Date – 29/07/2024

ON Job Training

Name : Dipak Sanjay Salunke

S.Y.M.Sc Industrial Polymer Chemistry
Industry Institute:K.D Joshi Rubber Industries Pvt Ltd
PRN No : 1132230906 1
2 ACKNOWLEDGMENT

I take this opportunity to express our profound gratitude and deep regards to
Mr.Milind Joshi (Director, K.D. Joshi Rubber Industries Pvt. Ltd., Pune) for their
exemplary guidance, monitoring and constant encouragement throughout the course
of this Training. A big thank you to Makarand Joshi and Mr.Ninad Joshi who has
been extremely helpful in suggesting worthwhile content and offering advice on
authoring and styling new techniques. I extend my sincere thanks to Dr.Vandana
Mooss mam for giving this opportunity.
 Sr No. Contents
INDEX Page No

3 1 Overview of the Company 3

2 Rubber Compounding 5-7

Mixing
3 Rubber Testing 8-23
a)Oscillating Disc Rheometer
b)Specific Gravity
c)Abrasion Testing Machine
d)Colorometry
e)Tensile Testing
f)Tear Test
g)Hardness Testing

4 Production 24-38
a)Calendaring
b)Extrusion
c)Injection Moulding
d)Compression Moulding

5 Projects
a)Injection moulding excess flash management
b)ODR Vs MDR Project
4 Overview Of The Company

 K.D.Joshi Rubber Industries Pvt Ltd is the outcome of the passion to meet the industries
needs for global quality products.visionary entrepreneur K.D.Joshi single - handedly setup
the business in the late 1960s.now involved into an ISO 9001:2015 Certified enterprise for
its proactive approach to customer concerns
 Efficiently managed by second generation enterpreneurs Milind K.Joshi and
Makarand K.Joshi ,the company is growing rapidly with bigger and bigger things on the
horizon over the years,the company has earned matchless credibility for manufacturing
rubber squeegees,rollers,industrial rubber products and wide ranging cast polyurethane
products.
5 Introduction To Rubber

 Rubber change their shape on applying force and regain their original shape on removal of
the applied,Hence the term elastomer can be interchanged with term ‘rubber ’.They
posseses property of elasticity.rubbers can be vulcanized into rubber products which show
good strength and can be elongated to a larger extent reversibly at a relatively low stress.
 Rubbers(both natural and synthetic) are used widely in the
industries such as for the manufacturing of tires,tubes,hoses,conveyor
belts,gloves,balloons,rubber bands,erasers,electrical insulations,and adhesives.
6 Rubber compounding

 Various rubber can be manufactured by adding additives and raw rubber materials .
 Additives like ,SABIC 756,DUTRAL 4437,RUBAID 1687,LOWLITTE 77,VAPROXAL
3F,VN3,IPOL,SILLICONE OIL,SSW BARYTE,CHINA CLAY,CISSAMER 1220,MGO
GAROLITE,DEOTACK 70 DL,PVI100,LUPEROX,TUBALL,JSR 230
SH,NITREX,ABL,GPF N660,AL-SILICATE,DOP(KANATOL 800) are used in rubber
compounding.
7 mixing

 With a proper formulation of rubbers additives are mixed in kneader

 mixing machine .followed by two steps :
 1:Adding raw rubber and good quality rubber (for good colour formation)also some
recycled rubber is used .
 2:The proper formulation of rubber is dropped into kneader for proper mixing and mixed
rubber is processed in open roll mill.
8

OPEN ROLL KNEADER

MACHINE MACHINE
9 Rubber testing
with a wide variety of equipment in the laboratory can test measure the rubber properties .

 1:Oscillating Disc Rheometer (ASTM2084)

 Determination of vulcanization characteristics of rubber compounds,including the scorch
time ,ts2(the time a compound has to take the shape of the mould),tc90,Minimal and
Maximum Torque and Delta S.
 These all properties are determined by oscillating disc rheometer.it determines
the length of time a particular product needs to be vulcanized.
Oscillating Disc Rheometer : Rheometric curve is a graph of the torque against the actual cure time.

10Disc
Oscillating
Typical Rheometric Curve

The parameters are essential for rubber producers and formulators,as they show the processability and property
values (crosslink density,thermoplasticity and modulus)of the final product.
11

Rheochart of NB175 Rubber

 Derived values
12

 Rheometric curves are divided into three phases:

 :
A) Phase 1 Provides the information of the processing nature of the rubber compound.
 B) Phase 2: Depicts the curing characteristics of the rubber compound.
 C) Phase-3: Provides the knowledge of the physical properties/ property values of the
rubber compound.
 In the rheometric curve, the following values are obtained:
 ➤ Torque Values
 "Torque" in rheometry can be defined as the torque generated by the resistance of the
material to the shearing action of the rotor in the orifice.
 MI (Initial Torque): Torque recorded at the beginning of the test.
ML (Minimum Torque): The lowest value of torque recorded.
: MH (Maximum torque) : The highest value of torque recorded.
13 Time Values :

Scorch time (ts2): After achieving minimum torque, in cure phase, scorch time (ts2) is recorded as
the torque rises two units above ML

"Scorch" is a premature vulcanization in which the compound is partially vulcanized before the product is
in its final form and is ready for vulcanization.

Optimum cure time (tc90): The time required for 90% rubber compound to cure.

Derived Values:
From MI,ML, MH,tc90 and ts2 Following are derived.
14

Oscillating Disc Rheometer Machine

Cure rate index CR: It denotes the time required for complete curing process. Cure Rate Index is an
important vulcanization parameter.
CR =100/(tc 90-ts2)
Thermoplasticity: Tp = (MH - ML)
Thermoplasticity is the difference between initial viscosity and the minimum viscosity.
Crosslink Density (MH-ML): The cross-link density is defined by the density of chains or segments that
connect two infinite parts of the polymer network. rather than the density of cross-link junctures.
 Specific Gravity
15

 Specific gravity is the ratio of mass of a unit volume of composite to mass of a unit volume of water
(Density with respect to water). Specific gravity analysis is done by the hydrostatic weighing method as per
ASTM standard D 297.
 Specific gravity = a / |(a + w) - b|
 a = of specimen in air.
 b = mass of specimen and sinker (if used) in water.
 W = of totally immersed sinker if used and partially immersed wire.
 Density (kg/m³) (specific gravity) x (997.6)
 Specific gravity and density are highly relevant in the rubber industry because rubber is sold on a cost per
pound/kg basis and a lower density or specific gravity means more material per pound/kg or varied part
weight.
16

Specific Gravity Balance

 Abrasion Resistance Testing
17

 The test method for abrasion (ISO 4649/DIN 53516) is actually quite simple. Abrasion resistance is
measured by moving a test piece of rubber across the surface of an abrasive sheet mounted on a
revolving drum. It is expressed as volume loss in cubic milli meter, for instance. 50 mm².
 colorimetry
18

COLORIMETER
 Portable Spectrophotometer is powerful performance configuration device which makes color
measurement more professional. Offers integrated camera to see the measurement area for accurate
test. It features full spectrum LED with high life as the light source, and excellent inter- instrument
agreement ensures consistency of the measurement data of multiple samples. UV Included/ UV
Excluded to measure color and color difference for samples with fluorescence.
19 TENSILE TESTING

 Tensile testing is an independent and ISO17025 accredited research and test laboratory
which offers a wide range of methods to determine rubber properties ,such as tensile
strength ,elongation at break ,50%,100% stress modulus.
 The elongation at break is the extent a rubber material can be strained (%) before
it breaks. We apply tensile force and stretch the material. A percentage of the original
length is used to express the elongation at break. It is typically in the order of 100-600%,
and some examples even go up to 1000%. When the rubber ruptures, we have found the
ultimate elongation.
20

Tensile test machine Tensile test Specimen

 21

Tensile Test Graph

Determining tensile properties begins with sample preparation and testing of the specimens. specimens are in the shape of
dumbbells, rings or straight pieces of uniform cross-sectional area .Key properties measurements include tensile stress,
tensile stress at a given elongation, tensile strength, yield point, and ultimate elongation, with all measurements done on
specimens that have not been prestressed. Tensile stress, yield point, and tensile strength are based on the original cross-
sectional area of a uniform cross-section of the specimen. Measurement of tensile set is made after a previously unstressed
specimen has been extended and allowed to retract by a prescribed procedure.
 Tear Test
22

 ASTM D624 and ISO 34-1 are similar tear strength test methods for rubber test samples. The test
results in the measurement of a materials resistance to tearing Tear strength can also be used to
monitor material anisotropy of a material. ASTM D624 and ISO 34-1 both define tear strength as the
measurement of force required to tear a test sample divided by specimen thickness.
 HARDNESS TESTING
23

SPECIMEN DIAGRAM : TIP

 Durometer hardness (ASTM standards: D 2240) is used to determine the relative hardness of soft
materials, usually plastics or rubbers. The test measures the penetration of a specified indenter into
the material under specified conditions of force and time.Significance and use .The indentation
hardness gives information about the elastic modulus and viscoelastic behavior of the material
(degree of curing). This is an empirical test used in quality control process to minimize errors in
production.the test specimens used are generally 6.4mm (4 in) thick and in shape of a button.
24

HARDNESS TESTER
25 PRODUCTION

 The next step after testing is production.if the rubber samples gives ideal parameters as per
the standards ,the rubber is manufactured in big master batches.
 Rubber sheets are manufactured into final finished products.
26 calendaring

 Calendaring :Material Preparation: The raw rubber, along with any additives or fillers, is
mixed and prepared.
 Rolling: The rubber compound is fed through a series of heated rollers called calendars.
These rollers flatten and smooth the rubber into thin sheets.
 Thickness Control: The gap between the rollers determines the thickness of the rubber
sheet. Adjusting this gap allows precise control over the sheet thickness.
 Surface Finishing: The surface texture of the rubber sheet can be controlled by the finish
of the rollers. Smooth or patterned rollers can produce different surface finishes on the
final product.
 Cooling and Winding: After passing through the calender, the rubber sheets are cooled and
wound onto rolls for further processing or use.
27

3 Roll calendaring machine

28 extrusion

After calendaring the rubber is extruded in preforms for various products.

 Preparation: The raw rubber material, often in the form of pellets or strips, is prepared and fed into
an extruder.
 Feeding: The rubber is fed into the barrel of the extruder, which contains a rotating screw. The
rotation of the screw forces the rubber through the barrel towards the die.
 Heating: As the rubber moves through the barrel, it is heated to reduce its viscosity, making it
easier to shape. The heating must be controlled carefully to avoid premature curing.
 Shaping: The heated rubber is forced through a die, which gives the rubber its final shape. The die
can be designed to produce a wide variety of profiles, such as tubing, gaskets, seals, and more.
 Cooling: Once the rubber exits the die, it is cooled, typically in a water bath or with air cooling, to
maintain its shape.
 Curing: After cooling, the extruded rubber is often cured through vulcanization, a process that
involves heating the rubber with sulfur to create cross-links between the polymer chains,
enhancing the material's strength, elasticity, and durability.
 Cutting: The extruded and cured rubber is then cut to the desired lengths for its final application .
29

Extruder
30 Injection moulding

 Inection mouding is followed by following steps:

 Material Preparation: Rubber compounds, often in the form of pellets or strips, are
prepared. The material typically includes a base polymer, fillers, curing agents, and other
additives..
 Heating: The rubber material is fed into a heated barrel where it is melted and
homogenized. The temperature and pressure within the barrel are carefully controlled to
ensure the rubber reaches the correct viscosity.
 Injection: Once the rubber is melted, it is injected into a mold cavity under high pressure.
The mold is designed to the shape and dimensions of the desired final product.
 Curing: After injection, the rubber must be cured (vulcanized) to set its final properties.
This is usually done by maintaining the mold at a specific temperature for a certain period,
allowing the rubber to chemically cross-link and harden.
31

Injection Moulding Machine

Cooling and Ejection: Once the rubber is cured, the mold is cooled, and the finished part is ejected. Cooling ensures that
the rubber part retains its shape and dimensions.

Finishing: The part may require additional finishing processes, such as trimming excess material (flash), surface
treatment, or inspection for quality assurance.Injection molding for rubber is widely used in various industries, including
automotive, medical, and consumer goods, to produce parts like seals, gaskets, O-rings, and more. The process allows
for high precision, repeatability, and efficiency in mass production.
32 Compression moulding

 As the name suggests the the rubber manufactured by compression at higher pressure.the process
followed by 6 steps :
 Mold Preparation: The mold consists of two halves, usually made of metal, which are heated to a
specific temperature. The mold design includes cavities that shape the final product.
 Placing the Material: The preform is placed directly into the mold cavity. Proper placement is crucial
to ensure uniform filling and avoid defects.
 Compression: The mold is closed, and pressure is applied to force the rubber into the cavity. The
combination of heat and pressure causes the rubber to flow and fill the mold completely.
 Curing: While under pressure, the rubber is heated to vulcanize (cure) it. The curing process involves a
chemical reaction that cross-links the rubber molecules, giving the material its final properties such as
elasticity, strength, and durability. The curing time and temperature depend on the specific rubber
compound and the part being produced
h

33

Compression Moulding
Cooling and Ejection: After curing, the mold is cooled, and the part is removed. Cooling solidifies the rubber and
ensures the part retains its shape.

Finishing: The molded part may require finishing operations, such as trimming excess material (flash), surface
treatments, or quality inspections.

Compression molding is widely used for producing medium to large rubber parts, such as gaskets, seals, and large O-
rings. It is particularly suitable for parts with complex geometries and high dimensional tolerances. The process is cost-
effective for low to medium production volumes and is capable of handling high-viscosity rubber compounds.
 Project-injection moulding
34 INJECTION MOLDING KD-400 CABLE BOOTS (PROJECT)- 120
 According to cavity :
 Mold Cavity 1&2 gives excess flash compare to mold cavity 3&4,
 According to pins:
 Combination (1&5) weight range of 509-514g
 Maximum weight-514.4g
 Minimum weight-509.3g
 Mean weight- 512g
 Combination (18,4) weight range of 506-512g
 Maximum weight 511.7g
 Minimum weight 506.4 g
 Mean weight- 508.50
 Combination (16,18) weight range of 506-515g
 Maximum weight-514.8g
 Minimum weight-506.g
 Mean weight 510.4g
 Combination (12,20)weight range of 508-511g
 Maximum weight-511.1g
 Minimum weight 508.6g
 Mean weight 509.9g
35 Combination (10,19) weight range of 504-510g
Maximum weight = 509.8g
Minimum weight = 504.7g
Mean weight 507.6g
Combination (4,6) weight range of 503-519g
Maximum weight = 518.6g
Minimum weight = 503.7g
Mean weight = 510.5g
Combination (5,11) weight range of 504-508g
Maximum weight = 507.8g
Minimum weight = 504.4g
Mean weight 506.3g
Combination (13,3) weight range of 509-511g
Maximum weight = 510.9g
Minimum weight = 509.1g
Mean weight 510.2g
36 INJECTION MOLDING KD-400 CABLE
BOOTS (PROJECT)- 103A
 according to cavity-Mostly mold Cavity 380 gives excess flash compare to meld cavity 1&2.
 According to pins:Combination (15,6) weight range of 527-532g
 Maximum weight 531.7g
 Minimum weight-5279
 Mean weight 529.6g
 Combination (2,1) weight range of 525-532g
 maximum weight- 531.8g
 Minimum weight-525.4g
 Mean weight 527.9g
 Combination (11,12) weight range of 530-537g
 maximum weight-530.1g
 Minimum weight 530.0g
 Mean weight 5339
 Combination (7,16) weight range of 526-53lg
 Maximum weight=530g
 Minimum weight-526g
 Mean weight 529.7g
 Combination (17,15)
37 weight range of 530-538g
Maximum weight-537.4g
Minimum weight-530.g
Mean weight-533.8g
Combination 112,13)
weight range of 530-530g
Maximum weight 533.7g
Minimum weight-530.6g
Mean weight 531.8g
Combination (6,8) weight range of 526-531g
Maximum weight 5.30.3g
Minimum weight-520g
Mean weight-529g
Combination (14,10) weight range of 526-533g
Maximum weight 532.4g
Minimum weight-526.6g
Mean weight 529.4g
38 According to machines:
Machine: 103 gives approximately 530g product with flash and machine: 120 gives
approximately 510g product with flash.
Therefore, machine: 103 gives 20g excess weight compared to machine: 120.
Excessive flash due to
:High injection pressure.
High barrel temperature.
Low clamping pressure.
Mold dimensions.
Depends on sprue volume, runner volume, gate volume, between mold-cavity
39 PROJECT –MDR VS ODR

 Why values differ in MDR and ODR

 1)Why torque is less in MDR: The MDR generates less torque than ODR due to optimize design for
precise, controlled shear deformation, smaller contact area, and ability to operate over range of
frequencies and amplitude. Less optimum cure (min) in MDR
 :2) Optimum cure is time required for torque to reach 90% of torque (90% of MH value). Therefore,
less MH value in MDR compared to ODR gives less optimum cure(min) in MDR
 3).More Cure Rate in MDR: As optimum time for cure is less i.e. fast curing in MDR gives higher cure
rate.
 4)Less Thermoplasticity (MI-ML) in MDR due to less torque values
 5).MDR for characterization (research) and ODR for test (quality).Apart from elastic modulus (S’)
additionally visco-elastic properties (tanD) and loss modulus or viscous modulus (S”) we get.
 Therefore, even after same temperature, same angle of oscillation, same runtime, same compound used
values differ as MDR generates less torque than ODR (in MDR angle of oscillations are usually less
than ODR).
40 CONCLUSION

At the end of On Job Training we have gained significant knowledge about rubbers. Before we
join the K.D. Joshi Rubber Industry we thought like it's going to be tough for us to work in
industry but from the very first day we are just going deliberately good. We enjoyed positive
working environment where staff were both supportive and kind. We're especially thankful to
respected Mr. Milind Joshi sir, Mr. Makarand Joshi sir, Mr. Ninad Joshi sir and Dr. Aparna
Joshi ma'am and Mr. Chinmay Joshi sir for their constant guidance, feedback and
encouragement throughout our training, we were also cooperated by Ritik Balde sir, Nitin
Jondhale sir and Sujit Deshmukh ser. The knowledge and skills gained during this training
have been invaluable, and we are confident that they will benefit us in our future endeavors.
We're expressing our gratitude to K.D. Joshi Rubber Industry for this enriching experience.
41

 THANK YOU !