TRAINING REPORT

TRAINING REPORT
At Indian rubber manufacturers research association

Under the Guidance of

Mr. Mohammad Anees Assistant director (IRMRA)

&

Assistant Prof. Dr. Mohd Zain Khan (AMU)

MOHD BILAL & ASHISH KUMAR

4/10/2019

M.VOC POLYMER & COATING TECH.

ALIGARH MUSLIM UNIVERSITY ALIGARH
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ACKNOWLEDGEMENT

It is my proud privilege to express feelings of my sincere gratitude to several

people who helped me either unswervingly or secondarily to conduct this
industrial training. I would like to express my special thanks of gratitude to my
teacher Assistant Prof. Dr. Mohd Zain Khan for his guidance and invaluable
advice imparted through this training.

I would like to deeply acknowledge Dr. K. Rajkumar, Director, IRMRA for his
kind cooperation.

I am extremely thankful to my project co-guide Mr. Mohd Anees, Assistant

Director, Indian Rubber Manufacturers Research Association Thane (IRMRA)

I am also thankful to Mr. Sameer Gandhi, Mr. Shanta Ram Naik, Mr. Saburaj in
physical testings’ and Mr. Manohar Nawale, Mr. Anil Bhujwal in chemical
testing’s and all other staff members of IRMRA for their kind help.

I also thank all my friends who have more or less contributed to the preparation
of this project report. I will be always indebted to them.
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MOHD BILAL

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Contents
1. Introduction……………………………………………………….…………………..….….…pg-3
1.1 Elastomer…….…………….………………………………………………………………………….…………………….…..…..pg-3
1.2 What is rubber.………………………………………………………………………………………………………................pg-3
1.3 How rubber is made……………………………………………………………………………………………………………...pg-3

2. Processing………………….………………………………..………………………..………….pg-5
2.1 compounding ………………………….………………………………………………………………………………………….…pg-5
2.2 Mixing……………………………………………………………………………………..…..………………………………………..pg-5
2.3 Composition………………………………………………………………………..…………………………….………….……...pg-7

3. SBR (styrene butadiene rubber) ...…………………………………….……………….pg-8

3.1 Introduction…………………………………………………………………………………………………………………………..pg-8
3.2 Properties………………………………………………………………………………………………………………….……..…..pg-9
3.3 Application………………………………………………………………………………………………..…………………………..pg-9
3.4 Formulation…………………………………………………….…………………………….……………………………..………pg-10
3.5 Testing results………………………….………………………………………………………………………….………..……..pg-11

4. CR (chloroprene rubber) ..…………………………………………………………..……pg-12

4.1 Introduction………………………………………………………………………………………………………………..……..pg-12
4.2 Properties……………………………….………………………………………………………………………………..………...pg-13
4.3 Application……………………………………………………………………………………………..……………….……….….pg-13
4.4 Formulation…………………………………………………………………………………………………………….……………pg-14
4.5 Testing results……………………………………………………………………………………………………………………...pg-15

5. NBR (nitrile butadiene rubber) ………………………………………….…………….pg-16

5.1 Introduction…………………………………………………………………………..…………………………………………….pg-16
5.2 Properties……………………………………………………………………………………………….…………………….……..pg-17
5.3 Application………………………………………………………………………………..……………..………………………….pg-17
5.4 Formulation…………………………………………………..………………………………………………………….…………pg-18
5.5 Testing results…………………………………………………………………………………………..……………………..…..pg-19
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6. CNR (neoprene and nitrile blend) ……………………………………………..……..pg-20

6.1 testing results…………………………………………………………………………….………………………..………………pg-21

7. Physical testing………………………………………………………..………….……….….pg-23
7.1 Moving die rheometer………………………………………………………………………………………………………….pg-24
7.2 Tensile test……………………………………………………………………………………………….………………………….pg-26
7.3 Abrasion test………………………………………………………………………………………………………………………..pg-29
7.4 Tear test……………………………………………………………………………………………………………………………….pg-31
7.5 Hardness test……………………………………………..……..……………………………………………………………..….pg-33

8. Tyre testing………..…….....…………………………….………………………….………pg-34
8.1 Basic info…………………………….…………………………………………………………………………………………..…pg-35
8.2 Rolling resistance…………………………………………………………………………………………………………………pg-37
8.3 Endurance test…………………………………………………………………………………………………………………….pg-38
8.4 Universal machine tests………………………………………………………………………………………………….….pg-39

9 Chemical testing………………………………………………………………………….……pg-40
9.1 Ash content ……………………………………………………………………………………………………..………….……..pg-41
9.2 FTIR………………………………………………………………………………………………………………………………..……pg-42
9.3 ICP……………………………………………………………………………………………………………….…………………..….pg-43

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hink of rubber and you probably think of elastic bands, car tires, or pencil

T erasers. But this super -stretchy material actually finds its way into tens of
thousands of different products —everything from rubber stamps and
waterproof shoes to surfing wetsuits , swimming caps, and dis hwasher hoses.
Rubber, which has been commonly used for over 1000 years, once came entirely
from natural sources; now rubber products are just as likely to be made artificially
in chemical plants. That's largely because we can't produce eno ugh natural rubb er
to meet all our needs. And that, in turn, is because rubber is so fantastically useful.
Let's take a closer loo k at one of the world's most amazing materials!

What is rubber?

When people talk abo ut "rubber", they don't usually specify what kind. There are
many different kinds o f rubber, but they all fall into two broad types: natural rubber
(latex—grown from plants) and synthetic rubber (made artificially in a chemical
plant or laborato ry). Commercially, the most important synthetic rubbers are
styrene butadiene (SBR), polyacrylics, and polyvinyl acetate (PVA); other kinds
include poly vinyl chloride (PVC), polychloroprene (better known as neoprene), and
various types of poly urethane. Although natural rubber and synthetic rubbers are
similar in some way s, they're made by entirely different processes and chemically
quite different.

How rubber is made?

It takes several quite distinct steps to make a product out of natural rubber. First,
you have to gather y our latex from the rubber trees using a traditional process
called rubber tapping. That involves making a wide, V -shaped cut in the tree's bark.
As the latex drips out, it's collected in a cup. The latex from many trees is then
filtered, washed, and reacted with acid to make the particles of rub ber coagulate
(stick together). The rubber made this way is pressed into slabs or sheets and then
dried, ready for the next stages of production.
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By itself, unprocessed rubber is not all that useful. It tends to be brittle when cold
and smelly and sticky w hen it warms up. Further processes are used to turn it into
a much more versatile material. The first one is known as mastication (a word we

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typically use to describe how animals chew food). Masticating machines "chew up"
raw rubber using mechanical roller s and presses to make it softer, easier to work,
and stickier. After the rubber has been masticate d, extra che mical ingredients
are mixed in to improv e its pr operties (for e xample, to make it more hardwearing).
Next, the rubber is squashe d into shape by ro llers (a pr ocess calle d cale ndaring) or
squeezed through spe cially shaped hole s to make hollow tube s ( a proce ss known
as extrusion). Finally, the rubber is vulcanized (cooke d): sulfur is added and the rubber
is heated to about 140°C (280°F) in an autoclave (a kind of industrial pressure cooker).

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Processing into finished goods, consisting

a) Compounding
b) Mixing
c) Molding

(a) Compounding
Rubber is always compounded with additives

 compound is a large group of components, including curing agents, accelerators and

vulcanization activators, antioxidants, plasticizers, fillers and special additives (blowing
agents, dyes, etc.). The list of ingredients in phr (parts per hundred rubber) called rubber
compound recipe.
 Most of the rubber products can also contain reinforcing materials – fibers, filaments, wires,
metal.
 Compounding adds chemicals for vulcanization, such as sulfur
 It is through compounding that the specific rubber is designed to satisfy a given application in
terms of properties, cost, and processability.

(b) Mixing

Due to the partly elastic nature and very high viscosity of rubber, power intensive sturdy machinery
like mixing mills or internal mixers is necessary to achieve the mixing of additives into the
polymer. The ingredients are in form of liquids, solid powders or solid agglomerates.

# Order of mixing

Raw rubber; Zinc oxide + TDQ + Stearic acid, Carbon Black + oil (DOP) + CBS + TMTD
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Phase during mixing of rubber

The mixing of solid ingredients into the solid polymer occurs in phases. During subdivision large lumps or
agglomerates are broken down into smaller aggregates suitable for incorporation into the rubber.

For instance, carbon black pellets which have dimension of the order of 250-2000 µm get broken down
into aggregates with dimensions of the order of 100 µm. Then these aggregates are absorbed or
incorporated into the rubber to form a coherent mass.

During mixing, shearing of the rubber generates shearing stress

in rubber mass which imposes in turn shear stress on these
aggregates and breaks these into their ultimate fine size
which in case of carbon blacks is of the order of about
1µm. in size. This phase is also known as intensive mixing
or homogenization in micromolecular level.

Distribution or homogenization in micromolecular level or

extensive mixing is “the moving of the agglomerates / particles from one point to
another, without changing the shape of the particle to increase the randomness of the mixture”. The
ingredients incorporation is a very slow process.
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(i)Zinc oxide
• works as activator

(i)Stearic acid
• works as a co-activator

(i)Sulfur
• sulfur is the most curing agent for diene rubber

(i)GPF black and FEF black 550

• (carbon black) works as a filler and enhance property of rubber

(i)Aromatic oil
• works as a plasticizer

TDQ
• antioxidant

(i)CBS
• accelerator

TMTD
• accelerator
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1. SBR (STYRENE BUTADIENE RUBBER)

Styrene butadiene rubber (SBR) is one of the cheaper synthetic general-purpose elastomers that is
sometimes used as a substitute for natural rubber (NR). It can be produced by free-radical solution
polymerization or by emulsion polymerization either warm at 30 to 60°C (hot rubber) or cold at
temperatures near 0°C (cold rubber). Emulsion SBR (ESBR) continues to lose ground to solution SBR
(SSBR) which is better suited for high-performance tires. Nevertheless, emulsion SBR grades still
account for more than 75% of the total world capacity as of 2015. However, more and more SBR is
produced by solution polymerization.

SBR is a highly random copolymer of butadiene and 10 to 25 percent styrene.

The addition of styrene lowers the price and contributes to the good wear and bonding properties.
The addition of styrene also improves the strength, abrasion resistance, and blend properties of
polybutadiene.

The fatigue resistance and low temperature properties of SBR are usually inferior to natural rubber,
whereas its heat-aging properties and abrasion resistance are better. Like natural rubber, SBR is
vulnerable to thermal and oxidative degradation due to the presence of double bonds in the polydiene
backbone. Degradation generally occurs through cross-linking, which leads to an increase in stiffness
(embrittlement). SBR also has poor chemical resistance, that is, its solvent resistance and weathering
properties are inferior to most other elastomers.
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PROPERTIES

Temp. Range, °C -25 / 100

Compression Set Good

Strength Properties Good

Low Temp. Prop. Fair

Abrasion Resist. Excellent

Gas Permeability Good

Weather Resist Poor

Water Resistance Good

Ozone Resistance Poor

Mineral Oil Resist. Poor

Chemical Resist. Poor/Fair

Flame Resistance Poor

Heat Resistance Fair

APPLICATIONS
Styrene butadiene rubber (SBR) is the highest volume general purpose synthetic rubber. It can be used
in similar applications as NR / IR elastomers, except in severe dynamic application due to the inferior
fatigue resistance. Typical applications include drive couplings, haul-off pads, conveyor belts, shoe
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soles and heels, adhesives, roll coverings and car tires (but not truck tires) and various other molded
rubber goods.

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Formulation SBR
For ASBR (Styrene butadiene rubber)
SBR 1502 1 kg

ZnO 40 gm

Stearic acid 15gm

ISAF 220 400gm

TDQ 10gm

Aromatic oil 710 90gm

Sulfur 22gm

CBS 10gm

01gm
TMTD

For ASBR rubber content percentage

Rubber content = 62.96%

Carbon black content = 25.18%

Low Boiling material = 7.24%

Ash content = 4.60%

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Test results of ASBR

ID Mark: Rubber Slab+Button-ASBR Specification: NIL

Section Test Name Condition Method Unit Result Spec.Value

M&R Tensile Before Ageing IS-3400-I MPa 24 17Min

Strength

M&R Elongation at Before Ageing IS-3400-I % 620 400Min

Break

M&R Hardness Before Ageing IS-3400, Shore 60 63±3

XXIII A

M&R Change In After Air IS-3400- % -13 -15Max

Tensile ageing@70°C/168hrs. I&IV
Strength

M&R Change in After Air IS-3400- % -16 -30Max

Elongation at ageing@70°C/168hrs. I&IV
Break

M&R Change in After Air IS-3400- Points, +3 +7/-2

Hardness ageing@70°C/168hrs. XIII &IV

M&R Compression @70°C/72hrs/25%defle. ASTM D- % 23 30Max

Set 395
Method B

C&I Volume Fuel-B/27°C/22hrs ASTM D- % +148.8 150Max

Change 471

C&I Volume Sea Water/27°C/22hrs ASTM D- % -0.52 0.50Max

Change 471

C&I Specific IS: 3400: 1.10 1.11±0.05

Gravity IX
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3. CR (chloroprene rubber)

Chloroprene Rubber (CR), also known as chlorobutadiene rubber, is an important diene-based

elastomer. The name Neoprene® is a registered trademark of DuPont Performance
Elastomers.

The commercial grades are mostly trans-1,4-polychloroprene produced by free-radical

emulsion polymerization of 2-chloro-1,3-butadiene. The chlorine in the polymer reduces the
reactivity to many oxidizing agents.

Chloroprene rubber typically displays good resistance to ozone cracking, heat aging and to
chemical attack. For example, it has good resistance to many chlorofluorocarbons, aliphatic
hydrocarbons, mineral oils, greases and ozone, but only moderate or poor resistance to acids,
solvents, and fuels. Its flame resistance is excellent. In fact, chloroprene is one of the few
rubbers that are self-extinguishing. It also gives excellent rubber-to-metal bonds. However,
chloroprene tends to harden over time and degrades in the presence of some fairly common
chemicals such as hydrochloric acid, acetone, xylene, acetic acid, and hydrogen peroxides.

Its mechanical properties are generally inferior to those of natural rubber but it has superior
chemical resistance.
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Properties
Temp. Range, °C -35 / 100

Compression Set Fair/Good

Strength Properties Good

Low Temp. Prop. Good

Abrasion Resist. Good

Gas Permeability. Good

Weather Resist. Good

Water Resistance. Fair

Ozone Resistance. Good

Mineral Oil Resist. Good

Chemical Resist. Fair

Flame Resistance. Excellent

Heat Resistance. Good

Applications
Chloroprene is used primarily for gaskets, cable jackets, tubing, seals, O-rings, tire-sidewalls,
gasoline hoses and weather-resistant products such as wet suits and orthopedic braces. It is
also used as a base resin in adhesives, electrical insulations and coatings.
It has many useful properties and a reasonable price.

It’s typical working temperature range is between -35°C and +100°C.

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Formulation For ACR

Neoprene rubber 1kg

MgO 40gm

Stearic acid 5gm

GPF 660 500gm

4020 5gm

MBTS 5gm

DOP 80gm

NA-22 5gm

ZnO 50gm

For ASBR rubber content percentage

Rubber content = 59.17%

Carbon black content = 29.59%

Low Boiling material = 5.32%

Ash content = 5.90%

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Test results of ACR

ID Mark: Rubber Slab+Button-ACR Specification: NIL

Section Test Name Condition Method Unit Result Spec.V

alue
M&R Tensile Before Ageing IS-3400-I MPa 20 15Min
Strength

M&R Elongation at Before Ageing IS-3400-I % 310 200Min

Break

M&R Hardness Before Ageing IS-3400, XXIII Shore 66 70±5

A

M&R Change in After Air IS-3400-I&IV % 0 -12

Tensile ageing@70°C/1
Strength 68hrs.

M&R Change in After Air IS-3400-I&IV % -3 -20

Elongation at ageing@70°C/1
Break 68hrs.

M&R Change in After Air IS-3400-XIII &IV Points +3 +7/-2

Hardness ageing@70°C/1 ,
68hrs.

M&R Compression @70°C/72hrs/2 ASTM D-395 % 7 25Max

Set 5%defle. Method B

C&I Volume Fuel- ASTMD-471 % +62.8 70Max

Change B/27°C/22hrs

C&I Volume Sea ASTMD-471 % +0.23 1.0Max

Change Water/27°C/22
hrs

C&I Specific IS:3400: IX 1.38 1.37±0.

Gravity 05
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4. NBR (Nitrile butadiene rubber)

NBR (Nitrile butadiene rubber)

Acrylonitrile butadiene rubber (NBR), usually shortened to nitrile, is a unique elastomer. It

can be produced by free-radical emulsion polymerization of butadiene with 15 to 45 percent
acrylonitrile either hot (hot rubber) or cold (cold rubber):

NBR grades with high acrylonitrile content have better oil and abrasion resistance, whereas grades with

low acrylonitrile content have better low temperature flexibility and resilience. In general, nitrile rubbers

have only moderate physical properties but good abrasion and excellent oil and hydrocarbon solvent

resistance. However, they are not suitable for use with polar solvents. Nitrile rubbers also have low gas

permeability particularly those with high nitrile content but poor ozone and modest heat resistance. To

improve the physical properties, nitrile rubbers are sometimes carbonylated (XNBR) which improves their

temperature resistance.

Its main application is in fuel hoses, gaskets, rollers and other products in which oil resistance is required.
NBR producers vary polymerization temperatures to make “hot” and “cold” polymers. Polymeric mixture
of butadiene and acrylonitrile in the respective ratio 2:1. Ratios can be varied to change physical
properties...higher levels of acrylonitrile yield low temperature flexibility, and increase compound
hardness, highly polar elastomer (large and reversible elastic deformation)

Many properties can be adjusted by varying the acrylonitrile content in the nitrile rubber. The higher the

nitrile content, the higher the resistance to aromatic hydrocarbons and the lower the nitrile content, the

better the low temperature flexibility.

 High Nitrile: > 45 % Nitrile

 Medium Nitrile: 30 - 45%
 Low Nitrile: < 30%
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The best overall balance for most applications is a medium nitrile content.

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Properties
Temp. Range, °C -25 / 100

Compression Set Good

Phys. Strength Good

Low Temp. Prop. Good

Abrasion Resist. Good/Excel.

Gas Permeability Good

Weather Resist. Poor

Water Resistance Good

Ozone Resistance Poor

Mineral Oil Resist. Excellent

Chemical Resist. Fair

Flame Resistance Poor

Heat Resistance Fair

Applications

NBR’s are used where excellent oil resistance is required. They are widely used in sealing applications,

particularly for oils and gasoline (aliphatic and aromatic hydrocarbons). Major applications include

gaskets, seals, diaphragms, gasoline hoses, liners, tubing, O-rings and cable jacketing. Carboxylated

grades find also uses as rubber toughness in many epoxy formulations.

Typical grades have a working temperature range of -25°C to +100°C. Some low acrylonitrile

materials are suitable for application down to -50°C and some peroxide cured grades go up to +150°C.
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5. Formulation for ANBR (Nitrile Rubber)

Nitrile rubber 1kg

Sulfur 10gm

ZnO 50gm

Stearic acid 10gm

FEF black 550 500gm

DOP 80gm

TDQ 1ogm

TMTD 12gm

CBS 15gm

For ANBR rubber content percentage

Rubber content = 59.70%

Carbon black content = 29.85%

Low Boiling material = 2.98%

Ash content = 7.47%

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Testing results of ANBR

ID Mark: Rubber Slab+Button-ACNR Specification: BS-2752-2003

SE SPEC.
TEST NAME CONDITION METHOD UNIT RESULT
C VALUE

M
Tensile
& Before Ageing. ISO-37 MPa 14.9 12.5Min
Strength
R
M
Elongation
& Before Ageing. ISO-37 % 380 250Min
at Break
R
M
& Hardness Before ageing ISO-48 IRHD 61 70+5/-4
R
M Change in
& Tensile After 70°C/7days ISO-188 % -2 -10Max
R Strength
M Change in
& Elongation After 70°C/7days ISO-188 % -13 -35Max
R at Break
M
Change in
& After 70°C/7days ISO-188 Points +5 -0/+10
Hardness
R
M
Compressio @70°C/24hrs/25%def ISO-
& % 6 20Max
n Set le. 815-1
R
Adhesion to
M No
and BS-ISO- Passes the
& @70°C/168hrs. -- corrosion
Corrosion 6505 test
R and pitting
of Metals*
Acrylonitril Acrylonitril
Polymer e e
C ISO
Identificatio By FT-IR - Butadiene Butadiene
&I :4650
n Rubber [ Rubber [
NBR] NBR]

C Volume ISO-
Liquid B/40°C/24hrs. % +24 -0 To +25
&I Change 1817

C ISO:278 mg/m
Density 1.16e+9
&I 1 3

Low Should
C Temperatur ISO- not
Stiffness {@-20°C Mpa 19
&I e 1432 exceed
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Resistance* 70MPa

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ACNR (Neoprene and Nitrile blend)

It is a common practice to blend two elastomers of different properties with a view to combine the
best properties of each in terms of its technical and economic values. Nitrile rubber (NBR) is blended
with neoprene rubber (NR) to meet the requirements for very good oil resistance as well as high
mechanical strength. The former is a polar rubber and provides very good oil resistance, while the
latter is non-polar and provides excellent mechanical properties. Numerous works on rubber blends
that have been reported are based on dry rubber. On the contrary, the work on rubber blends base
on latex received less attention than the dry rubber. This paper describes the work on NR latex and
NBR latex blends. NR and NBR were blended at several ratios incorporating NBR up to 50% to study
their effect on the mechanical properties and crosslink concentrations. The glass transition
temperatures, Tg and the morphology of NR/NBR latex blends were determined to verify the
compatibility of the blends. The results indicated that tensile strength (TS) showed a good linear
relationship with loadings of NBR. The decreased in TS with decreased in NR content of the blends was
associated with low crosslink concentrations in the rubber blends. Both elongation at break (EB) and
tear energy are affected non-linearly by the presence of NBR indicating the incompatibility of the two
rubber components.

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For ACNR (Neoprene nitrile blend)

Neoprene rubber 800gm

Nitrile butadiene rubber 200gm

MgO 32gm

Stearic acid 10gm

ZnO 50gm

GPF black 500gm

DOP 80gm

4020 5gm

TDQ 5gm

TMTD 12gm

CBS 3.0gm

Sulfur 10gm

NA-22 4gm

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Testing results for ACNR (Neoprene Nitrile blend)

ID Mark: Rubber Slab+Button-ACNR Specification: BS-2752-2003

Section Test Name Condition Method Unit Result Spec. Value

M&R Tensile Before Ageing ISO-37 MPa 19.0 13.0Min
Strength
M&R Elongation at Before Ageing ISO-37 % 360 200Min
Break

M&R Hardness Before Ageing ISO-48 IRHD 62 70+5/-4

M&R Change in After air ISO-188 % -1 -12Max

Tensile ageing@70°C/7days
Strength
M&R Change in After air ISO-188 % 0 -20Max
Elongation at ageing@70°C/7days
Break

M&R Change in After air ISO-188 Points +2 -0 to +7

Hardness ageing@70°C/7days

M&R Compression @70°C/24hrs/25%defle ISO-815 % 9 25Max

Set
M&R Adhesion to @70°C/7days BS-ISO- -- Passes There shall
and Corrosion 6505 the test be no
of Metals* corrosion or
pitting of
metals

C&I Volume Change Liquid B/40°C/22hrs. ISO-1817 % +59.7 -0 to +70

C&I Density ISO:2781 Mg/m3 1.33e+9

C&I Low Stiffness {@-30°C ISO-1432 MPa 15 Should not

Temperature exceed
Resistance* 70MPa
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1. MOVING DIE RHEOMETER (MDR)

The Moving Die Rheometer MDR- 3000 measures the change in stiffness of a rubber sample. The
sample is compressed between two heated platens and by an applied oscillating force. The degree of
vulcanization determines the cure characteristic of the sample as it is heated and compressed. Our
Moving Die Rheometer offers affordable testing and stunning results. We offer sealed die and un-
sealed die type configurations to suite your application. The Servo driven system provides extremely
steady oscillation frequencies as well as low noise to ensure test accuracy, convenience and increased
lifespan of the machine. Operated with a remote computer via RS-232, we can analyze results taking
data at 100,000 readings per second. The machine allows for selectable times and torques during
setup or in testing to accommodate limitless configurations. You can monitor the test from the
computer or large LCD displays on the front for in test evaluation. The design features Modular
internal parts for in house servicing and overall easy maintenance.

The Moving Die Rheometer MDR- 3000 SOFTWARE: Software is an integral part of any testing
apparatus this is why we have developed a program to work dependably with our machine and
intuitive with the operator. The software allows you to configure a variety of tests. Auto detection
makes this program simple to setup and initiate testing. Safeguarding data is an important factor so
we have an automatic back-up system to ensure data will not get lost. For the operator’s comfort, the
program is customizable in terms of fonts, color settings, beep alerts and selectable measuring units.
There is an Import / Export function which allows the user to exchange data from one format to
another. (Example: export data to Excel) Customizable reports allow the user to determine up to 300
different parameters including multiple charts and tables so your reports can look just the way you
want them.

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SPECIFICATIONS OF MOVING DIE RHEOMETER (MDR)

Standard Complies with ASTM D5289, ISO 6502, GB T/16584

Oscillation Frequency 10~300 cpm, driven by DDR motor

Oscillation Amplitude ±0.5°~±3°

Temperature Control Control by Computer & PID SSR Range

Temperature Range Room Temp. ~ 230°C

Temperature Accuracy ± 0.3°C

Temperature Sensor Grade Class A

Temperature Minimum Reading 0.1°C

30°C to 190°C < 6 min

Heating Time
175°C to 190°C < 1 min

Elasticity Sˊ - 1~200 lb-in

Torque Range Viscosity Sˊˊ - 0.3~200 lb-in
(Auto or manual range)

Torque Unit kgf-cm / lbf-in / N-m / dN-m

Minimum Torque Reading 0.001 Unit

Test Time Range No time limit

Power 1∮, 220V ±10%, 50Hz ± 3Hz, 10A

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2. TENSILE TESTING
Tensile properties are used in selecting materials for various applications. Material specifications
often include minimum tensile properties to ensure quality. Tensile tests must be made to ensure
that materials meet these specifications. The tensile stress-strain curves can be used to predict a
material’s behavior under loading forms other than the uni-axial tension.

Tensile-testing Machine
A modern tensile-testing machine allows users to select force, strain, strain rate, stroke motion that
can be enforced upon a test specimen. Linear variable differential transformers (LVDTs) are used to
measure displacements accurately.

 Definition: tensile set the extension remaining after a specimen has been stretched
and allowed to retract in specified manner, expressed as a percentage of the original
length

 Tensile strength: the maximum tensile stress applied in stretching a specimen to rupture
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 Ultimate elongation: the elongation at which the rupture occurs in the application of
continued tensile stress

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Tensile test machine

TENSILE TEST MACHINE IRMRA

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……………………..
TENSILE TEST SPECIMEN
The figure below shows a typical tensile specimen. The cross-sectional area of the gauge section is
less than that of the shoulders and grip section, so the deformation will occur in the gauge section.
According to St. Venant’s principle, the gauge section should be long compared to the diameter
(typically four times). The transition between the gauge section and the shoulders should be at least
as great as the diameter so that the larger ends do not constrain the deformation in the gauge section.

A. ELONGATION AT BREAK
Elongation at Break, also known as fracture strain or tensile elongation at break, is the ratio between
increased length and initial length after breakage of the tested specimen at a controlled temperature.
It is related to the ability of a plastic specimen to resist changes of shape without cracking.

Elongation between zero stress and final rupture, as a percent of original specimen length, a 1-meter
specimen that stretches to 1.1 before breaking in two has 10% elongation at break. Also, simply called
elongation

It is a measure of ductility, and the value for brittle materials can be vanishingly small-typically
assumed to be zero. Value above 100% tend to be limited to elastomers and a few particulars soft
thermoplastics. All else being equal, materials with higher elongation have a better capacity to handle
an excessive load without separating.

B. TENSILE MODULUS
A tensile modulus is a measure of the resistance to elastic deformation that a material has. Materials
that require higher stresses to induce elastic deformation have higher tensile moduli. The tensile
modulus is commonly measured by taking the amount of stress applied to a material and dividing it
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by the strain the material undergoes.

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The value of the tensile modulus of a material defines how well it resists elastic deformation, which
occurs when a force is applied to a material that causes its shape to change. However, once the force
is removed, the material returns to its original shape and size because elastic deformation is simply
the stretching of atomic bonds. This differs from plastic deformation, which occurs when the material
does not return to its original shape and size even after the applied force is removed. Plastic
deformation is permanent because the applied force is so great that the atoms actually move past
each other.

The tensile modulus is an important characteristic to evaluate when selecting a material. Excessive
elastic deformation could result in the material not being able to perform to the application's
requirements. A material that has a very high tensile modulus and does not deform at all could also
be detrimental if the application requires elasticity.

The tensile modulus is recorded during material tensile testing. It is graphed on a plot that has stress
on the vertical axis and strain on the horizontal axis.

3. ABRASION TEST
The resistance of a rubber manufacture to abrasion is measured as the percentage loss of weight,
compared to the original material’s weight. Whereas the cutting or nicking of a manufacture’s surface
is an instantaneous event, abrasive rubbing or scraping is much more of a progressive phenomenon,
that develops over time. Generally, rubber items in motion are most susceptible to abrasion, then
static ones.
Hard compounds tend to exhibit less abrasive wear than soft compounds, but to use a hard compound
can also increase friction in dynamic sealing systems, generating degradation by heat.
Due to many potential variables (including heat fluctuation and surface contamination), the abrasion
resistance is hard to measure accurately. To test it, it typically involves the uniform application of an
abrasive material (such as glass paper) to the surface of a sample. The relative amount of the sample
material, that is lost due to abrasion, is a good indicator of abrasion resistance.
Generally speaking, hydrocarbon-based elastomers tend to offer better abrasion resistance than
fluorocarbon elastomers. Polyurethane offers the most outstanding abrasion resistance, while
carboxylate nitrile and hydrogenated nitrile offer abrasion resistance, that is superior to other
hydrocarbon-based elastomers.
Abrasion resistance is a performance factor of paramount importance for many rubber products, such
as tires, conveyor belts, power transmission belts, hoses, footwear, and floor covering. A test capable
of measuring resistance to abrasion of rubber, including uniformity of wear behavior under
abrasive/frictional service conditions is therefore highly desirable. This test method may be used to
estimate the relative abrasion resistance of different rubbers. Since conditions of abrasive wear in
service are complex and vary widely, no direct correlation between this accelerated test and actual
performance can be assumed. This test method is suitable for comparative testing, quality control,
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specification compliance testing, referee purposes, and research and development work.

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This test method covers the measurement of abrasion resistance of rubbers (vulcanized thermoset
rubbers and thermoplastic elastomers) that are subject to abrasive/frictional wear in actual service.
The abrasion resistance is measured by moving a test piece across the surface of an abrasive sheet
mounted to a revolving drum, and is expressed as volume loss in cubic millimeters or abrasion
resistance index in percent. For volume loss, a smaller number indicates better abrasion resistance,
while for the abrasion resistance index, a smaller number denotes poorer abrasion resistance

This test method is suitable for comparative testing, quality control, specification compliance testing,
referee purposes, and research and development work.

 Scope

This test method covers the measurement of abrasion resistance of rubbers (vulcanized
thermoset rubbers and thermoplastic elastomers) that are subject to abrasive/frictional wear
in actual service. The abrasion resistance is measured by moving a test piece across the
surface of an abrasive sheet mounted to a revolving drum, and is expressed as volume loss in
cubic millimeters or abrasion resistance index in percent. For volume loss, a smaller number
indicates better abrasion resistance, while for the abrasion resistance index, a smaller number
denotes poorer abrasion resistance

 Significance of Performing Abrasion Test

The test is used to measure the resistance of products to abrasion in a certain environment. The
importance of abrasion test helps to evaluate the rank of the material after providing it under abrasive
environment. The percentage of loss of content is judged and compared with the original material.
This comparison helps to measure the worth of the materials and the actual life of the product when
continuously subjected to the abrasive environment.

Abrasion of components which are subject to flow of materials across their surfaces is a perplexing
matter for plant operators, as selection of the incorrect polymer material can have serious cost
implications and associated down time on the processing plant. Exceed Consulting can assist our
clients by identifying the most appropriate polymer material to use for the application by testing
materials on our rubber abrasion test apparatus, which has been design in accordance with ASTM
5963, DIN 53516 & ISO 4649.
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 Procedure
The standard test involves running a polymer sample against a rotating drum coated with a carbonado
sheet. The abrasion resistance is measured by moving the test piece across the surface of the abrasive
sheet mounted to a revolving drum and is expressed as a volume loss in mm 3 or abrasion resistance
index percent. For volume loss, a smaller number indicates better abrasion
resistance, while for the abrasion resistance index; a smaller number
denotes poorer abrasion resistance.

Materials that can be tested in the abrasion test rig include: Rubber,
Polymers and Plastics

Abrasion test button

4. TEAR TEST

A tear test applies a force to a material that already contains a partial fracture or rupture otherwise
known as a “tear” in order to bring the material to complete failure. This is done by placing the test
sample into a tensile testing or universal test machine so that the section on one side of the fracture
is pulled up and the section on the other side is pulled down. A steady load is then applied until the
tear has propagated through the entirety of the sample and the two sections have been completely
separated from one another.

PURPOSE OF TEAR TEST

The overall goal of a tear test is to determine a materials ability to resist the growth of the initial tear
or its “tear resistance”. The value of a material’s tear resistance is generally accepted to be the force
required to complete the tear so that it has gone completely though the material so that it has been
separated into two sections. This characteristic is particularly important to applications that use
flexible materials that may suffer a partial rupture intentionally or otherwise.
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 TYPES OF TEAR TEST

Most tear resistance tests are performed statically and commonly take one of three forms. These
forms differ from one another in the configuration and preparation of the test sample, the grip
placement, and the rate of testing.

The first form is referred to as the trouser shape tear test and involves a rectangular sample that has
a cut down the middle of one half of the sample so that two legs are formed and the sample resembles
a pair of trousers. Each leg is then placed into one of the test grips and is then pulled apart so that the
tear continues down the middle of the sample.

The second form is the tongue tear test and requires that the sample have a tab cut in the middle.
This tab is cut so that so that it is separated the rest of the sample on the bottom and sides but not
the top. The tab is then placed in the top grip while the rest of the sample is placed in the bottom grip.
As the top grip is moved upward the tab is pulled so that the cuts on both sides are extended upward
to the top of the sample and the tab is eventually pulled free leaving a rectangular piece in the top
grip and a “U” shaped piece in the bottom.

Finally, in the case of the trapezoid tear test the test sample is cut into the form of an isosceles
trapezoid with a small cut made in one side. The sample is then loaded into the test fixture so that the
tear made by the cut will propagate as the grips move apart. Generally, the sample is orientated so
the tear extends horizontally.

The tear strength of thermoset rubbers, thermoplastic elastomers, and silicones can be measured
according to specification ASTM D624. The test measures the strength required to initiate a tear in a
material. D624 describes multiple different types of sample shapes that can be tested in a standard
universal testing machine (tensile testing machine). Usually materials that are tested to D624 are also
tested according to specification ASTM D412 to measure the tensile strength and elongation. If you
are going to perform this test, you should read the entire specification from ASTM. This is a quick
summary to decide if this test is right for you, and to point out what equipment you need to perform
the test.
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5. HARDNESS TEST

The hardness test is a mechanical test for material properties which are used in engineering
design, analysis of structures, and materials development. The principal purpose of the
hardness test is to determine the suitability of a material for a given application, or the particular
treatment to which the material has been subjected. The ease with which the hardness test can
be made has made it the most common method of inspection for metals and alloys.

Hardness is defined as the resistance of a material to permanent deformation such as

indentation, wear, abrasion, scratch. Principally, the importance of hardness testing has to do
with the relationship between hardness and other properties of material. For example, both the
hardness test and the tensile test measure the resistance of a metal to plastic flow, and results
of these tests may closely parallel each other. The hardness test is preferred because it is simple,
easy, and relatively nondestructive.

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Tires
Structure
The structure of tires is much more complex than it seems. Here is the basic structure of
passenger tire.

Passenger tires are usually constructed with five main components.

Tread
The tread is made of rubber compounds and it is the part of a tire that makes contact with
the road.

Side wall
The side wall is a rubber component of a tire that covers between the tread and the bead.

Body ply
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The body ply is the skeleton of a tire which is made of artificial fibers, such as polyester and
rayon.

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Belt
The belt provides stiffness to the tread and protect the carcass. It is usually made up of stiff
steel cords.

Bead
The bead is designed of firmly grip the tire to the wheel. The breads contain a steel loop
made from a bundle of fine steel wire, making the bead extremely strong.

Function of Tires
 To support a vehicles weight.
 To transmit accelerating and breaking force to the ground.
 To change and maintain direction.
 To absorb shock from the road surface.

Variety of Tires
 Trucks.
 Motorcycles.
 Mining and construction equipment.
 Air craft.

Machines for tire testing

 Rolling resistance test machine
 Endurance test machine
 Universal test machine
 Profilometer
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 Tire cutting machine

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1 Tire Rolling resistance

Tire rolling resistance is measured in a laboratory in under controlled condition. The test condition
varies between the various SAE and ISO test standard but the basic premise is the same in tha a tire is
mounted on a free rolling spindle
with no chamber or slip angle,
loaded against a large-diameter
powered test drum, turn by the
drum to simulated on-road rolling
operation, and sub measure rolling
loss evaluated.

Rolling resistance is the effort required to keep a given tire rolling. Its magnitude depends on the tire
used, the nature of the surface on which it rolls, and the operation conditions – inflation pressure,
load and speed.

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2. Endurance test
Endurance test is carried out by freely rotating the tyre on a smooth surface metal wheel or
drum at a fixed speed; increasing load step-wise to certain kilometer limit or till failure.

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3. Universal test machine

(i) Plunger test: This test was implemented as a regulation for bias ply tyres. The current US
DOT test procedure is the basis for most world-wide plunger energy test procedures. The
procedure specifies a rounded plunger to be forced into the center area of the tread of an
inflated tyre, measuring the energy required to either penetrate the carcass or contact the rim
surface (commonly referred to as a “bottom out”). The tyre industry does not believe that this
type of test is applicable to radial ply tyres. In the course of the Government-Industry effort
on global harmonization known as GTS 2000 (work conducted from 1997-2000), participating
members were in general agreement that
plunger energy would not be required for
radial ply tyres. The plunger energy test
would continue to be required for bias ply
tyres

(ii) Bead unseat test: Under the TREAD

Act, NHTSA was assigned the task of
revising and updating the Federal Motor
Vehicle Safety Standards (FMVSS) for tires. Part of this effort included research to support a
possible update or replacement of the FMVSS No. 109 Tubeless Tire Bead Unseating
Resistance test. In the current FMVSS test, a profiled metal “block” is located perpendicular to
the sidewall of a mounted and inflated tire, then force is applied until the bead component
(region where the tire meets the rim) unseats with the resulting air loss or the specified
minimum force value is achieved. The objective of the test is to evaluate the ability of the
tubeless tire’s bead to remain seated on the rim and retain tire inflation pressure when the
tire is subjected to high lateral forces such as during severe turning maneuvers, curb
scrubbing, or negotiating deep ruts in the roadway. For tires with rim codes above 18 (e.g.,
P345/30R18), the bead unseating blocks in the current Federal standard can contact the rim
or slide down the tread during tests (especially for low aspect ratio tires).
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Bead unseat block

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1. Ash content

Measuring the properties of rubbers is the major task to access the quality of the materials. One
of the major properties is the percentage of ash content in rubber. The ash content property in
rubbers can be determined by treating the rubber sample at a specific temperature and time.
Along with this, setting accurate time and the temperature is also mandatory to treat the rubbers
and to measure the actual percentage of ash in the materials. This can be done easily using high-
quality of testing machines.

Procedure
 First identification of halogen. If halogen is present, we follow by sulfation.
 Treat it by adding sulfuric acid and dry it on a hot plate and keep it in muffle furnace at 900 OC
for 1 hour.
a. Take weight of the empty crucible
b. Take 1 gram of sample in crucible
c. Take weight of the crucible + sample
d. Place the sample in muffle furnace 550 oC or (900 oC for halogen containing rubber sample)
for two hours
e. After two hours remove the sample and place it in desiccator for half an hour to remove the
moisture
f. Take the weight of crucible + ash

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2. Fourier Transform infrared spectroscopy (FTIR)

An FTIR spectrophotometer is mainly used to estimate the structure of organic compounds.

This instrument shines infrared light onto the molecules, which absorb infrared radiation equivalent
to the interatomic vibrational energy of the atoms comprising the molecules.

Infrared spectroscopy can be used efficiently by polymer and rubber technologists for identification
of polymer, polymer–blend ratio calculation, raw material evaluation, study of reaction mechanism,
microstructure determination, etc. The present article represents a method to characterize nitrile
rubber by Fourier-transformed infrared spectrophotometry (FTIR). The absorbance ratio of specific
peaks of different grades of nitrile rubber was correlated with the acrylonitrile content measured by
the Kjeldhal method. The acrylonitrile content of unknown acrylonitrile butadiene rubber (nitrile
rubber, NBR) was calculated from a calibration graph.

The sample was measured using the Ge prism on the PIKE miracle single-reflection ATR accessory. Baseline
correction and a spectrum search were performed for the spectrum obtained from measurements. The
spectra below are for nitrile rubber.

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ICP test Analysis

ICP analysis is performed at LTI with computer-controlled spectrometers. Computer software controls
and monitors the instrument functions and also processes, stores and outputs the results of the ICP
test as it is performed. The spectrometers use Charge Coupled Device (CCD) technology which allows
the instruments to measure the broad spectrum of elements.
ICP metal analysis can be performed on solid and liquid samples, but a solid sample must be converted
to liquid form before testing by dissolving the sample in a solvent (typically acid) to produce a solution.
The sample solution is introduced into the ICP as a fine aerosol of droplets. The aerosol is produced
by a nebulizer which aspirates the sample with high velocity argon to form a fine mist.
The aerosol then passes into a spray chamber where larger droplets are removed. Droplets small
enough to be vaporized in the plasma torch pass into the torch body, where the aerosol is mixed with
more argon gas. ICP stands for Inductively Coupled Plasma, which is an excitation source generated
by directing the energy of a radio frequency generator into a suitable gas. A coupling coil is used to
transmit radio frequency to the heated argon gas, producing an argon plasma located in the torch. The
hot plasma dries any remaining solvent and causes sample atomization.
The ICP-AES spectrometer detects the atomic emissions produced as light. With ICP Mass
Spectrometry, the process uses ionization. The resulting mass of the ions indicates the elements
present in the sample.

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ELEMENTS ANALYZED DURING AN ICP TEST SCAN

Aluminum Antimony Arsenic Barium Beryllium Boron Cadmium

Calcium Cerium Cesium Chromium Cobalt Copper Dysprosium

Erbium Europium Gadolinium Gallium Germanium Gold Hafnium

Holmium Indium Iridium Iron Lanthanum Lead Lithium

Lutetium Magnesium Manganese Mercury Molybdenum Neodymium Nickel

Niobium Osmium Palladium Phosphorus Platinum Polonium Potassium

Praseodymium Rhenium Rhodium Rubidium Ruthenium Samarium Scandium

Selenium Silicon Silver Sodium Strontium Sulfur Tantalum

Technetium Tellurium Thallium Thorium Thulium Tin Titanium

Tungsten Uranium Vanadium Ytterbium Yttrium Zinc Zirconium

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Conclusion
 Firstly, we made a formulation of SBR, CR, NBR then we perform the mixing of components
of rubber on mixing rollers
 After the mixing we run a test for curing and started the molding we made a rubber slab and
compression button by molding machine for testing.
 Then we test these rubber samples in physical testing section there we perfomed Tensile
test, hardness test, rheometry, tear test etc.
 After physical samples were tested in chemical section and tests are ash content, FTIR, ATR,
TGA, etc.
 mean while we also performed tire testing

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