• saurabhjain
    saurabhjain

    Manufacturing of Tires

    Tires are the principal product of the rubber industry, accounting for about three fourths of total tonnage. Other important products include footwear, hose, conveyor belts, seals, shock-absorbing components, foamed rubber products, and sports equipment

    Tires

    Pneumatic tires are critical components of the vehicles on which they are used. They are used on automobiles, trucks, buses, farm tractors, earth-moving equipment, military vehicles, bicycles, motorcycles, and aircraft. Tires support the weight of the vehicle and the passengers and cargo on board; they transmit the motor torque to propel the vehicle (except on aircraft); and they absorb vibrations and shock to provide a comfortable ride.

    Tire Construction and Production Sequence

     A tire is an assembly of many parts, whose manufacture is unexpectedly complex. A passenger car tire consists of about 50 individual pieces; a large earthmover tire may have as many as 175.

    To begin with, there are three basic tire constructions steps

    • 1.      Diagonal ply
    • 2.      Belted bias
    • 3.      Radial ply

    In all three cases, the internal structure of the tire, known as the carcass, consists of multiple layers of rubber-coated cords, called plies. The cords are strands of various materials such as nylon, polyester, fiberglass, and steel, which provide inextensibility to reinforce the rubber in the carcass.

    The diagonal ply tire has the cords running diagonally, but in perpendicular directions in adjacent layers. A typical diagonal ply tire may have four plies.

    The belted bias tire is constructed of diagonal plies with opposite bias but adds several more layers around the outside periphery of the carcass. These belts increase the stiffness of the tire in the tread area and limit its diametric expansion during inflation. The cords in the belt also run diagonally, as indicated in the sketch.

    A radial tire has plies running radially rather than diagonally; it also uses belts around the periphery for support. A steel-belted radial is a tire in which the circumferential belts have cords made of steel. The radial construction provides a more flexible sidewall, which tends to reduce stress on the belts and treads as they continually deform on contact with the flat road surface during rotation. This effect is accompanied by greater tread life, improved cornering and driving stability and a better ride at high speeds. 

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    In each construction, the carcass is covered by solid rubber that reaches a maximum thickness in the tread area. The carcass is also lined on the inside with a rubber coating.

    For tires with inner tubes, the inner liner is a thin coating applied to the innermost ply during its fabrication. For tubeless tires, the inner liner must have low permeability because it holds the air pressure; it is generally a laminated rubber.

    Tire production can be summarized in three steps

    • 1.      Preforming of components
    • 2.      Building the carcass and adding rubber strips to form the sidewalls and treads
    • 3.      Molding and curing the components into one integral piece.

    Preforming of Components

    The carcass consists of a number of separate components, most of which are rubber or reinforced rubber. These, as well as the sidewall and tread rubber, are produced by continuous processes and then pre-cut to size and shape for subsequent assembly. The components and the preforming processes to fabricate them are:

    • 1.      Bead coil: Continuous steel wire is rubber-coated, cut, coiled, and the ends joined.
    • 2.      Plies: Continuous fabric (textile, nylon, fiber glass and steel) is rubber coated in a calendering process and pre-cut to size and shape.
    • 3.      Inner lining: For tube tires, the inner liner is calendered onto the innermost ply. For tubeless tires, the liner is calendered as a two-layered laminate.
    • 4.      Belts: Continuous fabric is rubber coated (similar to plies), but cut at different angles for better reinforcement; then made into a multi-ply belt.
    • 5.      Tread: Extruded as continuous strip; then cut and pre assembled to belts.
    • 6.      Sidewall: Extruded as continuous strip; then cut to size and shape.

    Building the Carcass

    The carcass is traditionally assembled using a machine known as a building drum, whose main element is a cylindrical arbor that rotates. Pre-cut strips that form the carcass are built up around this arbor in a step-by-step procedure. The layered plies that form the cross section of the tire are anchored on opposite sides of the rimby two bead coils. The bead coils consist of multiple strands of high-strength steel wire. Their function is to provide a rigid support when the finished tire is mounted on the wheel rim. Other components are combined with the plies and bead coils. These include various wrappings and filler pieces to give the tire the proper strength, heat resistance, air retention, and fitting to the wheel rim. After these parts are placed around the arbor and the proper numbers of plies have been added, the belts are applied. This is followed by the outside rubber that will become the sidewall and tread. At this point in the process, the treads are rubber strips of uniform cross section—the tread design is added later in molding. The building drum is collapsible, so that the unfinished tire can be removed when finished. The form of the tire at this stage is roughly tubular.

    Molding and Curing

    Tire molds are usually two-piece construction (split molds) and contain the tread pattern to be impressed on the tire. The mold is bolted into a press, one half attached to the upper platen and the bottom half fastened to the lower platen (the base). The uncured tire is placed over an expandable diaphragm and inserted between the mold halves. The press is then closed and the diaphragm expanded, so that the soft rubber is pressed against the cavity of the mold. This causes the tread pattern to be imparted to the rubber. At the same time, the rubber is heated, both from the outside by the mold and from the inside by the diaphragm. Circulating hot water or steam under pressure is used to heat the diaphragm. The duration of this curing step depends on the thickness of the tire wall. A typical passenger tire can be cured in about 15 minutes. Bicycle tires cure in about 4 minutes, whereas tires for large earth-moving equipment take several hours to cure. After curing is completed, the tire is cooled and removed from the press.

    Edited by saurabhjain


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