CALENDAR THICKNESS MEASUREMENT

and
ANALYSIS

SECOND PROGRESS

Presented by:
ALAWATHTHAGE G.C.
KULATHUNGA H.G.G.
RATHNAYAKA R.M.P.P.K.

(RU/E/2009/004)
(RU/E/2009/095)
(RU/E/2009/148)

PRESENTATION OUTLINE

CALENDARING PROCESS

INTRODUCTION TO THE PROBLEM

LITERATURE REVIEW

MEASURING AND ANALYSIS OF CALENDAR LAYER THICKNESS

MEASURING AND ANALYSIS OF CALENDAR ROLLER SURFACE

CONCLUSIONS OF INVESTIGATIONS

REASONS FOR ISSUE

AMOUNT OF MATERIAL WASTE

SOLUTION

CALENDARING PROCESS IN TYRE

MANUFACTURING
Why Calendaring in Tyre Manufacturing?

For making inner liner & calendar layer

What is Calendaring Process?

Calendaring process

INTRODUCTION TO THE PROBLEM

Research Problem

Cross Section of Calendar Layer

There is no any scientific investigation carried out to related to the

issue
project targets to find a most suitable solution and improve the
productivity, working efficiency as well as saving of valuable material

LITERATURE REVIEW
similar type of issue in metal strip manufacturing, but in that case,
metal strip thickness is varying along length of the metal strip.

Research is done by T. Widmaier, T. Salmela, P. Kuosmanen, J.

Juhanko, P. Karha and J. Uusima.

Try to understand the phenomena behind the rolling force variations

seen in the rolling force measurements.

The aim was to reduce the periodic rolling force variation and to
study how this affects the thickness variations of the steel strip.

Thickness Variation Along Length of Metal Strip

RESEARCH METHODOLOGY
1. Measuring the calendar thickness.
2. Data analysis and calendar surface mapping.
3. Measuring the calendar roller surface variation.

4. Data analysis and calendar roller surface mapping.

5. Impact of the side cutters to the issue.
6. Effect of tension variation and sagging of the calendar layer.
7. Cost estimation for the material waste.
8. Finding a most affordable solution to solve the issue.

RESEARCH METHODOLOGY
Calendar Thickness Measurement, Data Analysis and
Surface Mapping
Specifications of Obtained a inner liner
Thickness

Width

Length

2mm

1500mm

4250mm

Preparations for the Taking Measurements

Decided to measure the thickness of the calendar from the distance

of 5cm.
To achieve that firstly we divide the layer in widthwise in to 5cm

partitions and then lengthwise.

RESEARCH METHODOLOGY
Calendar Thickness Measurement, Data Analysis and
Surface Mapping

5cm square divisions

Measuring the Layer Thickness

Used Microsoft excel and MATLAB software

packages for Data Analysis and Surface Mapping

Thickness Gauge

RESEARCH METHODOLOGY
Calendar roller surface variation Measurement, Data
Analysis and Surface Mapping
A special methodology for roller surface measurement.
Measuring process
Marking Measuring Coordinates on the roller and reference edge

Reference Edge with Coordinates System

Paper Strip with Coordinates pasted on the roller

RESEARCH METHODOLOGY
Calendar roller surface variation Measurement, Data
Analysis and Surface Mapping
Measuring process
The Reference edge mounted to the machine using brackets.
Adjust the distance by moving the reference edge through the slots.

Measure the distance between reference edge & roller surface by

using two feeler gauges sets.

Feeler Gauge Set

Reference Edge Mounting to the Machine

RESEARCH METHODOLOGY
Calendar roller surface variation Measurement, Data
Analysis and Surface Mapping
Used Microsoft excel and MATLAB software packages for Data
Analysis and Surface Mapping

Impact of the side cutters to the issue

visually inspected the surfaces of both calendar rollers.

Compare the surfaces.

Effect of tension variation and sagging of the calendar layer

Based on the pattern of thickness variation.

RESEARCH METHODOLOGY
Cost estimation for the material waste
Measure the weight of a sample.

Calculate the density.

Calculate the excess material per unit length.
Estimate the annual loss.

Finding a most affordable solution to solve the issue

Changing the order of roller location.

Roller grinding or refurbishment.

Improvement for cutter mounting.
Roller replacement.

OBSERVATIONS, RESULTS & DISCUSSION

Calendar Thickness Measurement, Data Analysis and
Surface Mapping
Surface Plot of Calendar Layer Third Measurement
Surface Plot of Calendar Layer Second Measurement

Surface Plot of Calendar Layer First Measurement

2.9

2.9

2.9

2.8

2.8

3
2.5
2
1.5

2.6
2.5

2.7

2.7

2.5
2

2.6

1.5
30

2.5

THICKNESS(mm)

THICKNESS(mm)

2.7

THICKNESS(mm)

2.8

3
2.5
2
1.5

2.6
2.5

30

30
2.4

25

2.4

2.4
25

25
2.3
20

20

2.3

2.3
20

30
25

15
20
10

30

2.2

2.2

15
30

2.1

10

25

15
5
5

LENGTH

0 0

20

10

1.9
WIDTH

15

15
20

2.1

15

2
1.9

5
0

2.1

10

LENGTH

0
WIDTH

Surface Plots of Calendar Layer

Similar pattern of variation along the width.

Thickness vary from 1.9mm to 2.7mm.

No any considerable variation along the length

10

10

LENGTH

2.2

25

1.9
WIDTH

OBSERVATIONS, RESULTS & DISCUSSION

Calendar roller surface variation Measurement, Data
Analysis and Surface Mapping

Roller Surface Plot

Significant variation along the length of the calendar roller

OBSERVATIONS, RESULTS & DISCUSSION

Comparison of results
Defected Areas of Calendar
Layer

Surface Plot of Calendar Layer

Defected Areas of Calendar

Roller

Surface Plot of Calendar Roller

Defected Areas are similar in both calendar surface and roller surface

variation.

OBSERVATIONS, RESULTS & DISCUSSION

Comparison of results

Difference of Roller Surface and Calendar thickness

Difference of the calendar roller surface and the average calendar

thickness is having a linear relationship.
It is proven that the issue is occurred due to the surface variation of
the roller surface

OBSERVATIONS, RESULTS & DISCUSSION

Impact of the side cutters to the issue
Damaged area of
roller

Roller Contact
with cutters

Side Cutter

Direct Contact of Cutter Roller

Roller without
Contact cutters
Impact of Cutters

The roller which is directly contact with cutters are severely damaged
while other one in good condition.

Effect of tension variation and sagging of the calendar layer

No variation along the length of the calendar layer.

No impact of tension variation or calendar layer sagging.

OBSERVATIONS, RESULTS & DISCUSSION

Cost estimation for the material waste
Density of compound

1207.79Kgm^(-3)

Actual Weight in 1m length

3.648Kg

Expected Weight in 1m length

3.503Kg

Material Waste

0.145Kg

It is average loss per day 580kg and average cost of it is 350Rs.

580*350 = Rs. 203000

Think About loss

OBSERVATIONS, RESULTS & DISCUSSION

Finding a most affordable solution to solve the issue
1. Changing the order of roller location
Three roll mill machine.
only two rollers are using.

replace the defected roller with non used roller.

2. Roller grinding or refurbishment

cost is around Rs.85000 to Rs.145000.

3. Roller replacement with a new one

Cost is around $2000 to $5000 must imported.

4. Improvement for cutter mounting.

Only above 1 or 2 or3 solutions are not enough.
To avoid the issue permanently need to avoid direct contact of cutters and roller.
Modification is compulsory with a above solution.

OBSERVATIONS, RESULTS & DISCUSSION

Modification for Machine

New roller

Modified Design

Conclusion
Project

targets to measure and analysis of the calendar thickness

variation

Identified the amount of variation and the pattern of the variation

Studied

and investigate the impact of the most related facts to the

issue of the thickness variation

To avoid that issue it is suggesting the following solutions

Changing the order of roller location
Roller grinding or refurbishment

Roller replacement with a new one

Modification for cutting process