IEEE Transactions on Dielectrics and Electrical Insulation

Vol. 15, No. 3; June 2008

771

Theoretical Correlations amongst Electrical and

Mechanical Characteristics of Polymeric Housing
Materials for Outdoor Insulators
R. Raja Prabu
B.S.A Crescent Engineering College
Vandalur, Chennai 600 048
Tamil Nadu, India

S. Usa, K. Udayakumar
High voltage division, College of Engineering, Anna University
Guindy, Chennai 600 025
Tamil Nadu, India

M. Abdullah Khan and S.S.M. Abdul Majeed

B.S.A Crescent Engineering College
Vandalur, Chennai 600 048
Tamil Nadu, India

ABSTRACT
In this paper, theoretical correlation amongst various electrical characteristics of a
housing / weather shed material is attempted. Also, a correlation relating tensile
strength (a mechanical property) to insulation characteristics is proposed. The
housing material used, is made of polymeric blends (Silicone/EPDM) with and
without fillers (silica and alumina trihydrate).The proposed correlation is obtained
through Dimensional Analysis technique. An attempt is also made to provide
qualitative interpretations for these relationships, based on the fundamental
physical quantities. Multivariate regression analysis of experimental values of the
dependent and independent variables, that figure in these correlations is carried
out. It yielded almost the same values for the exponents as those in the correlations
developed using dimensional analysis. This confirmed similar quantitative and
qualitative influences of various insulation parameters on tracking resistance and
tensile strength, as predicted by the dimensional analysis approach.
Index Terms - Insulators, polymeric housing, weather shed material, silicone
rubber, EPDM, insulation characteristics, dimensional analysis, matrix analysis,
multivariate regression, tracking resistance, tensile strength, fillers, ATH, silica.

1 INTRODUCTION
POLYMERIC housing materials are being accepted
increasingly for use in outdoor insulators. It is difficult to
evaluate life expectancy of polymeric insulators. The
tremendous growth is due to their advantages over the
traditional ceramic and glass insulators [1].
Manuscript received on 28 August 2007, in final form 12 December 2007.

Faulty insulators are difficult to detect and the long

reliability is unknown. Usually, more than ten different
insulation characteristics are studied by conducting suitable
experiments and many of them are tedious and time
consuming. It has been noticed that the failure of outdoor
insulation structures is mainly due to tracking [2]. The

1070-9878/08/$25.00 2008 IEEE

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R. R. Prabu et al.: Theoretical Correlations amongst Electrical and Mechanical Characteristics of Polymeric Housing Materials

leakage current that leads to tracking depends on various

factors such as volume resistivity, surface resistivity,
dielectric strength, arc resistance, and thermal conductivity of
the composite [3].
In polymeric insulators, polymers are dependent for
enhanced electrical characteristics and fillers are used to
improve their mechanical properties.
Extensive experimentation on the housing material, with a
combination of silicone and EPDM (ratio on weight basis)
polymeric blend is conducted. The blends are tested for their
insulation characteristics as per IEC and ASTM standards.
Volume and surface resistivity, dielectric strength, dielectric
constant, tan , tracking resistance, arc resistance,
comparative tracking index, tensile strength, and percentage
elongation at break of the blends are studied and used [4].
The presence of fillers in the insulator offers defence in
helping to prevent tracking of the material. There are few
studies to establish the efficiency of surface treated filler
(e.g. silane treated silica flour).
Improved thermal
conductivity of the composite material due to the added
fillers is an important factor in deciding tracking silicone
insulators [5, 6]. There is a clear correlation established
between erosion and thermal conductivity of the composite
insulators with added filler [7].Hence, with 50% silicone
and 50% EPDM blend, experiments are carried out with
various levels of fillers such as alumina trihydrate and silica
and the results are used, for this work..
Having determined all the insulation characteristics with
various blends of EPDM / Silicone blend with and without
fillers, an attempt is made to derive correlation among the
various insulation characteristics.
Literature suggests [8] that tracking resistance is an
important index of the performance of outdoor insulators. In
this work, an empirical correlation is derived between the
tracking resistance and other insulation characteristics.
It is found that the Dimensional Analysis (DA) is a
powerful tool for simplifying the equations by reducing the
number of parameters into a set of essential parameters [911]. In this paper, a mathematical analysis is presented
based on DA that relates most of the insulation
characteristics. The empirical correlations derived based on
dimensional analysis not only relate electrical characteristics
of the housing material amongst themselves but also relate
electrical characteristics of housing / weather shed materials
to mechanical property (tensile strength). This assumes
importance when inorganic fillers like silica, alumina
trihydrate are added to improve its tracking resistance.
The strength of the empirical correlations amongst
insulator properties developed in this work is tested by the
multivariate regression analysis of the experimental results.
This is carried out to find the exponent values of each and
every independent parameter in the equation and compare
the same with the exponents obtained using dimensional
analysis technique. In the multivariate regression, the sumsquared error is the least for the dependencies expressed by
the dimensional analysis technique

Comparison is also made between the predictive abilities

of the correlations developed using dimensional analysis
technique and multivariate regression. These correlations
help to identify the dominant characteristics that influence
the efficiency of a polymeric housing material in an outdoor
insulator. Qualitative interpretations based on fundamental
relationships of physical variables are also attempted and it
lends credence to the correlations proposed in this work.

2 EXPERIMENTAL SET-UP AND

PROCEDURES
Test Samples: Blends containing various percentages of
silicone and EPDM with and without fillers (alumina
trihydrate and silica) are blended in a two-roll mill at room
temperature. Dicumyl peroxide is used as a vulcanizing
agent. Blends prepared are compression moulded into
sheets. Test specimens are prepared from compression
moulded sheets according to the standards. When the study
is carried out with fillers, various levels of alumina
trihydrate or silica are added at parts per hundred parts of
rubber (PHR) to the best combination (50:50) of silicone
and EPDM blend.
The blend preparation procedure is detailed in AppendixA.
In Appendix-B, the test conditions and procedure for the
insulation characteristics are provided.

3 RESULTS
The experimental data of various insulator properties for
the silicone/EPDM blend housing material are given in
Table 1 and the experimental data for 1:1 silicone: EPDM
blend with various levels of silica and alumina trihydrate (in
PHR) are given in Tables 2 and 3.
All the tests are carried out as per the IEC/ASTM
standards. In general, 5 samples are tested per blend
composition per test per property. Occasionally, 7 samples
are also tested, to rule out the experimental errors.
Various levels of silica filler are added to the silicone and
EPDM composite (in 1:1 weight ratio). The levels of filler
added are in parts per hundred parts of rubber (PHR).This is
shown along with the measured parameters and results in
Table 2.
Various levels of alumina trihydrate (ATH) filler are
added to the silicone and EPDM composite (in 1:1 weight
ratio). The levels of filler added are in parts per hundred
parts of rubber (PHR).This is shown along with the
experimentally determined parameters and their results in
Table 3.

IEEE Transactions on Dielectrics and Electrical Insulation

Vol. 15, No. 3; June 2008

773

Table 1. Experimental Data For Silicone:EPDM Blends.

Silicone:
EPDM
(weight ratio)

Tracking
Res. (TR)
(minute)

Vol. Res.
(VR) Ohmm

Surf. Res.
(SR)
Ohm

Arc Res.
(AR)
(second)

Dielec. Str.
(DES)
kV/mm

CTI
(Volt)

Tens. Str.
(TS) N/mm2

0:100
10:90
30:70
50:50
70:30
90:10
100:0

086
095
108
116
123
129
138

8.00 e12
2.00 e13
3.00 e13
4.70 e13
8.00 e13
1.30 e14
6.29 e14

5.65 e13
1.30 e14
1.80 e14
2.60 e14
5.00 e14
7.80 e14
3.10 e15

182
246
308
363
382
427
600

20.00
24.27
25.92
27.56
31.95
33.26
36.08

415
435
452
475
495
505
520

4.257
2.971
2.733
2.332
1.936
1.490
0.500

CTI
(Volt)

Tens.Str.
(TS) N/mm2

475
495
501
505
530
509
536
512
515
517
518
521
518

2.332
3.700
4.970
6.420
6.320
6.100
6.050
6.037
5.985
5.865
5.814
5.758
5.650

Table 2. Experimental Data For 50:50 Silicone:EPDM Blend With Silica Filler.

Silica filler in
PHR

Tracking
Res. (TR)
(minute)
0
116
10
127
20
135
30
146
30 (wst)
218
40
163
40 (wst)
235
50
175
60
193
70
205
80
213
90
222
100
228
wst with silane treatment

Vol. Res.
(VR) Ohmm
4.70e13
4.10e13
3.58e13
3.18e13
3.20e13
3.10e13
3.28e13
3.05e13
2.99e13
2.95e13
2.90e13
2.87e13
2.85e13

Surf. Res.
(SR)
Ohm
2.60e14
2.65e14
2.68e14
2.73e14
3.40e14
2.78e14
3.46e14
2.82e14
2.86e14
2.90e14
2.93e14
2.95e14
2.97e14

Arc Res.
(AR)
(second)
363
370
376
379
395
382
400
386
390
394
397
401
408

Dielec. Str.
(DES)
kV/mm
27.56
30.60
33.50
35.70
35.90
33.30
34.10
32.50
32.00
31.50
31.40
31.00
30.50

Table 3. Experimental Data For 50:50 Silicone:EPDM Blend With ATH Filler.

ATH filler in
PHR

Tracking
Res. (TR)
(minute)

0
116
10
149
20
155
30
164
30 (wst)
220
40
181
40 (wst)
238
50
193
60
211
70
223
80
232
90
240
100
246
wst with silane treatment

Vol. Res.
(VR) Ohmm

Surf. Res.
(SR) Ohm

Arc Res.
(AR)
(second)

Dielec. Str.
(DES)
kV/mm

CTI
(Volt)

Tens.Str.
(TS) N/mm2

4.70e13
3.85e13
3.45e13
3.18e13
3.36e13
3.10e13
3.31e13
3.05e13
2.99e13
2.96e13
2.90e13
2.87e13
2.85e13

2.60e14
2.68e14
2.71e14
2.74e14
2.78e14
2.78e14
3.60e14
2.82e14
2.86e14
2.89e14
2.94e14
2.98e14
3.02e14

363
384
391
395
400
400
412
404
408
412
417
420
424

27.56
30.92
34.80
36.90
37.20
35.10
35.50
33.20
32.50
32.10
31.60
31.30
30.80

475
482
495
515
540
527
546
532
544
556
No Failure
No Failure
No Failure

2.332
3.500
5.050
6.350
6.200
5.825
5.780
5.406
5.387
5.258
5.165
5.080
4.980

774

R. R. Prabu et al.: Theoretical Correlations amongst Electrical and Mechanical Characteristics of Polymeric Housing Materials

It is interesting to note from Tables 2 and 3, that as the

level of silica or alumina trihydrate(ATH) filler added to
silicone/EPDM blend increases, the volume resistivity
continues to decrease whereas the surface resistivity
continues to increase albeit marginally. The dielectric
strength and tensile strength increase up to the filler loading
of 30 PHR to silicone/EPDM blend and thereafter both the
dielectric strength and tensile strength start decreasing.
However, the tracking resistance, arc resistance, and
comparative tracking index continue to increase with the
increase in the level of fillers (silica and ATH). With more
than 80 PHR of ATH added to the silicone/EPDM blend
insulator, there was no failure observed, while assessing the
comparative tracking index.

4 DIMENSIONAL ANALYSIS TECHNIQUE

TO PREDICT TRACKING RESISTANCE
Dimensional analysis technique is a very widely used
technique in engineering to explain and/or predict the
experimental data. It is rigorous than regression-based
correlation or data fitting as it takes into account the
relationships amongst the parameters chosen to explain or
predict the data.
The electrical parameters that are measured are tracking
resistance, arc resistance, dielectric strength, dielectric
constant, dissipation factor, volume resistivity, surface
resistivity, and comparative tracking index. The mechanical
parameters that are of interest are the tensile strength and %
elongation at break.
Amongst these parameters, dielectric constant, dissipation
factor, and % elongation at break are dimensionless and
they are reported as numerical values. Thus, there are seven
dimensional parameters that are assessed for housing
material of any insulator.
Tracking resistance takes a longer duration to determine.
Also, there are no relationships established amongst these
various electrical parameters. More importantly, the
mechanical properties and electrical properties go in
opposite direction when housing materials made with blends
such as silicone and EPDM are tested. Hence, a relationship
that links up the mechanical property with electrical
properties of an insulator is always useful to have a
combined assessment of the housing material of an insulator
instead of looking at either electrical or mechanical
properties.
The objective is to arrive at such useful relationships that
connect electrical and mechanical properties and also help
in predicting a parameter that is difficult to measure i.e.
tracking resistance of an insulator. The aim is not only to
develop relationships but also to develop them based on
fundamental logic. Thus, it is attempted here to predict
tracking resistance based on few other electrical properties
variables considered common and repeated, to arrive at the
two expressions are (AR/VR), DES, SR, and CTI.

and also to establish a relationship between tensile strength

and some of the electrical properties based on dimensional
analysis technique.
In the electrical properties listed, tracking resistance (TR),
arc resistance (AR), dielectric strength (DES), volume
resistivity (VR), surface resistivity (SR), and comparative
tracking index (CTI) are dimensional parameters. Amongst
the mechanical properties mentioned, only tensile strength
(TS) is the dimensional parameter. Thus, these seven
insulator parameters alone are considered to develop a
relationship between them. These parameters can be
expressed with the combination of four fundamental
dimensions MLTQ where M, L, T, and Q are the mass,
length, time and charge respectively.
There are two alternatives, either to develop expressions
for three different characteristics based on a common set of
four repeated variables or to develop two equations one for
tracking resistance and another one for tensile strength
relating all the seven dimensional properties. However, in
this case, it is necessary to suitably club the properties to
reduce them to four repeated variables for the sake of
dimensional analysis. Here, the latter approach is adopted,
as one does not know a priori as to which characteristics
can be ignored. Hence, as described in the Dimensional
Analysis (DA) approach, volume resistivity (VR) and arc
resistance (AR) are clubbed to reduce them into one variable
The dimensions of the above parameters are:
TR -> T
AR -> T
DES -> M L T-2 Q-1
VR - M L3 T-1 Q-2
SR -> M L2 T-1 Q-2
CTI -> M L2 T-2 Q-1
TS -> M L-1 T-2
The dimensional matrix of the six parameters and the four
fundamental dimensions can be written as follows:
TR TS VR/AR DES SR CTI
M 01
L 0 -1

1
2

1
2

T 1 -2

-2

-2

-1

-2

Q 00

-2

-1

-2

-1

The rank (r) of the above dimensional matrix is 4 and the

number of parameter (n) is 6. The solution can be expressed
as two (n -r = 2) independent dimensionless products (1
The
and 2) with the dimension M0 L0 T0 Q0.
The two expressions for TR (Tracking Resistance) and TS
(Tensile Strength) are given, as under.
(1)
1 = [CTI]a1 [DES]b1 [SR]c1 [VR/AR]d1 TR

IEEE Transactions on Dielectrics and Electrical Insulation

Vol. 15, No. 3; June 2008

2 = [CTI]a2 [DES]b2 [SR]c2 [VR/AR]d2 TS

(2)

Here an, bn, cn, and dn are the power indexes of the
repeated variables. The dimensionless expression for 1 and
2 are:
1 D1 [M L2 T-2 Q-1]a1 [M L T-2 Q-1]b1 [M L2 T-1 Q-2]c1
[ M L3 T-2 Q-2]d1 [T]
= [M0 L0 T0 Q0]
(3)
2 D2 [M L2 T-2 Q-1]a2 [M L T-2 Q-1]b2 [M L2 T-1 Q-2]c2
(4)
[ M L3 T-2 Q-2]d2 [M L-1 T-2] = [M0 L0 T0 Q0]
Equating the powers of fundamental units M, L, T, and Q
on both sides of the above two expressions would lead to
homogeneous linear algebraic equations. The solutions of
those linear algebraic equations would give the values of the
power indexes using which one can construct the
mathematical relationship for Tracking Resistance (TR) and
Tensile Strength (TS) using the repeated variables.
Using equation (1), an expression for Tracking Resistance
(TR) can be written as
1 D1 [M] a1+b1+c1+d1
a -b -2c -2d
= [M]0
1 1 1 1

[ L] 2a1+b1+2c1+3d1 [T] 2a1-2b1-c1-2d1+1 [Q]

[L]0 [T]0 [Q]0
(5)

2a2 + b2 + 2c2 + 3d2 = 1

2a2 + 2b2 + c2 + 2d2 = -2
a2 + b2 + 2c2 + 2d2

=0

As described before, the above homogenous linear

equations can be solved using the matrix solution of linear
systems and thus a2 = 0, b2 = 2, c2 = 0, and d2 = -1.
Using the a2, b2, c2, and d2 values i.e. power index values
in equation (2), the mathematical relationship with the
dimensionless constant for predicting the Tensile Strength
(TS) of an insulator is obtained.
Thus,
TS = D2 [CTI]0 [DES]+2 [SR]0 [VR/AR]-1
This can be rewritten as,
TS = D2 [DES]+2 [AR/VR]+1

(8)

The units of the above equation are

The dimensionless constants D1 and D2 are determined

from the experiment. The predictions of tracking resistance
and tensile strength are made using the above mathematical
equations (6) and (8). The predictions are very satisfactory
and match with the experimental data.

2a1 + b1 + 2c1 + 3d1 = 0

2a1 + 2b1 + c1 + 2d1 = 1
a1 + b1 + 2c1 + 2d1 = 0
The above homogenous linear equations can be solved
using the matrix solution of linear systems.
Using the a1, b1, c1, and d1 values i.e. power index values
in equation (1), the mathematical relationship with the
dimensionless constant (D1) for predicting the Tracking
Resistance (TR) of an insulator is arrived. Thus,
TR = D1 [CTI]+1 [DES]-1 [SR]+1 [VR/AR]-1
This can be rewritten as,
TR = D1 [CTI]+1 [DES]-1 [SR]+1 [AR/VR]+1
Rearranging the RHS of the above equation, we get
(6)

5 DIMENSIONAL ANALYSIS TECHNIQUE

TO PREDICT TENSILE STRENGTH
Using equation (2), an expression for Tensile Strength
(TS) can be written as
2 D2 [M] a2+b2+c2+d2+1 [ L] 2a2+b2+2c2+3d2-1 [T]
[M]0 [L]0 [T]0 [Q]0
[Q] a2-b2-2c2-2d2 =

= -1

N/m2 = (Volt/m)2 (sec/Ohm.m)

i.e., N/m2 = (Volt2/m3) (sec/Ohm)

a1 + b1 + c1 + d1 = 0

TR = D1 . {[CTI] /[DES]} . [SR][AR]/ [VR]}

a2 + b2 + c2 + d2

775

2a -2b -c -2d -2
2 2 2 2

(7)

6 MULTIVARIATE REGRESSION
ANALYSIS
In order to make sure whether the relationship arrived at
using the DA approach is the best possible equation for
predicting TR, the multivariate regression is done on the
entire set of experimental data obtained with and without
fillers and with and without tri ethoxy vinyl silane treatment
involving the above mentioned variables. Here, the TR is
the dependent variable (Y). CTI, DES, SR, AR and VR are
the independent variables (X1, X2, X3, X4, X5)
respectively.
While carrying out the dimensional analysis, the
exponents of the independent variables in that equation are
arrived at purely by adjusting the dimensions on either side
of the equation. The multivariate regression gives the
exponent values for the independent variables and also the
value of the constants. Multivariate regression is trying to
correlate or fit the entire set of independent variable data
obtained with and without fillers and with tri ethoxy vinyl
silane treatment (X1, X2, X3, X4 and X5) to the dependent
variable (Y) and this gives rise to the exponent values.
Multivariate regression often leaves a residual dimension to
the constant. Thus, the constant arrived at using
multivariate regression is 'dimensional' in nature whereas

776

R. R. Prabu et al.: Theoretical Correlations amongst Electrical and Mechanical Characteristics of Polymeric Housing Materials

the empirical constant in the DA technique is

'dimensionless'. The errors in predictions are basically
minimized in multivariate regression as it adjusts the
dimensional constant.
Similarly, the multivariate regression is done on the
entire set of experimental data obtained for TS. Here, the TS
is the dependent variable (Y) and DES, VR and AR are the
independent variables (X1, X2, X3) respectively.
Table 4 shows a comparison of the predictive
capabilities of expressions arrived at using dimensional
analysis and multivariate regression for tracking resistance
(TR) for the silicone-EPDM blend with and without fillers
and with tri ethoxy vinyl silane treatment.
Residual Dimensions of the Multivariate Regression
constant D1 used in the correlation to predict tracking
resistance of silicone-EPDM blend, with and without fillers
and with tri ethoxy vinyl silane treatment is obtained by
equating the powers of M, L, T and Q on both sides of the
expression arrived by using multivariate regression.

Similar procedure is followed for tensile strength. Table

6.2 shows a comparison of the predictive capabilities of the
dimensional analysis and multivariate regression for tensile
strength (TS) of the silicone-EPDM blend with and without
fillers and with tri ethoxy vinyl silane treatment.
As described above, by equating the powers of M, L, T
and Q on both sides of the multivariate regression equation,
the residual dimensions of constant D2 in Table5 is
obtained.

Table 4. Comparison of Predictive Capabilities of Dimensional Analysis

and Multivariate Regression to Predict Tracking Resistance for an Insulator
Housing Material made of Silicone/EPDM Blends with and without
Fillers.

Exponent for
CTI (X1)
Exponent for
DES(X2)
Exponent for
SR (X3)
Exponent for
AR (X4)
Exponent for
VR (X5)
Value of
Constant (D1)
Dimensions of
Const. D1
Range of Errors

(AR)

Exponent for
DES (X1)
Exponent for AR
(X2)
Exponent for VR
(X3)
Value of
Constant (D2)
Dimensions of
Const. D2
Range of Errors

Dimensional
Analysis
+2

Multivariate
Regression
+2.017

+1

+0.747

-1

-0.966

412

460.37

NIL

M-0.051 L-0.119
T0.321 Q0.085
-12.88% to
8.53%

Dimensional
Analysis
+1

Multivariate
Regression
+0.884

-1

-0.674

7 PREDICTIONS OF TR AND TS

+1

+0.978

+1

+0.843

-1

-0.974

2,00,000

3344.2

NIL

M-0.214 L-0.128 T0.581

Q0.218
-10.17% to 5.2%

The comparison between experimental values of

tracking resistance and tensile strength against the values
predicted by the empirical relationships equations (6) and
(8) for the silicone-EPDM blend housing material are shown
in Tables 6 and 7.
As can be seen from Table 6, the empirical correlations
based on dimensional analysis and multivariate regression
predict the decrease in tensile strength with increasing levels
of silicone in the blend.
It is to be mentioned that the tracking resistance (TR)
and tensile strength (TS) are given in their typical units i.e.
minute and N/mm2 respectively, although the values of the
independent variables appearing in the equations are taken
in SI units. The experimental values of dielectric strength
are given in kV/mm. These are converted to V/m when
predicting tracking resistance and tensile strength using
equations (6) and (8).
Tables 8 and 9 show the comparisons between
experimental values of tracking resistance and tensile
strength against the values predicted by the empirical
relationships (arrived at using dimensional analysis and
multivariate regression) for the housing material made of
50:50 Silicone-EPDM blend in an outdoor insulator with
various levels (in phr) of silica added to the blend as filler
(Table 8 and Table9).

-3.033% to
0.793%
The equation based on multivariate regression to predict
tracking resistance is:
0.843

Table 5. Comparison of Predictive Capabilities of Dimensional Analysis

and Multivariate Regression to Predict Tensile Strength for an Insulator
Housing Material made of Silicone/EPDM Blends with and without Fillers.

TR = D1 (CTI)0.884 (DES)0.674 (SR)0.978

(VR)-0.974

In terms of the dimensions, the above equation is

represented as
[T] = D1 [M L2 T-2 Q-1]0.884 [M L T-2 Q-1]0.674
[M L2 T-1 Q-2]0.978 [T]0.843 [M L3 T-1 Q-2]-0.974
By equating the powers of M, L, T and Q on both sides,
the residual dimensions of the constant D1 is obtained as
[M]-0.214 [L]-0.128 [T]0.581 [Q]0.218.

-11.91% to
3.92%

IEEE Transactions on Dielectrics and Electrical Insulation

Vol. 15, No. 3; June 2008

Table 6. Measured and Predicted Values of Tracking Resistance for 50:50

Silicone:EPDM Blends.

Silicone
:EPDM
(Weight
Ratio)

measured
Tracking
Resis. (TR
in Minute)

0:100
10:90
30:70
50:50
70:30
90:10
100:0

86
95
108
116
123
129
138

Predicted
TR
based
on
DA
(minute)
88.91
95.53
107.42
115.37
123.3
129.67
142.06

Predicted TR
based on
Multivariate
Regression
(minute)
84.48
92.22
102.16
108.85
120.45
126.19
135.56

Table 7. Measured and Predicted Values of Tensile Strength for 50:50

Silicone: EPDM Blends.

Silicone:
EPDM
(weight
ratio)

Measured
TS
(N/mm2)

Predicted TS
based on
DA
(N/mm2)

0:100
10:90
30:70
50:50
70:30
90:10
100:0

4.257
2.971
2.733
2.332
1.936
1.49
0.5

3.75
2.98
2.84
2.42
2.01
1.50
0.512

Predicted TS
based on
Multivariate
Regression
(N/mm2)
4.10
3.13
2.86
2.37
1.99
1.46
0.485

Table 8. Measured and Predicted Values of Tracking Resistance for 50:50

Silicone:EPDM Blend with Various Levels (in PHR) of Silica Filler.

Silica
filler in
PHR

Measured
Tracking
Res. (TR)
(minute)

Predicted
TR based
on DA
(minute)

0
10
20
30
30 (wst)
40
40(wst)
50
60
70
80
90
100

116
127
135
146
218
163
235
175
193
205
213
222
228

115
129
140
153
206.53
175
221.08
187
200
212
221
231
241

Predicted TR
based on
Multivariate
Regression
(minute)
108.85
124.42
138.37
153.58
203.69
170.26
213.77
180.82
191.51
201.2
208.78
217.07
224.55

777

Table 9. Measured and Predicted Values of Tensile Strength for 50:50

Silicone/EPDM Blend with Various Levels (in PHR) of Silica Filler.

Silica
filler in
PHR
0
10
20
30
30 (wst)
40
40 (wst)
50
60
70
80
90
100

Measured.
Tensile
Strength
(TS)
(N/mm2)
2.332
3.7
4.97
6.42
6.32
6.1
6.05
6.037
5.985
5.865
5.814
5.758
5.65

Predicted
TS based
on DA
(N/mm2)
2.42
3.48
4.86
6.26
6.55
5.63
5.84
5.51
5.50
5.46
5.56
5.53
5.49

Predicted TS
based on
Multivariate
Regression
(N/mm2)
2.37
3.39
4.7
6.02
6.24
5.4
5.55
5.26
5.24
5.18
5.26
5.22
5.15

It is interesting to note that the equations predict the

decline in tensile strength as silicone composition is
increased in the blend of the insulator while predicting the
increase in electrical properties such as tracking resistance
and dielectric strength. This adds credence to the approach
used in this work and also the prediction capability of the
proposed equations.
Similarly, Tables 10 and 11 show the comparisons
between experimental values of tracking resistance and
tensile strength against the values predicted by the empirical
relations (arrived at using dimensional analysis and
multivariate regression) for the housing material made of
50:50 Silicone:EPDM blend with various levels (in PHR) of
ATH added to the blend, as filler.
Table10. Measured and Predicted Values of Tracking Resistance for
50:50 Silicone:EPDM Blend with Various Levels (in PHR) of Alumina
Trihydrate (ATH) Filler.

ATH
filler in
PHR
0
10
20
30
30(wst)
40
40(wst)
50
60
70
80
90
100

Measured
Tracking
resistance
(TR)
(minute)
116
149
155
164
220
181
238
193
211
223
232
240
246

Predicted
TR based
on DA
(minute)
115
139
146
158
201.61
180
229.73
200
218
232
-

Predicted TR
based on
Multivariate
Regression
(minute)
108.85
133.84
144.53
158.81
200.45
176.16
223.4
191.61
206.64
218.51
-

778

R. R. Prabu et al.: Theoretical Correlations amongst Electrical and Mechanical Characteristics of Polymeric Housing Materials

Table 11. Measured and Predicted Values of Tensile Strength for 50:50
Silicone/EPDM Blend with Various Levels (in PHR) of Alumina
Trihydrate (ATH) Filler.

ATH
filler in
PHR
0
10
20
30
30(wst)
40
40(wst)
50
60
70
80
90
100

Measured
Tensile
Strength
(TS)
(N/mm2)
2.332
3.5
5.05
6.35
6.2
5.825
5.78
5.406
5.387
5.258
5.165
5.08
4.98

Predicted
TS based
on DA
(N/mm2)
2.42
3.93
5.65
6.97
6.79
6.55
6.46
6.02
5.94
5.91
5.92
5.91
5.81

Predicted TS
based on
Multivariate
Regression
(N/mm2)
2.37
3.78
5.41
6.64
6.46
6.21
6.1
5.68
5.59
5.54
5.53
5.51
5.40

based on dimensional analysis. This adds to the strength

of the equation derived based on dimensional analysis.
4. The ranges of errors in both the approaches are small
(given the fact that the data are collected from different
set of experiments) and regression equation is obtained
using the entire set of experimental data.
5. The constants D1 and D2 arrived at using multivariate
regression are dimensional and carry the residual
dimensions of the independent variables in order to
match with the dimensions of the dependent variable.
Going by the above comparisons, the equations arrived at
using the dimensional analysis technique for predicting
tracking resistance and tensile strength are quite robust as
the constants D1 and D2 are dimensionless. It gains
credence as the multivariate regression also gave rise to the
equations that are very similar to the ones developed.

8 QUALITATIVE INTERPRETATIONS
The equation (6) can be qualitatively interpreted based on
their units and dimensions as follows:
CTI / DES = V/ (V/m) = m i.e. length that withstands
tracking;

It is clear from Tables 8 and 10 that the increased arc

resistance and surface resistivity enhance the tracking
resistance of the silicone:EPDM blend with fillers (silica or
ATH) added to it.
Tables 9 and 11 show that the empirical correlations based
on dimensional analysis and multivariate regression predict
the maxima in tensile strength with 30 parts of filler (silica
or alumina trihydrate) per hundred parts of rubber in
silicone / EPDM blend housing material in an insulator.
This clearly establishes the fact that tensile strength, which
is a bulk property, is highly dependent on or influences the
other bulk properties such as dielectric strength and volume
resistivity.
This establishes the qualitative influences of independent
variables on dependent variables.
1.

2.

3.

It is quite interesting to note that both dimensional

analysis and multivariate regression technique matched
with respect to the sign of the exponent values and
numerical values for the independent variables (X1 to
X5 in Table 4 and X1 to X3 in Table 5)..
There are two orders of magnitude difference between
the two values of the constant D1 which is used to
predict tracking resistance using DA technique and
multivariate regression (Table 4) and the values of the
constant D2 which is used to predict tensile strength by
both the approaches are more or less the same (Table
5).
The same values of D1 and D2 are used to predict
tracking resistance and tensile strength of the siliconeEPDM blend housing material with and without fillers
and with silane treatment, using the equations derived

(SR * AR) / VR = (Ohm. Sec) / (Ohm. m) = sec/m i.e. 1/

velocity of tracking
Thus, equation (6) is interpreted as
TR (in seconds) = D1 * (Length that withstands tracking)
/ (Velocity of tracking)
Of course, this is only a qualitative interpretation of the
mathematical relationship.
Considering the definition of CTI and DES, it is possible
to understand the qualitative feature of dividing CTI by
DES. According to IEC 60112, CTI (comparative tracking
index) is the maximum endurable voltage for a certain
insulator without causing tracking up to 50 drops of the
electrolyte in each of the 5 repeated tests. Dielectric strength
(DES) is the voltage at which dielectric failure of the
insulating material occurs under specific condition of test.
According to IEC 60243-1 (ASTMD149) standard,
dielectric breakdown strength (kV/mm) is calculated by the
ratio of dielectric breakdown voltage (kV) to the thickness
of the specimen (mm). In a way, the physical meaning of
dividing CTI divided by DES is nothing but [maximum
endurable voltage (against tracking)] / [(dielectric
breakdown voltage /thickness of the insulator specimen)].
This is nothing but the thickness of the specimen.
Volume resistance is the resistance to leakage through the
body of the material. It takes into account the
length/thickness of the material that possess resistance to
leakage and that is how the unit for volume resistivity is
reported (Ohm. m). Hence, VR/SR must represent length or
thickness of insulator that possesses the resistance to

IEEE Transactions on Dielectrics and Electrical Insulation

Vol. 15, No. 3; June 2008

leakage. As per ASTM D495, arc resistance is the time

taken for failure when an arc is struck between two
electrodes and in practice it is an arc struck on the surface of
the insulator.
Thus, the physical interpretation for equation (6) should
be:
Tracking Resistance (in seconds) = D1 * (Thickness of
insulator that withstands tracking and dielectric failure) /
[(Thickness of insulator that possess the resistance to
leakage) / (time taken for failure due to an arc)]
Similarly, the equation (8) can be qualitatively interpreted
based on the fundamental principle of conservation of
energy. The dielectric failure or tracking occurs when the
mechanical strength of the insulator housing material is not
able to resist the insulation failure. The equation (8) is
attempting to relate the electrical properties such as
dielectric strength, volume resistivity, and arcing resistance
- of an insulator housing material to its mechanical property,
which is tensile strength. It gains credence and gets justified
when the mechanical energy to the electrical energy of an
insulator is compared.
Tensile strength means the stress at the maximum load. It
is shown as the load divided by the minimum cross sectional
area of the specimen before the initiation of the test (as due
to the application of load there would be elongation). Hence,
tensile strength is nothing but the stress or pressure that a
material can withstand.
According to the law of conservation of energy,
(Mechanical Energy)= (Electrical Energy)

(A)

779

Thus (E) becomes,

Mechanical Power = (Volumetric flow rate) (Pressure
difference) = I x V = Electrical Power
In the units and dimensions analysis, the term (Cosine) in
the expression for electrical power is ignored.
Since tensile strength is nothing but the pressure term, if
we multiply this with volumetric flow rate (Q), we must get
the value of mechanical power. This product must be equal
to V x I, which is electrical power based on the above
analogy. Therefore,
TS * Q = V * I
I can be expressed as (V / R) or alternately I is expressed
as (V ) where is the electrical conductance (which is
1/R).
(TS) (Q) = (V) (V ) =V2
This same expression for electrical power can be obtained
by an alternate way also.
Dissipative power or Joule heating in an insulator is
given by
P = I2 R = (V/R)2 * R = V2 (1/R) = V2
i.e. Power = electrical conductance * V2
Thus,

The time differential of mechanical and electrical energy is

TS* Q = V2 * ;

Mechanical Power = Electrical power

Divide both sides by volumetric flow rate to get,

(B)

Mechanical Power = (Volumetric flow rate) (pressure

difference)
(C)
The analogy of pressure difference in electrical terms is
the product of charge density and electrical potential
difference.
Pressure difference = (charge density) (electrical potential
difference)
(D)
Electrical potential difference is denoted as voltage (V)
and is given in Volts.
Substituting (D) in (C), we get,
Mechanical Power = (Volumetric flow rate) (pressure
difference) = (Volumetric flow rate) (charge density)
(electrical potential difference)
(E)
However, (Volumetric flow rate) (charge density) =
Current (I)
(F)

TS = (V2 * ) / Q;
The units on both sides of above equation are,
N/m2 = (Volt)2 * (1/Ohm) * (sec/m3)
This can be rearranged as,
N/m2 = (Volt/m)2 * (1/Ohm.m) * (sec)
In terms of the electrical properties of an insulator that are
considered in this work, it is expressed as,
TS = (DES)2*(1/VR)*(AR) = (DES)2 * (AR/VR)

9 SUMMARY
1.

Dimensional analysis technique is used to

develop a mathematical relationship between
tracking resistance and other electrical
characteristics and also between tensile strength

780

R. R. Prabu et al.: Theoretical Correlations amongst Electrical and Mechanical Characteristics of Polymeric Housing Materials

2.

3.

4.

5.

6.

7.

and electrical characteristics of a polymeric

housing material used in outdoor insulators.
These correlations are valid for the set of
electrical and mechanical properties that are
taken into account. The constants D1 and D2 are
obtained from experimental data.
It is found that the equation predicts the decline
in tensile strength as silicone composition is
increased in the blend while predicting the
increase in electrical properties such as tracking
resistance and dielectric strength. This adds credit
to the approach used in this work and also the
prediction capability of the proposed equations.
The multivariate regression analysis of the
physical variables in the proposed empirical
correlations, found to get errors in acceptable
limits.
The comparison between the predictive abilities
of the correlations based on dimensional analysis
and the multivariate regression analysis proves
that the correlations proposed based on
dimensional analysis approach are quite better, as
the constant in those correlations are
dimensionless whereas, the constants in the
correlations from multivariate regression analysis
have residual dimensions.
These correlations would help in predicting an
electrical property (tracking resistance), that is
tedious and time consuming, to experimentally
determine, based on a few insulation
characteristics that are easy to measure and
quantify.
Also, the relationship derived between tensile
strength and electrical characteristics would help
in choosing the right type and amount of filler
that offers optimal tracking resistance while
improving the mechanical strength of the housing
material used in an outdoor insulator.

APPENDIX A
A.1 PREPARATION OF BLENDS
Passing through the rollers for three minutes softens
EPDM rubber initially and then silicone rubber is mixed.
The mixing of EPDM and silicone rubber is carried out for
twelve minutes. Di cumyl peroxide is mixed at the final
stage of mixing.
The blends of silicone and EPDM containing various
proportions of component polymers are prepared in a
laboratory model two roll mixing mill at a temperature of
353 K. Dicumyl Peroxide is mixed during the mill mixing
as a curing agent to all the blends at 2.5 parts per hundred
parts of rubber (phr).

A.2 VULCANIZATION
The vulcanization of the blends is carried out in a
hydraulically operated press at 443 K for 10 minutes. The
vulcanized samples are post cured at 423 K for 2 hours in an
air circulated oven. Test specimens are punched out from
the compression moulded sheets.
A.3 BLEND COMPOSITION
Various compositions of silicone rubber and EPDM
blends prepared are given as follows
First EPDM rubber is blended with silicone rubber in a
complementary mixture of 0, 10, 30, 50, 70, 90, and 100
percent by weight. 2.5 phr of di-cumyl peroxide is added as
the curing agent. With the above set of mixtures, it becomes
possible to analyze the performance characteristics of
silicone rubber alone, EPDM rubber alone and a mixture of
silicone and EPDM in various ratios.

APPENDIX B
B.1 CHARACTERIZATION
In this section, the test conditions and procedure for the
important electrical and mechanical insulation characteristics of
a polymeric insulator are described.
B.2 TRACKING RESISTANCE
A partially conducting part of localized deterioration on
the surface of the insulating material is called a 'track. The
process that produces track as a result of action of electrical
discharges on or close to insulation surface is called
'tracking'. 'Tracking resistance' is the quantitative expression
of the voltage and time required to develop tracking under
specified conditions. Tracking resistance was assessed as
per IEC-60587 standards.
Tracking resistance is determined as per IEC-60587. The
distance between the top and bottom electrode is adjusted to
be equal to 50 mm and 4.5 kV is applied. Ammonium
chloride solution of 0.1 % concentration is used as
contaminant at a flow rate of 0.6 ml / min, which is
controlled by using a peristaltic pump. The conductivity of
the contaminant is 2500 S/cm. The conductivity is
measured using Lutron CD 4302. Time to failure due to
tracking is noted.
B.3 VOLUME RESISTIVITY AND SURFACE
RESISTIVITY
The volume and surface resistivity of the samples are
measured as per ASTM D257 (IEC 60093) Standards. The
voltage applied is 500 V (DC) for 60 seconds at room
temperature. The diameter and thickness of the specimen are
100 mm and 3 mm respectively. Million meg-Ohm meter is
used to measure volume and surface resistivity

IEEE Transactions on Dielectrics and Electrical Insulation

Vol. 15, No. 3; June 2008

781

B.4 ARC RESISTANCE

Arc resistance of the sample is determined as per ASTM
D 495 standard at 250 V and 50 Hz. The applied voltage is
12.5 kV and the distance between the electrodes is 6 mm. The
thickness of the specimen used is 3 mm. Two electrodes are
kept above the specimen, which is placed on the specimen
holder. The voltage is applied intermittently and severity is
increased in steps, until the failure occurs. An arc is struck in
between the electrodes. After some time, the carbon path
developed on the surface of the material led to conduction. The
arc resistance is measured in terms of time in seconds for
failure to take place.

are also as per ASTM D-412. The tensile testing machine

of constant rate of crosshead movement is used.

B.5 COMPARATIVE TRACKING INDEX (CTI)

The comparative tracking index is determined as per IEC
60112. The voltage applied is 500 V. The electrolyte used is
0.1 % of aqueous ammonium chloride. The distance between
the electrodes is 4 mm. The thickness of the electrode is 3 mm.
Two chisel edged electrode, usually of brass are rested on
horizontal test piece 4 mm apart. Drops of specified size of 0.1
% NH4Cl solution are made to fall between the electrodes at 30
seconds interval. The number of drops required to cause failure
is found for several voltages and a curve of number of drops to
failure against voltage is constructed. The voltage
corresponding to 50 drops is noted. The numerical value of this
voltage is called C.T.I.

The authors wish to thank All India Council for Technical

Education (AICTE), Government of India, for providing
funds to carry out the research work.

B.6 DIELECTRIC STRENGTH

Dielectric strength of the blended sample is determined as
per IEC-60243-1 (ASTM D 149) standard at 250 V and 50
Hz. The diameter and thickness of the samples are 100 mm
and 1 mm respectively. Test specimen is placed between
two electrodes and the voltage is increased at a fixed rate of
2 kV/s, until the dielectric breakdown occurs. The voltage at
which dielectric breakdown occurs is read as dielectric
breakdown voltage. Dielectric breakdown strength (kV/mm)
is calculated from the ratio of dielectric breakdown voltage
(kV) to the thickness of the specimen (mm). The Top
electrode size is 25 mm and the Bottom electrode is 75
mm.
B.7 DIELECTRIC CONSTANT AND DISSIPATION
FACTOR (tan )
The measurement of dielectric constant and dissipation
factor (tan ) is carried out as per IEC 60250 standard at 50
Hz. The specimens with 50 mm in diameter and 3 mm in
thickness are used
B.8 TENSILE STRENGTH AND PERCENTAGE
ELONGATION AT BREAK
The tensile Strength and percentage elongation at break
are assessed by ASTM D-412, using universal testing
machine. The shape and the size of the test specimen used

ACKNOWLEDGEMENT
The authors wish to express their gratitude to the
Management of B.S.A Crescent Engineering College, Mr
Abdul Qadir A. Rahman Buhari, Correspondent, Dr.V.M.
Periasamy, Principal, Dean(s) and Director, for their support
and encouragement.
Special encomiums are due to the faculty, department of
High Voltage Engineering, College of Engineering, Guindy,
Anna University, Chennai-25.

REFERENCES
[1]

R. Hackam, Outdoor HV Composite Polymeric Insulators, IEEE

Trans. Dielectr. Electr. Insul., Vol. 6, pp. 557-585 , 1999.
[2] N.Yoshimura, S. Kumagai and B. Du, Research in Japan on the
Tracking Phenomenon of Electrical Insulating Materials, IEEE Electr.
Insul. Mag., Vol. 13, No.5, pp 8-18, 1997.
[3] S.H. Kim and R. Hackam, Effects of Saline-Water Flow Rate and Air
Speed on Leakage Current in RTV Coatings, IEEE Trans. Power
Delivery, Vol. 10, pp. 1956-1964, 1995.
[4] R. Raja Prabu, S. Usa, K. Udayakumar,M. Abdullahkhan and S.S.M.
Abdulmajeed,Electrical Insulation Characteristics of Slicone and EPDM
Polymeric Blends Part I, IEEE Trans. Dielectr. Electr. Insul., Vol. 14,
pp.1207-1214, 2007.
[5] R.S. Gorur, E.A, Cherney and R. Hackam, "The AC and DC
Performance of Polymeric Insulating Materials under Accelerated Aging
in a Fog Chamber", IEEE Trans. Power Delivery, Vol. 3, pp..1892-1902,
1988.
[6] L.H. Meyer, S.H. Jayaram, and E.A. Cherney, "Thermal Characteristics of
RTV and Hot Pressed Silicone rubber filled with ATH and Silica under Laser
Heating", IEEE Conf. Elect. Insul. Dielect. Phenomena (CEIDP), Albuquerque,
pp.383-386, 2003.
[7] L.H. Meyer, E.A. Cherney and S.H. Jayaram, "The Role of Inorganic
Fillers in Silicone Rubber for Outdoor Insulation - Alumina Trihydrate or
Silica", IEEE Electr. Insul. Mag., Vol. 20, No. 4, pp.13-21, 2004.
[8] A. M. Piah and A. Darus, Modelling Leakage Current and electric
field behaviour of wet contaminated insulators, IEEE Trans. Power
Delivery, Vol.19, pp. 432-433, 2004.
[9] G.A.Vignaux, Dimensional Analysis in Data Modelling, Kluwer
Academic Publishers, 1992.
[10] E.Q. Isaacson and M.Q. Isaacson, Dimensional Methods in
Engineering and Physics, Edward Arnold, 1975.
[11]H.L. Langhaar, Dimensional Analysis and Theory of Models, Wiley,
1951.
Dr. R. Raja Prabu (M05-SM07) was born in
1967. He received the B.E. and M.E. degrees in
Electrical Engineering and Power System
Engineering, respectively in 1988 and 1990. He
received the Ph.D. degree in High Voltage
Engineering from Anna University. Currently, he
is working as Professor and Head in the department
of E.E.E in B.S.A. Crescent Engineering College,
Chennai.
All India Council for Technical
Education, India, sponsored his research work. He
is a member of IEEE, CIGRE, I.E (I) and I.S.T.E. His research interests
include Outdoor Insulation, Digital Protection, High Voltage Engineering ,
Nano- Dielectrics etc.,.

782

R. R. Prabu et al.: Theoretical Correlations amongst Electrical and Mechanical Characteristics of Polymeric Housing Materials

Dr. S. Usa received the B.E, M.E., and Ph.D., degrees in electrical
engineering from College of Engineering, Anna University in 1986, 1989
and 1995, respectively. From 1992 to 2000, she worked as Lecturer and
since 2000 as Assistant Professor at the College of Engineering, Anna
University. Her research interests include electromagnetic field
computation and high voltage engineering. She is a member of IEE, UK.

Dr. K. Udayakumar (SM80) received the B.E.,

M.E., and Ph.D., degrees from the College of
Anna University in 1972, 1974 and 1987,
respectively. He started his career as Lecturer in
Anna University and subsequently promoted as
Assistant Professor and currently he is a Professor,
in the Department of Electrical and Electronics
Engineering, Anna University. He guided a number
of Ph.D. students and has several publications in
journals. He served as Director of various centers
of the University. His research interest is in high voltage engineering. Dr.
Udayakumar was the Chair of the Madras Chapter of IEEE.

Dr. M. Abdullah Khan (M78) was born in 1940.

He obtained the B.E. degree in electrical
engineering, the M.E. degree in high voltage
engineering and the Ph.D. degree in power system
engineering, respectively in 1961, 1968 and 1974.
He guided several Ph.D. and M.E. students.
Currently he is working as a Professor in the Dept.
of EEE, Crescent Engineering College. He is a
member of ISTE (India). He published several
papers in journals and conferences. Previously, he
was the Dean and Director of Anna University. He has teaching and
research experience of more than 40 years.
Dr. S.S.M. Abdul Majeed received the M.Sc.
degree in industrial chemistry from Bharathidasan
University, India and the Ph.D. degree in polymer
science and technology from Anna University,
India, in 2002. He has been with Crescent
Engineering College, Chennai, India, since 1988
and currently he is serving as Assistant Professor
in the Department of Polymer Technology. His
research interest includes the development and
characterization of polymeric insulators, polymer
blends, biodegradable plastics and composites.