KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY EXPERIMENTAL STUDIES ON THE REDUCTION IN MANUFACTURING COST OF ROLLER SKATING WHEELS External Guide, Internal Guide, Mr.J.Jenagaraj, Mrs. M.Jeya Priya,M.Tech., Sr, Consulltant, (Assistant Professor) The Consultanzy,Madurai. Bharath Rubber (INDIA) limited M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY ABSTRACT The manufacturing cost of roller skating wheels is reduced by replacing the black fillers in the existing material composition ,with non-black fillers, such that the properties of the wheels are unaltered . Change in designs have been included to improve its end application. Comparison between two processing techniques based on the production time and material wastage is analysed. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

Parts of skating wheels: Natural rubber roller Aluminium hub KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Parts of skating wheels: Natural rubber roller Aluminium hub Average weight of a skating roller: Al Hub : 0.020 g Rubber : 0.088 g ---------------- Total = 0.108 g M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Compounding: Cure systems: Vulcanizing agents, boosting accelerators, activators. Without these the polymer properties cannot be achieved. Reinforcements: Fillers, plasticizers, other processing aids For improving strength and easy processing. Anti degradiants: Anti oxidants To protect against degradation of properties M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Material Composition: Material phr ISNR 20 - 100 Zinc Oxide - 5.0 Stearic acid - 2.0 Antioxidant - 1.5 Silica - 50.0 Clay - 30.0 TiO₂ - 5.0 Rosin - 5.0 Paraffinic oil - 5.0 DEG - 2.0 Sulphur - 1.0 CBS - 1.25 TMT - 0.2 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Two roll mill: The process of mixing is carried out between two contrary rotors. The wicks of both rotors are arranged in parallel manner and posses different speeds. Due to the difference in tangential speed and nip constriction, rubber compound experiences displacement and pressure energy during the process of mixing. Pressure energy increases the displacement energy, and displacement energy will break the rubber molecule bonding. The breakage of rubber molecules allow carbon and other chemicals to be uniformly mixed with rubber. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Transfer Molding Procedure: The mold is removed from the press and opened. A precut "slug" of unvulcanized rubber, at a set weight, is placed into the transfer "pot " The loaded mold is then placed back into the press and the press is then closed. The pressure forcing the plates together distributes (transfers) the precut "slug " of unvulcanized rubber in the "pot" down through the "spruces" and into the cavities. The unvulcanized rubber is then forced into the shape of the cavity in the mold. The mold remains closed until the rubber is vulcanized, completing the cycle. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Specifications: Temperature: 165 to 175°C Clamping pressure: 1500 to 1800psi Curing time: 2 to 2min 20s Slug weight: 93-95g M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

Compression Moulding Procedure: KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Compression Moulding Procedure: Heat press and empty the mould. Load mould with sufficient quantity of pre mixed rubber compound to ensure complete fill of cavity. Drop top platen until it touches the pre-form. Heat filled mould with no pressure on press for 1 to 2 minutes (up to 5 minutes for thicker parts). Bring press to full pressure and hold for at least 1 minute and cool at full pressure before releasing pressure. Remove from press and release the products. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY TRANSFER MOULDING COMPRESSION MOULDING High product consistency Cycle time is lesser in mass production High setup and process cost Material wastage due to flash is low Suited for large scale industries Mould tends to be complex Better product consistency Cycle time is higher for mass production Low setup and process cost Material wastage due to flash is high Suited for small scale industries Mould tends to be simple M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY TESTING Hardness: (ASTM D 2240) This test method is based on the penetration of a specific type of indentor when forced into the material under specified conditions. The indentation hardness is inversely related to the penetration and is dependent on the elastic modulus and viscoelastic behavior of the material. The geometry of the indentor and the applied force influence the measurements for hardness. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Tensile testing: (ASTM D 412) It is carried out to determine the tensile strength, percent elongation of rubber when subjected to tension. Dumbbell specimen of the prescribed dimension is taken The specimen is placed between the grips and tension speed is applied and the specimen starts to elongate until it breaks or ruptures. Tensile strength = Force/Cross-sectional area (Final length-Initial length) Elongation at break= ----------------------------------- X 100 Initial length M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Abrasion Resistance: (DIN 53516) The abrasion resistance is measured by moving a test piece across the surface of an abrasive sheet mounted to a revolving drum. It is expressed as volume loss in cubic millimetres or abrasion resistance index in percent. For volume loss, a smaller number indicates better abrasion resistance. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Rebound resilience: (ASTM D 1054) This test method covers a means of determining the resilience of rubber, within a range of impact strain and strain rate, by means of the impacting. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Black-filler Formulation Material phr Cost Rs. ISNR 20 - 100 x239 = 23900 ZnO - 5.0 x110 = 550 Stearic acid - 2.0 x72 = 144 Antioxidant - 1.5 x295 = 442 FEF Carbon - 60.0 x69 = 4140 HAF Carbon - 20.0 x68 = 1380 Aromatic oil - 5.0 x42 = 210 Sulphur - 2.5 x28 = 70 CBS - 0.8 x245 = 196 TMT - 0.1 x135 = 13.50 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

Effective Replacements KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Effective Replacements Fillers: PPT Silica Clay For Pigment dispersion & fixing: TiO₂ Processing Oil: Paraffinic Oil Activators: Rosin DEG M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Non-Black Filler Formulation TRIAL-1 ISNR 20 - 100 Zinc Oxide - 5.0 Stearic acid - 2.0 Antioxident - 1.5 Silica - 40.0 Clay - 30.0 TiO₂ - 5.0 Rosin - 5.0 Paraffinic oil - 5.0 DEG - 2.0 Sulphur - 1.0 CBS - 1.25 TMT - 0.2 TRIAL-2 ISNR 20 - 100 Zinc Oxide - 5.0 Stearic acid - 2.0 Antioxident - 1.5 Silica - 45.0 Clay - 35.0 TiO₂ - 5.0 Rosin - 5.0 Paraffinic oil - 5.0 DEG - 2.0 Sulphur - 1.0 CBS - 1.25 TMT - 0.2 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY TRIAL-3 Material phr ISNR 20 - 100 Zinc Oxide - 5.0 Stearic acid - 2.0 Antioxidant - 1.5 Silica - 50.0 Clay - 30.0 TiO₂ - 5.0 Rosin - 5.0 Paraffinic oil - 5.0 DEG - 2.0 Sulphur - 1.0 CBS - 1.25 TMT - 0.2 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Rheo-graph: M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

ML- Minimum torque MH- Maximum torque TC’(90) = ML+(MH-ML)90/100 KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY ML- Minimum torque MH- Maximum torque TC’(90) = ML+(MH-ML)90/100 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Property Comparison PROPERTY TRIAL-1 TRIAL-2 TRIAL-3 Hardness 89 90 Rebound Resilience (%) 79.3 79.8 80 Abrasion loss (g) 9.32 9.259 9.05 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

Comparison of the properties achieved in each trial KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Comparison of the properties achieved in each trial M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Hardness The hardness of non-black filler is found to be higher than that achieved using black filler composition. BLACK FILLER NON-BLACK FILLER Hardness 89 90 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Abrasion Resistance The Abrasion resistance offered by non-black filler incorporated wheels is much higher and hence results in prolonged lifetime of the wheels. BLACK FILLER NON-BLACK FILLER Abrasion loss(g) 9.26 9.05 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Tensile strength The tensile strength achieved is 17kg/m² higher in black filler composition than non-black filler composition . BLACK FILLER NON-BLACK FILLER Tensile strength (Kg/m²) 202 185 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Elongation at break The EB% is 58 higher in black filler composition than non-black filler composition . BLACK FILLER NON-BLACK FILLER Elongation at break(%) 386 328 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Rebound resilience The rebound resilience% achieved is 3 higher in black filler composition than non-black filler composition . BLACK FILLER NON-BLACK FILLER Rebound resilience(%) 83 80 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Property Comparison M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY FINAL FORMULATION Material phr Cost Rs. ISNR 20 - 100 x239 = 23900 Zinc Oxide - 5.0 x110 = 550 Stearic acid - 2.0 x72 = 144 Antioxidant - 1.5 x295 = 442.50 Silica - 50.0 x57 = 2840 Clay - 30.0 x3 = 90 TiO₂ - 5.0 x170 = 850 Rosin - 5.0 x66 = 330 Paraffinic oil - 5.0 x70 = 350 DEG - 2.0 x130 = 260 Sulphur - 1.0 x28 = 28 CBS - 1.25 x245 = 306.25 TMT - 0.2 x135 = 27 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Cost per Kg : Rs. 41.50 Cost Estimation: Rs. Material + Additives = 5.00 Al Hub = 1.50 Processing cost = 2.00 ---------------- 8.50 Margin = 2.80 Tax = 1.70 ----------------- 13.00 Regular cost per wheel 15.00 Cost saving per wheel 2.00 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Cost Comparison Rs. Regular cost/wheel: 15 Cost saving/wheel : 2.0 Overall cost saving:20% BLACK FILLER NON-BLACK FILLER Cost (Rs.) 157.50 42.50 M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Design Variation Knurling have been added in the wheel surface to improve the friction and grip between the floor and the wheel. This, Improves abrasion resistance properties Better stability & road grip to the skater It matches the compatibility of the ‘All Terrain Wheels’ M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY Wheel size Outer diameter : 50 mm Inner diameter : 20 mm Thickness : 30 mm Achieved Properties Hardness : 89-90 Shore A Rebound resilience: 80% Abrasion loss : 9.05g M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY CONCLUSION The manufacturing cost of the roller skating wheel is greatly reduced (20%) by replacing the black fillers The Abrasion resistance and hardness of the wheels have been improved while optimum results have been achieved in terms of tensile strength, elongation at break and rebound resilience. Manufacturing has been carried out in two different techniques considering the production rate. Changes in design has been made so as to improve its end application. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna

M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna KAMARAJ COLLEGE OF ENGINEERING & TECHNOLOGY DEPARTMENT OF POLYMER TECHNOLOGY THANK YOU OUR PROJECT IS GOING TO BE LAUNCHED IN BHARATH RUBBERS (INDIA) LIMITED SHORTLY. M.Aruna, K.Abinaya Saraswathi, B.Sasirekha, V.Varna