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    Tyre Manufacturing

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    Prashantha Nandavar
    This document provides an overview of the tyre manufacturing process at General Tyre Pakistan. It discusses the major steps which include: 1) Mixing the raw materials like rubber, fillers, chemicals and reinforcements in mixing mills and kneaders. 2) Shaping the rubber compound through extrusion and calendaring processes to form treads and sidewalls. 3) Assembling the tyre components on a tyre assembly machine which includes building the carcass, mounting beads, sidewalls, steel belts and tread. 4) Curing the assembled "green tyre" in a press/mould under heat and pressure in a process called vulcanization.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Tyre Manufacturing

    Uploaded by

    Prashantha Nandavar
    836 views34 pages
    This document provides an overview of the tyre manufacturing process at General Tyre Pakistan. It discusses the major steps which include: 1) Mixing the raw materials like rubber, fillers, chemicals and reinforcements in mixing mills and kneaders. 2) Shaping the rubber compound through extrusion and calendaring processes to form treads and sidewalls. 3) Assembling the tyre components on a tyre assembly machine which includes building the carcass, mounting beads, sidewalls, steel belts and tread. 4) Curing the assembled "green tyre" in a press/mould under heat and pressure in a process called vulcanization.

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    45144436-Tyre-Manufacturing.ppt

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    This document provides an overview of the tyre manufacturing process at General Tyre Pakistan. It discusses the major steps which include: 1) Mixing the raw materials like rubber, fillers, chemicals and reinforcements in mixing mills and kneaders. 2) Shaping the rubber compound through extrusion and calendaring processes to form treads and sidewalls. 3) Assembling the tyre components on a tyre assembly machine which includes building the carcass, mounting beads, sidewalls, steel belts and tread. 4) Curing the assembled "green tyre" in a press/mould under heat and pressure in a process called vulcanization.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    836 views34 pages

    Tyre Manufacturing

    Uploaded by

    Prashantha Nandavar
    This document provides an overview of the tyre manufacturing process at General Tyre Pakistan. It discusses the major steps which include: 1) Mixing the raw materials like rubber, fillers, chemicals and reinforcements in mixing mills and kneaders. 2) Shaping the rubber compound through extrusion and calendaring processes to form treads and sidewalls. 3) Assembling the tyre components on a tyre assembly machine which includes building the carcass, mounting beads, sidewalls, steel belts and tread. 4) Curing the assembled "green tyre" in a press/mould under heat and pressure in a process called vulcanization.

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    You are on page 1of 34

    Industrial training at General

    Tyre Pakistan

    Presented by
    Muhammad Saad Qureshi
    H0401063

    Basic Overview of a Tyre


    Industry

    The major steps in tyre manufacturing

    Ingredients
    Rubber
    (Natural
    And
    synthetic)
    Miscellaneous

    Fillers
    (Carbon black
    , silica,
    carbon
    chalk)

    Ingredients
    Antioxidants
    And
    Ozonants

    Chemicals for
    vulcanization

    Plasticizers
    (oils and
    resins)

    Reinforcing
    materials
    (steel,
    rayon, nylon

    Raw Materials
    1- RUBBERS:

    1.1- Natural Rubber ,


    1.2- Technically Specified Natural Rubber (TSNR),
    1.3- Synthetic Rubbers,

    2- FILLERS:

    2.1-Inert Fillers, (soft clays, & calcium carbonate)


    2.2-Reinforcing Fillers, ( Carbon blacks, hydrated Silica, Hard clays)

    3- AGE RESISTORS (Anti-oxidants & Antiozonants):

    4- WAXES

    5- PROCESSING AIDS, PLASTICIZERS, SOFTENERS,TACKIFIERS


    (Petroleum oils, vegetable oils, and synthetic plasticizers)

    6- VULCANIZING AGENTS. (sulphur )

    7-ACCELERATORS

    Raw Material

    7- ACTIVATORS:

    7.1- Zinc Oxide:


    7.2- Stearic acid

    8- RETARDERS:

    9-TEXTILE AND METALS

    Steel
    Cotton
    Rayon
    Nylon
    Polyester
    Fiberglass
    Aramid

    Mixing

    Open Mills

    Kneader

    Banbury

    Mixing Mills

    Kneader

    MIXING

    Extrusion

    Hot Extrusion
    - elevated temperature,
    make it easier
    to push the
    material through.

    Cold Extrusion
    -lack of oxidation,
    -higher strength,
    -closer tolerances,
    -good surface finish.

    Extrusion - Preparation of Treads


    and Sidewalls

    Calendering
    MACHINE

    PARTS

    Warm up Mills
    Stands
    Splicers
    Tensioning unit
    Temperature Unit
    Knives
    Beta gauge
    Wind up units

    Textile Calendering

    OPERATIONS
    Sheeting:
    Frictioning
    Coating
    Profiling
    Embossing

    Calendering Operation

    Steel Calendering

    Tyre Assembly Machine

    Carcass Building
    Bead wires are set at the applicators.
    Bead joint has to be in the right place
    to avoid tyre imbalance

    Inner liner is set at the drum and


    rotated around the drum at one turn.
    The joint is cut with a hot knife. Inner
    liner is set end to end so that the
    diagonal cutting seam is at the top.
    The ends are joined manually.

    Body Ply: Mounting


    Cord ply ends are set at the drum
    and rotated around the drum at
    one turn. The cord is cut by hand
    with a join of 2-5 overlapping
    wires. The join is pressed carefully
    together at the edges.

    Bead Wire Mounting and Turn-Up

    Bead wire mounting


    and turn-up is done
    automatically. Bead
    wire applicators bring
    the beads to the
    carcass. Edges are
    turned up with
    bladders over the
    beads and stitched
    tightly.

    Sidewall Mounting and Joining


    Sidewall ends are set
    at the drum and
    rotated around the
    drum at one turn.
    Sidewall is set end to
    end and the seam is
    fastened together
    manually.

    Steel belt tables go


    down on the drum
    automatically. Steel
    belt is joined by cutting
    it with a hot knife and
    setting the ends
    together.

    Cap Ply: Mounting and Joining


    The ends of the nylon
    cap ply, is set at the
    drum in the middle of
    the steel belts. Bandage
    is wound on top of the
    steel belts 1-2 times.
    The bandage is cut with
    scissors

    Tread Mounting
    Tread is pulled onto the drum
    automatically. Tread is set end to
    end and joined automatically.

    First and Second Stage Coupling


    Carcass (1st stage) and tread
    (2nd stage) packages are joined
    automatically. The carcass is set
    at the flanges of the carcass
    drum, pressurised, fastened to
    the tread package and stitched
    together.

    Green Tyre
    After building the green tyre it is
    transferred to the painting machine,
    where anti-blemish chemicals are
    applied.

    Curing Press / Mould

    VULCANIZATION

    MATERIAL TESTING
    TENSILE

    TESTER
    MOONEY VISCOSITY
    RHEOMETRY
    DENSITY TESTER
    HARDNESS TESTER
    ABRASION TEST
    MISCELLANEOUS

    TYRE CONSTRUCTION(RADIAL)

    TYRE CONSTUCTION(BIAS)

    CROSS SECTION
    TERMINOLOGY

    TREAD PATTERNS
    Rib shape Advantages: lower rolling resistance,
    good directional stability low levels of heat and
    generation
    Asymmetric pattern good for high speed cornering

    Block-shape good steering control and stability

    Directional pattern good driving force and braking


    performance
    Rib-Lug shape directional control ,good
    braking and driving power

    TYRE TESTINGS
    Endurance

    Tyre Testing Machines


    Force and Moment Tyre Testing Machines
    Tire Noise Testers
    Tire Stiffness Testers, UTTM
    Plunger Energy Tester
    Tire Uniformity Machines
    Tire X-ray machines

    Pully Wheel

    THANK YOU

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