body
plies and belts .

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BEAD BUILDING

3. Tyre building

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4.Curing or vulcanisation

Process of applying heat(for chemical reaction of rubber with
other components) and pressure(for shaping) .

Tyre kept in lower mould seat a bladder is inflated and kept
inside the mould.

Pressure in increased such that sidewall lettering and tread
pattern is engraved.

Heating medium may be steam , hot water , inert gas .

Temperature : 150 °c – 350°c

Pressure : 350psiaax

Curing time : 9-15 minutes (but for large off road tyres -24hrs)

Vulcanisation - chemical process

Process invented by Charles Goodyear in 1839.

Natural rubber (chemical name polyisoprene) consists of long
hydrocarbon chains

mixing molecular sulphur and heating the mixture, sulphur cross-
links are formed between the rubber molecules gives it the qualities
of strength and elasticity

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Only during vulcanisation process ,tyre

,tyre is converted
from plastic to elastic condition .

TTwo generic curing press types:

types
1.Mechanical
2.Hydraulic.

TTwo generic mold types :

1.Two piece molds and
2.Segmental molds

Moulds

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5. Finishing &testing

TYRE UNIFORMITY TEST : tyre mounted on wheel
halves, inflated, run against a simulated road surface, and
measured for force variation.

TYRE BALANCE TEST : tyre mounted on wheel halves
rotated at high speeds and unbalance checked.

X RAY INSPECTION:
INSPECTION x-rays used to analyse steel chord
structure.

VISUAL INSPECTION:
INSPECTION: visual defects such as incomplete
mold fill, exposed cords, blisters, blemishes, identified if
found.

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Wear in tyres
Shoulder wear Under inflation , improper
matching of rims .

Centre wear over inflation ,

Diagonal wear Faulty suspension , dynamic

imbalance

Spot wear sudden braking ,over inflation .

Aquaplaning / hydroplaning

As the tyre spins, the tread blocks force water into the sipes
and grooves and those channel water out.

But when tread wears down, the depth of the grooves and
sipes gets less , the tread will get down to a point where all
but the lightest of showers will turn any road into a skating .
This is called aquaplaning.

Braking, Accelerating and Steering have no effect because the
tyre is actually making no contact with the road surface .

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Tubes

Tube is present in all tube tyres

It is held between rim and tyre .

Pressure is maintained by inflating it with air through a non
return valve.

Advanced types of tubes are less prone puncture due to self
sealing constructions .

Construction sequence of tube is similar ti yre

Raw material used is butyl rubber instead of natural rubber
for its properties .

Tube manufacturing
Sequence:
Sequence:
• Rubber stock is
milled
thoroughly in Extruder
warm mills. machine • Cut into lengths.
• Extrusion • Stored in required
• Comes out as designs
endless sleeves .
•e Shearing
Warm mills
machine

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fitting
• Ends of tubes
are joined • Put in forming
together. • Valve fiitment ring
according to • Inflated to
splicing their sizes mould shape .
machine curing

Inspection for Polishing

defects using Packing
chemicals

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Process sequence 2. Inner liner mounting

1.Carcass mounting.

3.Ply mounting

4 .Beed wire mounting and 5 .sidewall mounting

turn up. .

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6.Tread package 7 .Tread mounting

8 .First & second phase 9 .Final green tyre

assembly

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Thank you

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