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   IndiaRubberDirectory.com > Rubber Engineering > Rubber Product Manufacturing


PROCESS FLOW CHART - BUTYL TUBE MANUFACTURE


SELECTION
OF RAW MATERIAL


INSPECTION
OF RAW MATERIAL


MASTER BATCH
MIXING

BLUE COMPAD MIXING  STRAINING VALVE CEMENT  COMPD MIXING
BLUE PAINT PREPA RATION FINAL MIXING  CEMENT
 PREPARATION
 
  EXTRUSION BEMENT
 
APPLICATION

VALVE FIXING

SPLICING

SPLILCE CHILLING

FORMING & CURING

INSPECTION

VACUUM & VALVE
BENDING

PACKING

EXTRUSION

GREEM TURE DIMENSIONS:-

FLAT WIDTH

TOTAL GAUGE

CUT LENGTH

TUBE WEIGHT=FLAT WIDTH X CUT LENGTH X TOTAL GAUGE X SPECIAL GRAVITY

-GREE TUBE CIRCUMFERENCE95% OF MOULD SECTIONAL PERIMETER

[FLAT WIDTH=CIRCUMFERENCE/2]

-CUT LENATH 3% MORE OF MOULD CAVITY INNER CIRCUMFERENCE

TUBE WEIGHT

Q TOTAL GAUGE=________________________________________________

 SPEC. GRAVITY                            FLAT WIDTH X CUT LENGTH X

GAUGES OF GREEN TUBE:-

TOP GAUGE

- TOTAL GAUGE X 0.4

BOTTOM      

- TOTAL GAUGE X 0.6

SIDE - TOTAL GAUGE X

VARITION IN TOTAL GAUGE - + 0.2mm (MAX)

 

AVERAGE CURED GAUGE 00.2mm LESS THAN

                        EXPECTED                TOP GAUGE ASSIGNED ABOVE

EXTRUSION (CONTS)

DIE AND CORE DIMEN SIONS:-

DIE:-               CIRCOMFERENCE 88-92% OF GREEN TUBE CIRCUMFERENCE

LESS THAN 88% LESSER PRODUCTION OUTPUT

 

MORE THAN 92% MORE SHRINKAGE OF GREEN TUBE IN         

STORAGE

DIE OPENING:-

 

-          DEPENDS ON BACK PRESSURE

-          HIGHER SIZE HAVE LESSER BACK PRESSURE

-          DIE SWELL WILL BE + 65% (APPROX)

-          FOR SMALLER SIZES, +75 to 80% DUE TO MORE BACK PRESSURE

-          DIE SWELL DEPENDS ON COMPOUND VISCOSITY ADDITION OF REWORK COMPOUND AFFECRTS IT.

 

RECOMMANDED EXTRUDER:-

 

-          CONSTANT SCREW RPM

-          VARIABLE CONUEYOR SPEED

SPLING - AUTOMATIC MACHINE

MACHINE SET UP:-

                                     LCV                TRACK

                                    4                      4

                                    PASS               TRACTOR

                                    _____              ____________

 i). LOW CLAMP PRESOURE (kg/cm) -     5-25                 25-35

ii) HIGH CLAMP PRESSURE (kg/cm) -     25-35               35-45

iii) BUTTING PRESSURE (kg/cm)- 35-45               45-55

iv) BUTTING TIME (Sec.) - 10        15

v) CUTTING OVER HANG (mm) -   0.8-1.0 1.0-1.2

vi) KNIFE TEMP. (C)

            a) LOW HEAT -         26020            26020

                                               

            b) HIGH HEAT-         60020            60020

 

CUTTING PATTERN:-

.. 

                     15                                                   15

              mm                                                      mm

 

ENTRY                                   TUBE              EXIT

                                         

HIGH SPEED RETURN

--------------------------------------------- - - - - - - - - - 

MEDIUM SPEED

________________________________
|

HIGH CURRENT                           

            LOW SPEED

            LOW HEAT

 

VLTIMATE OBJECT:-         TO ACHIEVE UNIFORM CUTTING SHADE THROUAHOUT THE CUT SURFACE.

 

SPLICING (CONTD)

 

  CUTTING KNIVES:-

 

            CUTTING ANGLE 11 RE COMMANDED.

            SLIGHTLY HORE ANGLE GIVE BETER RESULT

                INCREASE IN RUBBER JAWS GAP LEADS TO INCREASE IN ANGLE

 CROSS SEC. AREA OF KNIFE SHOULD BE

SAME FOR BOTH KNIVES

[CHECKING TO BE DONE BY MEASURING 4 WEIGHING]

  KNIFE CLENING IS MUST BEFORE EVERY CUT 

RUBBER JAWS:- 

-          FOR BETTER RESULT, SANDWITCH COMPOUND JAWS

-          JAWS SET TO BE CHANGED AFTER COMPLETION OF 50,000 CYCLES (OR  2 MONTHS)

-          JAWS ALIGHMENT SHOULD BE PERFECT

 CHECK LIST FOR GOOD JOINT IN GREEN TUBE:-

-          NO FLASH AT FOLD

-          THICKNING IS 10-15%, REQUIRED

-          FOLDS TO BE BLENDED WITH HOT KNIFE

-          CHECK FOR STEP AT FOLDS

-          CHECK FOR UNIFORM CLAMP IMPRESSION, ON TUBE SURFACE.

 

 

CURING

 SPLICE CHILLING:-

 

-          ENSURE ICE FORMATION

-          LEAST CHILLING AREA ON GREEN TUBE

-          BASE CHILLING FOR LESSER SD/ID RATIO SIZES

-          CROWN CHILLING FOR HIGHER SD/ID RATIO SIZES.

 

SHAPING FORMER:- (DESIGNING)

  D- 3% MORE OF MOULD CAUITY ID

R- RADIUS OF CONTOUR IS 2 X MORE OF SECTION RADIUS OF MOULD

Q- INCLUDED ANGLE IS 98-100

 

100% SHAPING IN FORMER IS GOOD

  TEEKWOOD FORMERS AT HOT PLACES PREFERABLE.

  

DEFECT ANALYSIS IN FINISHED PRODUCT

  

NATURE OF DEFECT                                  SUGGESTED REMEDIES

 

i) CIRCUMFEREVTIAL           -ENSURE 100% SHAPING

    INSIDE PUCKLE (CIP)        - ENSURE PROPER SHAPING TIME

 

ii) VERTICAL INSIDE             - ENSURE PROPER CUT LENGTH

    PUCXLE                           - CHECK FOR EXCESS FLAT WIDTH

                                            - DUST SHAPING FORMER

 

iii) VALVE PUCKER (VP)       - LOCATE VALVE ON GREEN TUBE AT

                                     PROPER POSITION

 

                                          -LOCATION OF VALVE HOLE IN

                                     FORMER SHOULD BE CORRECT

 

                                           - PROPER ALGNMENT OF CLIP/NOZZLE

                                     IN MOULD

 

iv) SPLICE CRACK              - PROPER APPLICATION OF HOT KNIFE

                                     AT SPLICING

 

 

 

PEFECT ANALYSIS OF FINISHED PRODUS (CONTD)

 

NATURE OF DEFEECT                               SUGGESTED REMEDY

 

v) PINCH SPLICE           - CHECK SPLICING MACHINE FOR

                                     SPECIFIED PRESSURES

                                     - CHECK FOR STARVATION OF

                                     POWDER AT FLODS INSIDE GREEN

                                     TUBE

                                    - CHECK FOR LESSER FLAT WIDTH

 

vi) BLISTERS                - CHECK FOR AIR  ENTRAPMENT AT

(NEEDLE TYPE)                   EXTRVSION

                                    [REJECT SOME GREEN TUBE DURING

                                    POWER FAILURE]

 

 

vii) AIR LOCK                -CHECK FOR LESSER SHAPING

 [ROUGH SURFALE]       - CLEAN MOULD VENT LINES

                                      -CHECK FOR MOISTURE ON MOULD

                                     SURFACE

 

QUALITY CHECK UP OF FINISHED PRODUCT

 (NON-DESTRUCTVE)

-         SPLICE APPEARANCE

-         NEAT VALVE AREA

-         UNIFORM GAUGE DISTRIBUTION THROUGHOUT CIRCUMFERENCC

-         EQVAL GAUGE ON BASE AND CROWN

-         FREE FROM VISUAL DEFECTS

-         NEAT AND UNIFORM BLUE LINE

-         NO DIRTY MOULD MARKS ON TUBE SURFACE

-         CLEAR MONTH CODE

-         FREE FROM BULGING

QUALITY CHECK UP OF FINISHED PRODUS:-

 (DESTRUCTIVE)

-         SPLICE STRENGTH - 45 Kg/cm (MIN)

-         UNIFORM BODY TENSILE STRENGTH

-         E.B% AT JOINT - 450% (MIN)

-         SPLICE FLEX TEST OF 2160 CYCLES (MIN) WHEN TESTED IN DE-MATTIA M/C

-         VALVE ADAESSION STRENGTH, 6.0 kg/cm (MIN) FOR TRUCK

-         5.0 kg/cm (MIN) FOR PASS.

            -          TENSION SET OF 35% (M,AX) [50% STRETCH/105C/5HRB]

 PERIODICAL CHECK UP OF ACCELERATED AGEING PROPERTIES FOR CONSISTANCY AS PER STANDARDS OF 120

-          FOR 24, 72 AND 96 HOURS. 

PROBLEM / DEFECTS

CAUSES

SOLUTIONS

MIXING

UNDISPERSED CHEMICALS

 

POROSITY

 

 

 

SCORCH

 

 

 

IMPROPER MIXING CYCLE

 

LOW HEAT BUILD UP

IMPROPER BATCH WEIGHT

 

 

WRONG ADDITION OF

CURATIVES CONTAMINATION

BY OTHER STOCK HIGH DUMP

TEMPERATURE

 

 

PROPER MIXING CYCLES

 

POLYMER PRE-

MASTICATION PROPER

BATCH WEIGHT

 

PROPER FOLLOW UP

CLEAN UP BETWEEN

DIFF. STOCK MIXING

EFFECTIVE COOLING

 

  

PROBLEM / DEFECTS

CAUSES

SOLUTIONS

MILLING 

STICKING TO MILL ROLL

 

  

MILL  BAGGING

 

STRAINING

MESH BLOCKAGE

 

EXCESS STICKY COMPOUND

EXCESS BLACK / OIL LOADING

   
MILL ROLL TEMP DIFFERENCE

 
 UNDISPERSED BLACK

 

ADD PROPER DETACKIFIERS

(STEARIC ACID)
PROPER CONTROL IN LOADING  
EFFECTIVE MILL ROLL RATIO

ENSURE PROPER COOLING
IMPROVE MIXING

TRY SOFTER PELLET HARDNESS

 

 

PROBLEM / DEFECTS CAUSES SOLUTIONS

EXTRUSION

 

SCORCH

 

 

 

 

BLILSTER

 

 

THINNING

 

 

 

GAUGE VARIATION

 

ADHESION OF INNER WALLS

HIGH BACK PRESSURE

UNDISPERSED CURTIVES

SCORCH SAFETY LOW

HIGH WORK AWAY ADDITION

 

AIR TRAPS

UNDISPERSED CHEMICALS

 

WRONG DIE FIXING

MISMATCHING IN CONVEYOR

SPEEDS

 IMPROPER DIE / CORE FIXNG

 LOW QUANTITY OF TALC

PROPER DIE DESIGN / LOWER SCREW SPEED

PROPER MIXING

CONTROLLING ACELERATOR COMPOSITION

STRAIN & USE IN A PROPER RATIO

 

HOMOGENEOUS INGREDIENTS

PROPER DUMP TEMPERATURE

 

AVOID LAPSES

CORRECT / CHECK AT REGULAR INTERVALS 

 

CORRECT FIXING

 

ENSURE PROPER TALC USAGE

 

PROBLEM / DEFECTS CAUSES SOLUTIONS

SPLICING

 

EXCESS OVERHANG

 

 

SMEAR, FLASH, TRIMMING

 

BAND, STEP FORMATION

 

 

BREAKDOWN AT FOLD

 

HIGH CLEARANCE BETWEEN KNIFE & JAW

 

 

HIGH KNIFE HEAT

 

IMPROPER JAW ALIGNMENT

IMPROPER BOBBIN BLOCK ALIGNMENT

 

HIGH CLAMPING & BUTTING PRESSURES

LESS CLEARANCE BETWEEN JAWS

 

USE PROPER TEMPLATE FOR CHECKS

 

 

ENSURE PROPER LOW & HIGH HEAT

 

ALIGN PREPERLY

 

 

OPTIMUM PRESSURE TO BE MAINTAINED

PROPER CLEARANCE TO BE MAINTAINED

 

                                   

PROBLEM / DEFECTS CAUSES SOLUTIONS

FLASH & EDGE BUILD UP

 

 

 

SPLICE OPENWITH

 

UNEVEN CLAMPING OF JAWS DUE TO

WIDTH VARIATION IN TUBE ENDS

DURING DUAL SPLICING

 

TALC CONTAMINATION WAVY CUT

UNEVEN BUTTING

IMPROPER ALIGNMENT OF JAWS

GAUGE VARIATION

 

GAUGE & WIDTH CONTROL

 

 

 

AVOID CONTAMINATION

SET KNIFE PROPERLY

ADJUST SETTINGS PROPERLY

 

 GAUGE CONTROL

 

 

PROBLEM / DEFECTS CAUSES SOLUTIONS

FORMING

 

THINNING

 

 OVERSHAPING

 

 

DAMAGE BY  FOREING MATERIAL

UNEVEN THICKNESS

  
HIGH INFLATION PRESSURE

PEG SET DISTANCE MORE

 

 

AVOID CUTS / DAMAGE BY FOREIGN MATERIALS
GAUGE UNIFORMITY CONTROL 
THROTTLE VALVE / MONITOR PRESSURE

SET PEG AT SPEC DISTANCE

 

 

PROBLEM / DEFECTS CAUSES SOLUTIONS

CURING 

ROUGH APPEARANCE

 UNDER CURE

 

 

 STICKING TO MOULDS

 POROUS VALVE BASE

 

 PINCHING / BUCKLING

 

 

DIRTY MOULDS

 PRESSURE FLUCTUATION

WATER PARTICLE INSIDE TUBE

  STICKY COMPOUND

 IMPROPER VALVE FIXING

  

IMPROPER FORMING

IMPROPER SHAPING

 

 

CLEAN MOULD FREQUENTLY

 CORRECT THE PROBLEM

AVOID SUCH LAPSES

  REDUCE TACK

 PROPER VALVE FIXING TO BE FOLLOWED

 PROPER FORMING / SHAPING

TO BE FOLLOWED

 

 

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