Beruflich Dokumente
Kultur Dokumente
Sourav
662/MP/12
Yadav
Rahul
649/MP/12
Yadav
Krishan
674/MP/12
Saraswat
Shivam
Submitted to:-
Sanjay Gupta
Assistant Professor
Netaji Subhas Institute of Technology
Contents
Introduction
..3
Tire
Type
6
Tire
Composition
.7
Raw Materials
Used.1
0
Design
Concepts
..14
Tire Manufacturing
Process.20
Indian Tire
Market
..25
Financial Analysis of MRF
Tires..27
Recycling of Worn
Tires31
INTRODUCTION
Tires are the only point of contact of the vehicle with the road.
The intentions of the driver are finally executed by the tires only,
hence the quality and design of the tires is important. The rubber
tube inflated with air supports the whole weight of the car, but
the rubber tube cannot directly come in contact with the road as
it cannot resist wear and it lacks strength. Tire encases the rubber
tube. Tires must perform a certain number of functions for the
3
Tire Type
What type of tires are customers looking for?
The answer to this question will depend on vehicle and driving
conditions.
For comfort and handling...
Touring tires help provide excellent dependability on wet and dry
pavement. They offer a balance of smooth and quiet ride with
performance handling.
For driving a sports car or looking for handling and
performance...High-performance tires are designed for use at
higher speeds in dry and wet weather. They have a softer rubber
compound for improved grip, especially on high-speed cornering.*
For driving a pick-up truck or an SUV...Light truck tires help
provide durability and traction in adverse off-road conditions. On
the flip side, SUV tires are ideal for on-road, comfort-tuned SUV
applications.
For a commercial vehicle...Commercial light truck tires are
designed to handle driving through dirt, mud and everyday wear
and tear from commercial applications.
Winter tires are designed to perform in cold, icy, wet and snowy
weather. They are optimized for handling and traction under wet
conditions, but can be used in dry conditions as well.
7
COMPOSITION
Tire is a composite structure consisting of many layers. They
usually consist of
1. Inner liner
2. Body ply
3. Side wall
4. Beads, Apex
5. Belt Package
6. Tread
7. Cushion Gum.
Inner Liner
It is an extruded halobutyl rubber sheet compounded with
additives that result in low air permeability. The inner liner
assures that the tire will hold high-pressure air inside, without the
air gradually diffusing through the rubber structure.
Body Ply
The body ply is a calendered sheet (two or more sheets are rolled
together such that mechanically they are bonded) consisting of
consecutive layers of rubber and reinforcing fabric.
9
Tread
The tread is a thick extruded profile that surrounds the tire
carcass and this is the layer which comes directly in contact with
the. Tread compounds include additives to impart wear resistance
and traction in addition to environmental resistance. Tread
compound development is an exercise in compromise, as hard
compounds have long wear characteristics but poor traction
whereas soft compounds have good traction but poor wear
characteristics.
Cushion Gum
Many higher-performing tyres include an extruded component
between the belt package and the tread to isolate the tread from
mechanical wear from the steel belts
Natural Rubber
Natural Rubber is an elastomer derived from latex, a milky colloid
produced by some of the plants like Hevea brasiliensis. These
plants produce latex when they are wounded as a healing
mechanism. The latex is collected in a vessel and it is allowed to
coagulate which gives you the solid rubber which can be further
processed in to sheets. The coagulation process can be controlled
by chemicals like Ammonia, Formic acid. Ammonia decelerates
the coagulation process whereas Formic acid accelerates it. The
purified natural rubber is same as polyisoprene.
The monomer of Natural Rubber is 2-methyl-1,3butadiene,CH2=C(CH3)-CH=CH2. The required properties of
rubber like elasticity, is mainly dependent on the cis form of C5H8
rather than its trans counterpart. As the natural rubber is formed
by coagulation of latex, the relative proportions of cis and trans
are fixed which can result in degradation of desired properties.
Synthetic Rubber
12
Carbon Black
Carbon black is a material produced by the incomplete
combustion of heavy petroleum products such as coal tar,
ethylene cracking tar etc., It is a form of amorphous carbon that
has a high surface-area-to-volume ratio and significantly lower
PAH (polycyclic aromatic hydrocarbon). It is used as a pigment
and reinforcement filler in the tyre. It helps in conducting heat
away from the tread and belt area of the tire, reducing thermal
damage and increasing tire life. While a pure styrene-butadiene
rubber has a tensile-strength of no more than 2.5MPa, and almost
nonexistent abrasion resistance, compounding it with 50% of its
weight of carbon black improves its tensile strength to 20MPa and
considerable wear resistance. The black color of the tyre is due to
carbon black, if we want to have anyother color with the same
reinforcing properties fumed silica is used.
Fumed Silica
It is also known as pyrogenic silica as it is produced in a flame,
consisting of microscopic droplets of amorphous silica fused into
branched, chainlike, three-dimensional secondary particles which
then agglomerate into tertiary particles. The resulting powder has
an extremely low bulk density and high surface area. Its threedimensional structure results in viscosity-increasing behavior
when used as a thickener or reinforcing filler.
Fumed silica also provides better trade-off for fuel efficiency and
wet handling due to a lower rolling loss compared to carbon
black-filled tires. Traditionally silica fillers had worse abrasion
wear properties, but the technology has gradually improved to
where they can match carbon black abrasion performance.
Vulcanization
Natural Rubber is sticky, deforms easily when warm, and is brittle
when cold. Vulcanization is a chemical reaction which helps in
14
15
DESIGN CONCEPTS
As a first step toward the evaluation of design concepts, the
wheel and tire assembly was considered in the light of its various
functions in the vehicle and its interaction with military logistics,
tactics and strategy.
The concept is that the tire and wheel might constitute a single
unit, eliminating weight and cost of beads, rims and associated
hardware. This concept is valid for tires that will not have to be
removed from the wheel during their life. It is anticipated that
foam-filled tires or tires packed with inflated spheres will not have
to be repaired as a result of punctures or other damage normally
deemed repairable. Any damage severe enough to take them out
of commission would normally require that the tire be discarded.
In order to utilize this concept, it is necessary to optimize the life
of the tire.
A very attractive prospect is that of a wheel and tire assembly
that
(1) Will have very long life,
(2) Require and permit no maintenance except possibly the
annual checking of inflation pressure and replacement of treads,
and
16
Visual design
This chapter describes the different steps of the design procedure,
which was focused on general and product design and meant to
form visual concepts before moving on to acoustic design. The
general workflow for the thesis is illustrated in the picture below.
Figure Workflow.
17
18
Concept results
Six concept patterns were generated that would fulfill the basic
requirements in the product specification, which also included a
basic manufacturing limitations such as repeatability, and also
basic principles regarding solid mechanics (limiting the patterns
to geometries that will not make the material too susceptible to
mechanical damage). The patterns were drawn first by hand, then
in Photoshop to enable a high flexibility of output formats. All
patterns were drawn with grooves represented as black areas,
while rubber that would have a chance of contact with the ground
was made white.
Precise
Speedy/fast
Precise
Clear & shiny
Clear & shiny
Precise
Hard
Speedy/Fast
Gedgety
19
Functionally supreme
Safe
Speedy/Fast
Clear & shiny
Functionally supreme
Gadgety
Hard
Hard
Gadgety
Concept evaluation
After generating the concept patterns a short questionnaire was
used to evaluate the expressions of the concepts. This particular
survey was made only to receive a general indication about how
10 people, of various backgrounds, appreciated the six designs.
The subjects were instructed that this is highly subjective and
they could use their gut feeling and put anything they wanted,
including comments on the sheet, but they also had to choose
three of the available seven expressions, and only one from the
user/buyer/customer box and two from the Continental box (figure
17). The survey showed that most of the designs according to this
study were perceived to illustrate the expressions they were
intended to Illustrate.
Acoustic design
After generating pictures in Photoshop these were made into
bitmap files, transferred and processed with Matlab, from which
the simulation software retrieves data. Material data and
structural geometry data for another Continental tyre had already
been prepared and installed from previous research on roads. To
get started with the simulation process within the limited time of
this thesis work this data was used. Each pattern had to be totally
20
Void content
Shoulder groove angle
Width of horizontal grooves
Randomization
Shift
By simulating, and hoping to confirm what was expected in terms
of general tendencies resulting from these basic modifications,
some of the concept patterns were meant to undergo modification
towards a better result. Other modifications of various patterns
were also made, some for investigation of the accuracy of the
software, some for finding the difference between basic patterns,
and for improvements of the previously generated initial patterns.
By modifying and simulating repeatedly the expected outcome
was to see the general tendencies resulting from modifications of
these basic characteristics in tread patterns.
By simulating, and hoping to confirm what was expected in terms
of general tendencies resulting from these basic modifications,
some of the concept patterns were meant to undergo modification
towards a better result. Other modifications of various patterns
were also made, some for investigation of the accuracy of the
21
22
23
4.2 Milling
Shaping of rubber begins in the milling process. At the completion
of the Banbury mixing cycle, rubber is placed onto a drop mill.
The milling process shapes the rubber into flat, long strips by
forcing it through two set rolls rotating in different directions at
different speeds. Mill operators are generally concerned with
safety hazards associated with the open operation of the turning
rolls. Older mills usually had trip wires or bars which could be
pulled by the operator if he or she is got caught in the mills.
Modern mills have body bars at about knee level that are
automatically triggered if the operator is caught in the mills. Most
facilities have extensive emergency rescue procedures in place
for workers trapped in mills. Mill operators are exposed to heat as
well as noise.
24
27
28
2013 2012 2011 2010 2009 2008 2007 2006 2005 2004
13444. 13054. 10637. 8080.4 6141.9 5715.5 5036.7 4233.6 3437.1 2989.4
75
03
03
5
4
2
5
6
3
3
Other
Income 37.40 39.73 33.14 29.13 34.40 40.83 24.17 27.07 44.96 58.54
Total
Income 13482. 13093. 10670. 8109.5 6176.3 5756.3 5060.9 4260.7 3482.0 3047.9
Profit
Before
Taxatio 1226.8 833.12 893.65 534.66 398.48 211.39 260.96 99.81 55.34 42.90
n
Provisio 0
n for
Taxatio 424.59 260.76 274.23 180.68 145.45 66.83 89.18 19.90 15.03 14.10
n
Profit
after
Taxatio 802.21 572.36 619.42 353.98 253.03 144.56 171.78 79.91 40.31 28.80
n
Share
Capital 4.24
4.24
4.24
4.24 4.24 4.24 4.24 4.24 4.24 4.24
Reserve 3640.9 2853.5 2293.5 1686.4 1357.1 1116.5 981.91 820.05 749.81 719.17
s
0
6
3
4
8
5
Net
Worth
Fixed
3645.14
2857.80
2297.77
1690.68
1361.42
1120.79
986.15
824.29
754.05
723.41
Assets
5834.14
5477.16
4967.07
3865.62
3020.57
2866.24
2289.77
1955.99
1787.85
1534.47
As shown in above table MRF Ltd. has shown tremendous growth in the last 10 years. Let
see these in the chart to have clear idea of growth
1.
Sales
Sales
31
14000
12000
10000
8000
6000
4000
2000
0
2012
2004
2013
2005
2006
2007
2008
2009
2010
2011
2. Net Worth
4000
3000
2500
2000
1500
1000
32
500
0
2012
2004
2013
2005
2006
2007
2008
2009
2010
2011
References
http://www.efymag.com
publications.lib.chalmers.se
www.continental-corporation.com
http://www.uniroyaltires.com
34
https://en.wikipedia.org
http://global.yokohamatire.net
http://www.madehow.com
https://www.scribd.com
35