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1. INTRODUCTION 01
a. Mixing 12
b. Calendaring
c. Extrusion
d. Bead Preparation
e. Tyre Building Process
f. Curing (Vulcanization)
g. Post Cure Inflation
h. Trimming
i. Final Inspection
4. METHODOLOGY 37
5. CONCLUSION 39
6. REFERENCE 40
Industrial training at JK Tyres
CHAPTER-1
Over the years, the company has expanded and diversified its business portfolio.
It has developed into a multi product, multi-location corporate entity comprising of
following business divisions.
Ever since its inception it has been JK Tyre's belief in the value of technological
superiority that has made it grow by leaps and bounds. This division produces
and sells tyres and tubes under the brand name "JK Tyre" for Truck, Buses,
Passenger Cars, Jeeps, Light Commercial Vehicles, Multi Utility Vehicles and
Tractors.
The company pioneered Steel Radial Technology in India in 1977 and continues
to be the industry leader in the Radial segment in India. JK Tyre is the only Tyre
Manufacturer in the country to produce high performance 'T' & 'H' -rated steel
radial tyres.
With three plants located in Rajasthan, Madhya Pradesh and Karnataka, JK Tyre
is the largest manufacturer of truck and bus tyres in India. The truck and bus
tyres produced account for nearly 74% of the total tyre business in India, thus
giving JK Tyre an undisputed position. Additionally, JK Tyre is the only
manufacturer of truck/ bus steel radial tyres, and the second largest
manufacturer of 4-wheeler tyres in the country.
Also, JK Tyre is the largest exported tyre brand from India. It was awarded the
CAPEXIL's Highest Export Award for 1997-97 by FIEO. It enjoys preferred
premium brand status in Truck Bias market in USA and across many markets in
Africa, Middle East and South East Asia.
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Quality Management
ISO 9001
JK Tyre world's first tyre company to receive 'ISO 9001' certification for its entire
operations in 1995 in one go. Our Quality Management System is completely
integrated into all aspects of our operations.
QS 9000
JK Tyre the world's first tyre company to receive Quality Management System
certification QS 9000', in 1998 for multi location operations. We are using 'QS
9000' system as a tool for continuous incremental improvement.
DEFINTION OF TYRE:
A Tyre is a most essential component of a vehicle. Depending on
the various factors several definitions may be attributed for the Tyre.
Geometrically --- A Tyre is a Torus.
Mechanically --- A Tyre is a flexible membrane pressure composite.
Structurally ----- A Tyre is a high performance composite.
Chemically------ A Tyre consist of materials composed of long chain
macro molecules.
A TECHNICAL DEFINTION:
A Tyre is a Toroidal- shaped inflatable envelope made of an
elastic material, natural or synthetic rubber or a blend reinforced with
textile cord ply fabric carcass.
Thus Tyre is a strong and elastic shell, which takes over
stresses, ensures adherence to road avoids side slip and protects the
tube.
In other words “It is a thick rubber ring, often filled with air to
carry the load, which is fitted around the edge of the wheel of a
vehicle, allowing the vehicle to stick to the road surface and
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Industrial training at JK Tyres
improving the smoothness of the journey by acting as a shock
absorber”.
BIAS TYRES:
tread center line and is designed to hold the air pressure. The
stabilizing belt consist of reinforcement cords of high modulus steel
cords running circumferentially around the carcass at an angle of 18-
22 degree to the tread center line beneath the tread and is driving/
breaking / cornering torques. It is built such that the major short
comings of the bias construction are eliminated.
1. Increase in mileage.
2. Overall fuel efficiency up to 5% to 7% for car Tyres and 10% to
truck Tyres.
3. Excellent Traction and breaking on both dry and wet roads.
4. Safe high speed cornering.
5. Excellent riding comfort especially at high speed.
6. Improved endurance life and Retread ability.
7. Radial Tyres runs quieter.
8. Excellent impact breaks resistance.
TREAD PATTERNS:
1. Mixing
2. Calendaring
3. Extrusion
4. Bead Preparation
5. Tyre Building Process
6. Curing (Vulcanization)
7. Post Cure Inflation
8. Trimming
9. Final Inspection
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Industrial training at JK Tyres
Mixing:
Banbury unit
COMPOUNDING:
Is a process of mixing all the necessary ingredients with
elastomer, when compounding the ingredients are added step by step.
General compounding consists of following ingredients.
1. Base Polymer: The basic components of all rubber compounds
may be in the form of rubber alone or blends. The elastomer is
selected according to the physical properties. Normally Natural
rubber, Synthetic rubber (SBR, IIR, Reclaim rubber, Neoprene
etc...)
2. Reclaim rubber: For the purpose of cost reduction the reclaim
rubber is also used.
3. Reinforcing agent: Carbon black is the most widely used. It
increases the tensile strength, hardness and modulus of
elasticity. It has resistance to abrasion.
4. Processing oils: They are the dark green colored viscous
liquids, which are used as processing aids; commonly used oils
are pine tar, cast or oil, Napthanic oil, Paraffin oils, Aromatic oils.
5. Activators: ZnO and Stearic Acid are used as activators. They
mainly help in the curing. ZnO gives high tensile strength and
Stearic acid increases the vulcanizing rate.
6. Anti-degredants: These ingredients oppose the degradation by
ozone and atmospheric oxygen during service condition.
7. Cross-linking Agent: Sulphur is mainly used as the cross
linking agent to carry out the vulcanizing process.
8. Accelerators: Accelerators are used to accelerate the curing
agents, thus increasing the curing rate and decreasing the curing
time,
The compounding process mainly consists of the following three
processes:
1. Mastication: Mastication process is used for the natural rubber
because it has high viscosity. So mastication is done to
decreases the viscosity by using peptizer along with heat and
pressure to breakdown the molecules. The decrease in the
viscosity makes the compounding process easier.
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Industrial training at JK Tyres
Pentachlorothiophenol is commonly used as peptizer.
2. Master Batch: Master is the processes of mixing elastomers
with specified ingredients expect curing agents and accelerators.
A major element in the master batch is the carbon black and
other ingredients are also added in stage wise oils are added
many times as the processing aids. The following ingredients are
used in the master batch are;
FABRIC DIPPING
Fabric processing takes place in the Zell plant, during which the
processing adhesive is applied on the fabric and the woven fabric is
treated under electrically controlled conditions of time, temperature
and tension. Each fiber and fabric is contracted for different ends uses.
Dip Solution Preparation:
The solution is made in two stages under controlled temperature
conditions,
1. Master Batch: Contains the Resorcinol and Formaldehyde in
water with caustic soda as catalyst for the reaction. The Ph is
maintained by the caustic soda. The reaction is allowed between
3 to 6hr at 20-25C. This reaction is exothermic reaction.
Resorcinol Formaldehyde is the product of this reaction.
2. Final Batch: Contains the master in the rubber latex and water
for better adhesion. Vinyl Pyridine latex gives better adhesion
properties.
The process contains of the fabrics getting dipped in a containing
the dipping solution. After the dipping the excess dipped solution is
removed that uniform coating of the solution is obtained.
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Industrial training at JK Tyres
Record the observations and identity the fabric after the dipping
process. Adjust the width control devices justifiable. During the
process if any abnormal visual defects like water patches, oil/greases
contamination is observed, then identity neatly on the platform.
FABRIC CALENDERING:
Calendar is a machine, which consists of 3 or more rollers held in
a frame work. We can obtain rubber sheets of required width and
strength. It is used for fractioning and skim coating of the fabrics.
Calendar rolls have extra hardness and are made up of chilled cast
iron.
In a calendaring machine the following things are important:
Continuous lubrication system to roll bearings.
Drilled rolls to maintain temperature.
Precession gears to ensure smoothness of operation.
The parameter's that have to be taken care in the calendaring process
are;
The roller speed.
The roller temperature.
The friction ratio.
The accuracy in the roller setting.
The following are the processing machinery used in the 4 Roll Calendar
for the coating of textile fabric.
1. Let off roll: The aged fabric rolls from the Zell plant are loaded
to the let off stand.
2. Splicer: Splicer is used to splice the leading end of the first of
the fabric and the second roll of the fabric. Splicer having a hot
plate which is electrically heated and which used to join the 2
ends of the fabric.
3. Tension variable roll I: This rolls pulls the fabric from the let
off rolls in tension.
4. Let off Accumulator: The main purpose of the accumulator is
when the let off and tension roll I stopped or the supply of fabric
stops in the let off unit. The accumulator stores about 80 mts of
fabric. The upper part is fixed and the lower part moves down to
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store the fabric in this unit the fabric is supplied from the let off
rolls, thus enabling a continuous supply of fabric for the processing.
5. Tension variable roll II: It pulls the fabric the accumulator, so
that fabric remains under tension and fabric is passed on the
next unit.
6. Hot can: The hot cans are used to remove the moisture content
from the fabric. It consists of 21 rollers arranged in a zigzag
manner of temperature around 110 C.
7. Dancing roll I: It is used to maintain the uniform tension in the
fabric. It consists of 3 rollers, in which 2 are kept below the
fabric and one is above the fabric and driven by the chain gear
system.
8. Photo sensitive centering device I: The centering device
centers the fabric while in operation.
9. 4 Calendar: The Z-configuration 4-roll calender is used for
coating of the textile fabric. The main advantage of the 4-roll
calender is double side coating simultaneously. The upper
surfaces of the rolls are ground and high glass polished. The
temperature is maintained constants by using steam.
10.Cold cans: It has 6 rolls in zigzag manner. Cold water
circulation is provided for the cooling of rollers. The function is to
cool the fabric, and no external force is provided.
11.Tension variable roll III: It pulls the fabric from the cold can
rolls, so that fabric remains under tension and fabric is passes on
the next unit.
12.Tension variable roll IV: It pulls from the wind up
accumulator, adjusts the tension and passes the fabric to the
center device.
13.Wind up rolls: The set up has two winds up strands where the
coated fabric is winded in a liner to avoid sticking of the fabric to
one other.
EXTRUSION OF TREAD:
Extrusion is carried out through the extruder machine, which
forces the rubber through a nozzle or a die to give a profile strip of the
material. Screw extruder is used in the plant here. In the screw
extruder, a helical screw turning in a cylinder forces the compound
through the die. It is operated by the electric motor through the
reduction gear. The extruder consists of feed hopper through which
the rubber compound is fed into the extruder.
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Industrial training at JK Tyres
The following are the machineries used in the extruder section are;
Cracker mill, Homogenizing mill, Feeding mill, Single screw
extruder, 3-roll-calender, cooling conveyor and Cutting circular blade.
Steps in the Extrusion process;
(I). Compounding Milling:
• Open water circulation to the mill during the milling operation
and close the water when not in use.
• Take respective compound for milling as per requirement.
• Load the compound required to the cracker mill/ warm up mill
and mix well to get smooth surfaces by giving cut and rolls.
• Pass the compound to the feed mill.
• Set the feed strip dimension according to specifications.
• Pass the compound strips to the extruder hopper or over head
conveyor.
(II). Extrusion:
• Pick up the required die the pre-former from the hot chamber,
which is required for the extrusion as per shift schedule.
• Change the die and the pre-former. Apply the soap solution.
• Slide the die and the pre-former in the slot and clamp it.
• Start extruder and guide the compound strip to the extruder
hopper.
• Set the RPM and ensure feed of the compound as specified.
• Apply under tread cushion centrally as per specifications.
• Apply under tread polythene to truck and OTR treads.
• Allow tread to continue on inclined and cooling conveyor.
• Set the specified length and weight as per specification.
• Pass the extruded treads from the cooling to booking conveyor
through dancer rollers.
• Put auto switch in auto position and start cutting.
• Ensure the length and weight of treads extruded in each size
randomly while booking.
Book accepted treads in clean and neat leaf trucks and store the
treads in such a way that polythene/ under tread surface is facing
upward. 17
Industrial training at JK Tyres
BIAS CUTTING:
Bias cutter is a machine, which is used to cut the rubber-coated
fabric at the required width and angle, so as to suit it for the
production of various types of Tyres. Bias angle is the angle of cords in
Tyre w.r.t center line. The width is adjustable from (135-1300mm).
The cutting angle changes from 32-90 degree. The cut fabrics are
spliced in a roll of either 80 or 60 degree cuts. The fabric is shifted on
a driving roll.
As the conveyor pulls the fabric, the coated fabric comes out
from the let off roll. The fabric moves with the help of the photo-cell,
which instructs the motor to run by means of limit switches. The width
is adjusted before putting it into operation. The motor placed on the
carriage drives the cutting disc tools, which cuts the fabric. The cutter
runs on the cutting rail, which is diagonally adjustable to the
longitudinal axis of the conveyor.
BEAD PREPARATION:
One of the major components in the Tyre is the bead. The bead,
which anchor's the Tyre safety to the rim and it, functions as the
supporting components to carry the load. The bead is the combination
of multi treads copper coated high tensile steel wires. They have the
function of providing rigidity to the Tyre and to retain the inflated Tyre
on the rim under all condition of loading.
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Industrial training at JK Tyres
For the construction of the bead following stages are carried out.
1. Bead building unit.
2. Fillering machine.
3. Flipping machine.
4. Wrapping.
TYRE CURING:
The Tyre curing is a process of cross-linking of the rubber
compound through the heat and pressure. In the curing process the
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Industrial training at JK Tyres
Tyre is cross-linked in a series of chemical reaction. The press
contains the mold that determines tread design and final Tyre
dimensions.
Before the curing process, some of the preliminary process must be
carried out. They are;
1. Splice Jamming and Painting.
All green Tyres are to be splice jammed. The splice jamming
is done only to the tread joining area. After splice jamming
operation Tyres are taken for the Tyre painting area.
CURING CYCLE:
There are different methods of curing used depends upon the type of
the Tyre. They are;
1. Dome Steam, Bladder Steam: Usually used in production
of small Tyres like passenger car Tyre, bicycle Tyres, and
agricultural Tyres.
2. Dome Steam, Hot Water in Bladder: This is the most
common method in production of big Tyres. Often circulation of
cooling water is used at the end of curing phase to cool the
Tyres before release.
3. Nitrogen Curing: Steam or hot water in the bladder is
replaced by nitrogen. With nitrogen curing, the curing time can
be shortened and problems caused by water or steam can be
eliminated. This method decreases energy consumption in curing
compared to hot water or steam curing.
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Industrial training at JK Tyres
Green Tyre Curing Process:
A curing cycle starts just after the mold closing and last up to.
Apply naphtha mold opening. In between these there are many steps,
each having their own functions. These steps and its duration change
depending upon the type of Tyre. The major steps involved are the
following;
1. Dome heating: Circulating steam does dome heating. This is to
heat the mold thus helps to flow the compound. For truck Tyres
steam is applied at 146 C.
2. High pressure steam (HPS): High pressure steam as applied
to heat the bladder since the bladder compound (butyl rubber) is
a poor conductor of heat. For truck Tyres HPS has a temperature
of 194 C and 13.4kgsn pressure.
3. Circulating hot water (CHW): Circulating hot water with high
pressure and temperature is applied to enhance the cross linking
process. It has a temperature of 168C and a pressure of 26kgs.
The high pressure (double pressure than HPS) will consolidate
the rubber compound into mold cavity.
4. Circulating cold water (CCW): This is applied to cool the
bladder and Tyre.
5. Vacuum: Vacuum is applied to release the bladder from Tyre.
The PCI stage involves mounting the green Tyre on the flanges,
inflating it and cooling it according to a predetermined and preselected
procedure. The Nylon Tyres, which has thermal shrinkage property, or
post – inflated under stretched conditions, soon after the Tyres come
out of the mold after curing, by inflating with compressed air to avoid
deformation of Tyres and hence to stabilize their shape. This should be
done within three to five Min's of Tyres ejection from the mold and PCI
should be treated till the Tyre cools to 60 – 70 C.
PCI Process:
1. Refer the specification series displayed in the individual curing
processes.
2. Verify and ensure that the PCI air pressure and time are set as
per specified in the pressure gauze and timer provided.
3. PC Inflate all Nylon cure Tyres using PCI units as per
specifications.
4. Release the Tyre from the PCI unit after specified duration of PCI
treatment.
5. PCI treated Tyres/defective Tyres are to be sent to trimming and
inspection area.
6. For “Off The Road” OTR Tyres, soon after the Tyre is unloaded
from the press, insert no. of wooden peg sets for OTR Tyres at
the bead region at equal distances.
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Industrial training at JK Tyres
FINAL FINISHING:
The final finishing consists of the following stages;
trimming: It’s the process of removing the excess material
that includes vents. The cured Tyre is kept on the trimming
machine and rotated by motor, while the trimming device is held
to the Tyre, thus removing the excess material that makes the
Tyre look good.
Buffing: There are two types of buffing a). Rag Buffing and
b).Emery Buffing
Inspection: All cured Tyres are inspected for visual defects.
The defective Tyres are held up separately for the modification
work. The production and the technical staff inspect the held up
Tyres and classify the Tyres according to the quality.
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Industrial training at JK Tyres
1. Increases in mileage
RAW MATERIALS
1. NATURAL RUBBER
2. SYNTHETIC RUBBER
3. CARBON BLACK
a. N 339
b. N220
c. N320
d. N326
4. INSOLUBLE SULPHUR
5. PARAFFIN WAX
6. SILICA
7. 6 PPD (Antiozonant)
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Industrial training at JK Tyres
8. PEPTIZER
9. PROCESSING OIL
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Industrial training at JK Tyres
BANBURY DETAILS
Intensive mixer
Radial Compounds
Steel Tyre cord Body ply and Belts required for building All steel Truck
Radial Tyres are calendar at Hot Calender line.
Steel Tyre cords after conditioning in the creel room are mounted on
the creel stand let off and drawn out.
Four roll Calender has “S” form axis of the rolls Nos. 1 and 4 is placed
45° over the vertical axis. Rolls are made from chilled alloyed cast iron
and are peripherally drilled.
Individual wires are spread in to the Comb roll through the Reed and
fed in to the Calender gap between roll nos. 2 and 3.
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Industrial training at JK Tyres
By feeding rubber compound from feeding mills through swinging
conveyors in to the gap between Roll No1 and 2 and between roll no 3
and 4 rubber films of the required thickness are drawn on the roll no 2
and 3.
The thickness of the rubber films are controlled through the scanning
heads of the thickness measurement device (Beta gauge control)
Rubberized steel cord is passed through the cooling cans and
accumulator and wound in to the liners at wind up unit.
The Calender roll temperatures are monitored with the help of TCU.
Belts/Steel Chipper required for Building All steel Truck Radial Tyres
are cut and prepared at Belt cutter
The Calendared Rolls are mounted on the let off stand of the Belt
cutter and passed on the let off conveyor to the Cutting Blade nip
The let off is mounted on a carriage, which can be set to the required
angle between 15° to 75°.
The machine settings are done with the help of PLC.The cutting Blades
are operated hydraulically.
The material to be cut is fed to the Blade nip with the help of advancer
consisting of electromagnet battery and cut to the specified width and
angle.
Gum Strips are applied at both the edges of cut belt and turned down
using turning down tool.
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Bead wire spool is mounted on the let of stand of the winding machine
and passed through the wire pre heater to the Extruder.
The wire is wound to the specified construction on the former with the
help of pay on wheel and lying unit.
Body ply material required for Building All steel Truck Radial Tyres are
cut and prepared at Ply cutter
The Calendar Body Ply Rolls are mounted on the let off stand of the Ply
cutter and passed on the let off conveyor to the Cutting Blade nip
The machine settings are done with the help of PLC.The cutting Blades
are operated hydraulically.
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31
Curing Process:
of chuck loaders
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Industrial training at JK Tyres
TRUCK RADIAL TYRE INSPECTION PROCESS
Cured Tyres after Trimming are inspected before W/H.Tyre inspection
consists of Visual and x-ray Inspection
1. Visual Inspection:
All the Cured Tyres are checked for any Visual defect as per the
standards and Okayed. Rejected tyres are Repaired/Scrapped
depending upon the severity and merit of the defect.
2.X-Ray Inspection
All the Cured tyres are checked on x-ray to ensure the structural
integrity.
Equipment:
Tyre x-ray inspection System
LumenX Company,USA
The Tyre X-Ray inspection system is completely automated for online
inspection of Tyres for all the construction parameters like Ply cord
spacing, turn ups, Belt step off and splice, and concentricity of Bead
Bundles.
The Gemini X-Ray system will provide X-ray energy .X-Rays are
emitted from panoramic tube head in a 270 degree vertical arc. The X-
rays penetrate the Tyre in different amounts depending on the tyre
density and material of construction
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Industrial training at JK Tyres
The Image System:
The linear diode array (LDA) image scanner head in C – shape will
provide the image on the screen.
Tyre engineering:
Components used in Radial tyre building
1. Bead
2. Splice strip
3. Inner liner
5. Steel chipper
6. Body ply
7. Apex
9. Flange
10. Sidewall
11Crayon application
12. Carcass
13.Tread pack
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CHAPTER- 3
AIM AND ACOPE OF PRESENT WORK
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BIBILOGRAPHY
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