SYLLABUS

FOR
DIPLOMA COURSE (NEW)
OF
INDIAN RUBBER INSTITUTE

DIRI (New)

NO OF PAPERS : 4 (Each Paper has Two Parts)

MARKS IN EACH PAPER : 100

PAPER I : POLYMER SCIENCE

Part “A” POLYMER CHEMISTRY
Part “B” POLYMER PHYSICS

PAPER II : RUBBER PROCESSING TECHNOLOGY AND

PROCESS ENGINEERING
Part “A” RUBBER PROCESSING TECHNOLOGY
Part “B” PROCESS ENGINEERING

PAPER III : RUBBER MATERIALS, RUBBER COMPOUNDING

& REINFORCEMENT
Part “A” RUBBER MATERIALS
Part “B” RUBBER COMPOUNDING &
REINFORCEMENT

PAPER IV : RUBBER PRODUCTS MANUFACTURING

AND THEIR EVALUATION
Part “A” RUBBER PRODUCT MANUFACTURING
Part “B” RUBBER PRODUCT EVALUATION
 PAPER I DIRI (NEW)

POLYMER SCIENCE

This Paper consists of two parts – Part A : Polymer Chemistry and Part B :
Polymer Physics. Out of total five numbers of questions to be answered at least
three numbers must be from either Part.

The student will be required to :

(a) be familiar with Raw Materials and sources of Monomers
(b) have understanding on Structure – Property relationship
(c) have basic concept on Polymerisation – Method & Techniques
(d) be aware about properties of Polymers and Physics of Vulcanised Rubber
(e) have ability to use mathematics as a tool for solving problems related to
molecular weight of Polymers, shape factor etc.

PART “A” POLYMER CHEMISTRY

1. Raw materials
Concept of the basic starting materials of synthetic polymers, viz. petroleum and
natural gas;
Monomers – their characteristics, functionality and types; Natural polymers and
their derivatives.

2, Structure-Property Relationship
Size and shape of molecules. Concept of Polymers, macromolecules and
elastomers.
Classification of polymers – linear, branched, graft, crosslinked, thermosets and
thermoplastics, homo -, hetero -, co - & ter- polymers.
relation between rubbers, plastics & fibres interpreted in terms of bond strengths, .
Awareness on Configuration of polymers – isomerism and tacticity in polymers
and their effect on polymer properties.
Basic concept of Crystallinity in polymers; factors affecting crystalisability of
polymers; effect of
Crystallinity on polymer properties
Glass transition temperature – factors affecting tg; significance of tg in polymer
properties and processing.

3. Polymerisation – degree of polymerization, development of the ideas of

molecular mass averages, molecular weight distribution and their relevance to
mechanical properties and flow behaviour.
Polymerisation – basic types and criteria for polymerization – chain
and step growth (addition and condensation)
Concept of Free Radical, Ionic, Coordination polymerization;
types of monomers that can be polymerized through different mechanisms.
 -2-

Importance and significance of stereo-regular polymers & their practical

Importance and example
Ring opening polymerization and its practical importance & example .
Principles of polymerization techniques – mass, suspension, emulsion and
solution ; their suitability for producing important commercial
polymers
.

PART “B” POLYMER PHYSICS

1. Rubber Physics Basic principles involved on the origin of rubber like behaviour
and rubber Elasticity
Concept of viscoelasticity and fundamentals of rheology – ideal elastic response,
pure viscose flow, factors affecting flow behaviour – effect of temperature &
shear rate; application of the concept of viscoelasticity in rubber processing
such as calendar nip swell & extension die swell.
SI unit – fundamental & derived units; dimensional analysis as applicable to
Rubber science.
Stress/strain behaviour of rubber as compared to plastics, fibres and metals

1. Rubber Engineering
Poisson’s ratio, stored energy and energy loss – hysteresis and its
significance. Behaviour of rubber under stress – in tension, compression, shear
and torsion, concept of Shape Factor and its significance. Load-deflection
Fundamentals of the design principles involved in products like
Bridge Bearings, Suspension units Stress relaxation and Creep & their
significance.
 PAPER II (DIRI-NEW)

RUBBER PROCESSING TECHNOLOGY AND PROCESS ENGINEERING

This Paper consists of two parts – Part A Rubber Processing Technology and Part B
Engineering. Out of total five numbers of questions to be answered, maximum three
numbers from each Part are to be answered.

The student will be required to :

(a) Have understanding of the principles of the basic processing operations and
processability;
(b) be familiar with the features of design and construction f machinery used, including
ancillary equipment (e.g. feed and take-off systems, drive systems, temperature and
pressure measuring devices);
(c) be aware of the safe working practices;
(d) have ability to use mathematics as a tool for solving problems relating to hydraulic
presses, heating system, mixing batch weight, calendar coating weight, extrusion
die swell and Rheographs.

PART “A” RUBBER PROCESSING TECHNOLOGY

1. Storage and handling of materials

Storage life, FIFO, handling and weighing/batching systems

2. Processing and Processability

Review of methods of determining the processability of a rubber mix, using
Mooney Viscometer, Rapid Plastimeter, Rheometer and their application in process
control including description of such equipments

3. (i) Mixing
Principles of Mixing; distributive & dispersive mixing.

Description construction and comparision of mixers and compounding equipment --

open mills and internal mixers; mixing energy; mixer geometry and practical
mixing techniques including sequence of mixing and evaluation of quality of
mixing (e.g. specific gravity and rheograph; trouble shooting of mixing operation;.
post-mixing operations, handling and storage.

(ii) Latex – Dispersions and Emulsions – their preparation and use of surface active
agents in latex compounds, simple latex mix design and latex mixing equipments
 -2-
4. Extrusion

Basic principles involved; types of Extruders – Ram & Screw & their comparison.
Variations of rubber extruders viz hot feed, cold feed, pin barrel,. vaccum and their
comparison, screw design and fee arrangements, extruder head construction –
straight head & cross-head; temperature control unit. Die and Die-swell; Function
and layout of ancillary equipment for standard extrusion operations; trouble
shooting of extruder operation.

5. Calendering

Construction, types and function of calendaring machine; calendaring processes; –

fractioning, skim coating & sheeting; Roll floating, roll binding and calendar gauze
control devices; Function and layout of ancilliary equipment for standard
calendaring operation. Trouble shooting of calendaring operation. Other methods
of textile coating viz. spreading, dipping – their usefulness, limitation and
comparison.

6. Moulding

Description and construction of equipment used in Compression moulding, Transfer

moulding, and injection moulding – their comparison.Mould shrinkage; Trouble
Shooting of moulding operations.

Hydraulic systems used in moulding presses; Single daylight and multidaylight

presses, vaccum system in presses.

General features of mould design, (a) single impression, and (b) multiple
impression and construction of a mould, mould clamping and loading and opening
arrangements, mould cleaning mould lubricant. Methods of blank preparation,
Various Trimming and Finishing methods.

7. Continous Vulcanisation methods.

General description of methods currently used in industrial practices such as

rotocure, fluidized bed, electron beam and continuous vulcanization by RF, LCM
and Hot air, IR and their comparison.

PART “B” PROCESS ENGINEERING

1. Safety

Human aspect and Machine aspects – safety methods used in bale cutting, mixing
extrusion, calendaring, moulding presses and in autoclaVes.
 3

2. Mechanics

Work, Power, Energy, Torque, concept of efficiency.

3. Power Transmission

Principles and operational requirement of Flat Belt, V-belt, Toothed Belt & Chain
drives. Main types of gears – spur, helical & worm. Comparison of the different
forms of power transmission in term of efficiency and limit of application; safety
requirement of drive systems.

Selection of drive systems for a roll mill, extruder, moulding press, internal mixer, a
calendar and haul-off system.

4. Hydraulics

Major features of pumps including positive and non-positive displacement pumps,

fixed and variable displacement pumps – gear, vane & piston pumps; hydraulic
accumulator.

Pressure control valves including simple relief valves, pressure reducing valves,
unloading valves, flow control valves and direction al valves.

Hydraulic circuit for up-stroking compression moulding presses and for a simple
screw-ram injection moulding machine with description of functions of
components.

5. Heating systems used in rubber industry – steam boiler and their basic types;
dryness factor of steam, steam line and steam traps – their functions and basic
types and suitability; thermic fluid heaters and thermic fluid line; hot air
generators and their applications; infra red heating, microwave heating and their
applications and suitability.

6. Instruments used for measurement and control of temperature and pressure;

thermometers, pyrometers, PD & PID controller, pressure gauges and transducers
with reference to their application in rubber processing machineries.
 PAPER - III DIRI NEW

RUBBER MATERIALS, RUBBER COMPOUNDING & REINFORCEMENT

This paper consists of two parts : Part A Rubber Product Manufacturing and Part B
Rubber Product Evaluation. Out of total five number of questions to be answered, at least
two numbers are requirement to be answered from each Part

The students will be required to :

(a) Be familiar with different raw materials

(b) Understanding on the principle of compounding and functions of different
materials, accelerators, fillers, cross linking agents and other rubber chemicals
(c) Be aware of basic knowledge of specification, standards and testing of different
raw materials and their significance in rubber industry.
(d) Have ability to use mathematics as a tool for solving problems related to specific
Gravity, volume, percentage calculation of different materials (polymer, volatile,
Carbon black and ash) in a finished compound and costing.

PART “A” RUBBER MATERIALS

1. Natural Rubber -- source, production systems for sheet and block rubber, gradation
system, processing characteristics & curing systems.

2. Latex --- NR latex types and grades; preservation, concentration , stability,

gellation, coacervation,; .

3. Synthetic Rubbers such as SBR, PBR, NBR, CR, IIR, EPDM --

their grades, comparative properties and applications inlcluding high
performance synthetic rubbers such as FKM, ACM, ECO, CSPE,
Silicone, Polysulphide & XIIR

4. Polymer Blends --- their importance and applications, concept of miscibility/

compatibility; useful blends – rubber-plastic, rubber-rubber e.g. NBR/PVC blends,
NR/SBR, NR/PBR etc.
5 Thermoplastic Rubber (TPR) and Thermoplastic Elastomers (TPE) - their concept
and applications of SBS and EVA.

PART “B” RUBBER COMPOUNDING & REINFORCEMENT

6. Principles of compounding, Compounding Ingredients and Mix Design to meet

processing and vulcanisate properties
 2.

a. Functions and uses of accelerators, setarders, peptisers, tackifiers, process

aids, activators, softeners, extenders, reclaimed rubbers, crumb rubbers,
mineral rubbers, rubber substitute (factice), pigments, blowing agents.

b. Fillers --- reinforcing, semi – reinforcing and extending fillers, non-black

and black fillers – their grades and classification and usage..

c. Curing Systems -- conventional, semi – EV and EV systems,

classification of accelerators, provide, metal oxide and resin curing systems
and their applications. Principles of Mix Design and selection and application
of polymers such as NR, SBR, PBR, NBR CR and IIR with suspect to ageing
and weathering, heat resistance, oil and solvent resistance, abrasion
resistance, resilience, hysteresis , heat build-up ozone resistance, low
compression set, high tensile strength, low/high hardness and modulus, flex
cracking resistance, flame resistance, low temperature flexibility, electrical
insulation, conducting and antistatic properties --- cost efficiency.

6. d. Concept of waste as generated during different processing stages and avenue for
their re-use and cost optimization.

7. Textiles -- definition of fibres, yarn, cord, twist, count, denier, tex, types of textile
weaves and their application in different rubber products; structure and
comparative properties of cotton, rayon, polyamide, polyester, aramid,
glass and steel wire and their applications in rubber products. Textile
to rubber bonding systems – Dry and RFL.

8. Specification, Standards and Testing of Raw Materials.

Plasticity and Viscosity Test of dry rubbers and latices; sieve residue test, heat loss,
ash content acetone extract test for dry rubbers; their significance; total solids, dry
rubber content, pH, VFA content, KoH member, mechanical and chemical stability
test for latex and their significance; sieve residue test, Specific Gravity, bulk
density, heat loss, ash content, pH of water extract, aniline point, melting
point/softening point test for compounding ingredients and their significance.

9. Storage, Handling and Hazardous nature of compounding materials, oils and

solvents and safety measures involved; concept of eco-friendliness
 PAPER - IV DIRI NEW

RUBBER PRODUCT MANUFACTURING AND THEIR ELALUATION

This Paper consists of two parts ; Part A Rubber Product Manufacturing and Part B
Rubber Product Evaluation. Out of total five number of questions to be answered , atleast
two numbers are required to be answered from each Part

The students will be required to :

(a) have knowledge about manufacturing outline of major rubber products involving
the material, components, their functions, building and curing.
(b) be familiar on design construction and comparative advantages/disadvantages.
© be familiar with MIX design.
(e) have ability to use mathematics as a tool to solve problems related to design
parameter on products like Hose, expansion/shrinkage in cellular products etc.

PART A RUBBER PRODUCT MANUFACTURING

1 : Tyres and Tubes –cycle tyres, passeneger car tyres and truck tyres; tyre sizing and
marking; different types of tyre constructions – bias, radial & tubeless tyres – their
basic features and characteristics; different components of tyres and their
functioning; selection criteria of different reinforcement materials; method of tyre
building &
curing; post curing treatments.

2. Industrial Rubber Products

: (a) Belting – Conveyor, Transmission, V-Belt & Timing Belt – types,
grades functions, construction, selection of materials, mix design,
building and curing.
(b) Hose -- Types and grades; construction – hand-made, circular woven,
braided and spiral; their advantages; disadvantage and applicability;
design features, neutral angle and bursting pressure calculation;
selection of reinforcing materials and mix design, production flow
chart and curing methods.
(c) Footwear -- Sole manufacturing – microcellular, Unit Sole and Resin
Rubber Sole; hand-built footwear & DVP/DIP.
(d) Cables -- Types/grades -- Construction, insulation and sheath,
materials selection, mix design, building and curing.

3. Latex Products : Dipped Goods – balloons, prophylatices and gloves; latex Thread
and Foam and Carpet Backing

4 : Miscellaneous Rubber Products :

(a) Coated Fabrics and calendered sheeting.

 2

(b) Moulded items like seals, gaskets, auto components etc.

(c) Rubber to Metal bonded components -- engine mounting, rubber roller.
(d) Extruded items like tubing, weather strip etc.
e) Adhesives -- solvent based and aqueous systems.

PART – ‘’B’ RUBBER PRODUCT EVALUATION

The student will be required to :

(a) be aware of Philosophy of Testing.
(b) be familiar with SPECN, STDS and Quality Management systems.
© have knowledge about the following test methods and their application in the
rubber products covered in Part ‘A’ above.
© have ability to use mathematics as a tool to solve problems related to testing such
as tensile strength, resilience, resistivity, swelling etc.

1. Philosophy of testing : Standard test methods; limitation of test data, precision,

accuracy and validity of test methods. Quality Assurance a elements of statistical
quality control – mean, average, medium, variance, standard deviation .

2. Specification and standardization. Awareness about BIS and ISO standards on

rubber, rubber chemicals and rubber based products.

3. Testing methods and their significance with respect to product performance,

Stress/Strain properties : Tensile strength, Elongation, Modulus, Hardness,
Compression set under constant stress/strain – original and after accelerated ageing
conditions.
(a) Effect of environment and ageing of rubbers; swelling tests, oxidative and
thermal ageing, ozone cracking tests.
(b) Electrical properties of rubber; determination of resistivity and diaelectric
strength.
(c) Time dependent properties; determination of Creep and Stress relaxation;
determination of rebound resilience, effect of temperature on resilience,
determination of heat build-up by Goodrich flexometer, effect of temperature
frequency and amplitude of vibration on dynamic properties; forced and free
vibration machines, determination of loss modulus.
(d) Destructive tests -- Tens and Abrasion resistance tests; crack initiation and
crack growth by the De Mattia method and Ross Flexing machine, flexural
fatigue failure in rubber fabric composite.
(e) Adhesion/Bond testing -- peel test, Pull test and shear test -- their m
significance and limitations.
(f) Thermal Properties; Thermal Conductivity, Heat Diffusivity – their
importance and measurement.