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1、SRINI,FIBRE REINFORCEMENT,TOPICS,IntroductionHistory Of Tire Reinforcing MaterialsCurrent Reinforcement Line-upFibre Manufacturing ProcessesSpinning/Drawing Fabric ProductionTwisting/weavingProcessingFibre AdhesivesProperty Comparison of different fabricsSummary,FUNCTIONS OF A TYRE,Provide load-carr
2、ying capacityProvide cushioningTransmit driving and braking torqueProduce cornering forceProvide dimensional stabilityResist abrasionProvide steering responseBe durable&safe,DIFFERENT TYPES OF TYRES,TYRE COMPONENTS,THE TYRE IS A COMPOSITE OF A RELATIVELY LOW STRENGTH,HIGH ELONGATION RUBBER MATRIX&A
3、HIGH STRENGTH,LOW ELONGATION TIRE CORD.THE TYRE CORD GIVES THE TIRE SHAPE,SIZE,STABILITY,LOAD CARRYING CAPACITY,FATIGUE&BRUISE RESISTANCE.TYRE CORDS ALSO AFFECT IMPACT RESISTANCE,RIDE,HANDLING,TREAD WEAR&FUEL ECONOMY.,COMPONENTS AND THEIR FUNCTIONS-1,OVERLAY:Placed on top of belt,often called cap pl
4、y,used to further improve crown area durability and high speed performance.BELT/BREAKER:Belts have lower angle than plies,provide tread area stiffness for improved tread wear&provide protection from foreign objects(e.g.rocks).Breakers have nearly the same angle as the plies and do not restrict the c
5、arcass plies,but provide crown area durability.CARCASS:Extending from bead-to-bead,often called ply,primary reinforcing&strength member of the tire.,COMPONENTS AND THEIR FUNCTIONS-2,BEAD:Multiple strands of wire,rubber coated&formed into extensible hoops,anchors ply&tire to the rim,also provides bul
6、k&stiffness(in the bead area)to eliminate tire movement on the rim.FLIPPER:Provides a barrier between the ply and bead to prevent ply erosionCHIPPER:Provides lower bead-area stiffness to absorb deflection,and reduce chaffing,FIBER TERMINOLOGY-1,FILAMENT SMALLEST TEXTILE COMPONENT.A NEAR MICROSCOPIC,
7、HAIRLIKE SUBSTANCE THAT MAY BE NATURAL OR SYNTHETIC.YARN-A CONTINUOUS STRAND SPUN FROM A GROUP OF NATURAL OR SYNTHETIC STAPLE FIBERS,OR FILAMENTS.PLY-ALL YARNS ARE SINGLE PLY,UNLESS TWISTED WITH ANOTHER YARN.-2-PLY IF TWO YARNS ARE TWISTED TOGETHER AND 3-PLY IF THREE ARE TWISTED TOGETHER.-PLIED YARN
8、S ARE USED TO MAKE YARNS STRONGER.,FIBER TERMINOLOGY-2,TIRE CORD-THE PRODUCT FORMED BY TWISTING TOGETHER TWO OR MORE PLIED YARNS.WARP-THE LENGTHWISE,VERTICLE CORDS CARRIED OVER AND UNDER THE WEFT.WEFT-ALSO CALLED FILL OR PICKS.THE LENGTHWISE,SELVAGE TO SELVAGE HORIZONTAL,YARNS CARRIED OVER AND UNDER
9、 THE WARP.-USED TO HOLD FABRIC TOGETHER THROUGH SUBSEQUENT PROCESSING OPERATIONS.,FIBER TERMINOLOGY-3,DENIER/DECITEX-TERM FOR THE LINEAR DENSITY(MASS PER UNIT LENGTH)OF A TEXTILE MATERIAL.DENIER-THE WEIGHT IN GRAMS OF 9000 METERS;-DECITEX IS WEIGHT IN GRAMS OF 10,000 METERS.TWIST-THE NUMBER OF TURNS
10、 ABOUT ITS AXIS PER UNIT LENGTH OF A YARN OR OTHER TEXTILE STRAND.CORD STRENGTH(Tenacity)-ULTIMATE TENSILE LOAD OR FORCE REQUIRED FOR RUPTURE.-FREQUENTLY,TIRE CORD STRENGTH IS EXPRESSED IN TERMS OF CENTINEWTONS PER TEX-CALLED TENACITY.-THE FORMULA FOR TENACITY IS=(BREAK STRENGTH(N)/(DECITEX)*1000=cN
11、/TEX,FIBER TERMINOLOGY-4,CARCASS STRENGTH-CARCASS STRENGTH IS A FUNCTION OF CORD STRENGTH,CORD COUNT(ENDS PER INCH-EPI)AND NUMBER OF PLIES-CARCASS STRENGTH=(CORD STRENGTH*CORD COUNT*NUMBER OF PLIES)RIVET-SPACE AVAILABLE BETWEEN TWO ADJIOINING CORDS FOR GUM TO FILL-ALSO REFFERED AS FILL GUM SPACE.-FO
12、RMULA IS-1-(ENDS PER INCH X CORD GAUGE)/ENDS PER INCH,HISTORY,INTRODUCEDMATERIAL COMMENTS1890sBead wire Normal tensile1900 Cotton Staple fibers,NO treating1936Steel(Europe)Normal tensile/copper plated1938Rayon Tension treating w/simple RFL1947Nylon 6,66 Treating w/modified RFL1955Steel(USA)Normal te
13、nsile/brass plating1962Polyester Treating w/modified RFL,HISTORY,DATE MATERIALCOMMENTS1966FiberglassTreating w/simple RFL 1974Aramid Heat treat w/special RFL1982HMLS PET3T treating w/epoxy-based RFL 1986HT Steel/bead wireHigh tensile w/brass plating 1992ST SteelSuper tensile w/brass plating 1998UT S
14、teelUltra tensile w/brass plating,New development-HYBRID,HYBRID FABRIC-SOME EXAMPLESPET/NYLONARAMID/NYLON,SINGLE END CORD,SINGLE CORDS DIPPED TREATED USED IN VARIOUS APPLICATION-INCLUDING TYREOF DIFFERENT MATERIAL SUCH AS NYLON,ARAMID,HYBRID,USAGE,APPLICATIONPASSENGERRLTOVERLAYNylonNylonBELTSteelSte
15、elCARCASSPolyesterPolyester BEADSteelSteel CHIPPER/FLIPPERNylonNylon,USAGE,APPLICATIONAIRCRAFTFARMOTR RMTOVERLAYNylon n/aNylon n/aBELTNylonPolyester Steel/Nylon SteelCARCASSNylonNylon/Polyester Steel/Nylon SteelBEADSteelSteelSteel SteelCHIPPER/FLIPPERNylonn/aNylon Steel,FIBRE MANUFACTURING,SPINNING
16、SOLUTION SPINNING MELT SPINNINGDRAWING,FIBRE,CHEMICAL COMPOSITION,RAYON,Alkali Cellulose,Viscose,Ripening,Wet Spinning w/H2SO4,RAYON,Slashing,NYLON,NYLON 66,Adipic Acid+NH3,Adipic Acid,Nylon Salt,Polymerization+Melt Spinning,Adiponitrile+H,Hexamethylene Diamine,Nylon 66,POLY ESTER,POLYESTER,Ethylene
17、 Glycol+DMT/TPA,Polymerization,Solid State,Melt Spinning,PolyEthylene Terephthalate(PET),ARAMID,ARAMID,Terephthalate Acid,Polymerization,Wet Spinningw/Sulfuric Acid,p-Phenylenediamine,p-phenylene terephthalomide(aka ARAMID),Common Trade Names Twaron&Kevlar,FABRIC PRODUCTION,TWISTING WEAVING PROCESSI
18、NG,CONVERSION OF CORD TO FABRIC,STEP 1:TWISTING,TWISTING,TYRE CORD,TWISTING,Linear densityof base yarn(units:decitex),1400/1/3,315Z x 315S,#of yarns in ply,#,Twist count&direction for cord(units:turns per meter),#plies in cord,EXPLANATION,PERFORMANCE WITHOUT TWIST,EFFECT OF TWISTING,Improves bundle
19、integrity(holds filaments together)Combines two or more yarns Increases Durability&Elongation Decreases Tensile Strength&Modulus,WEAVING,The twisted cords lie in the machine direction,while the fill yarn is woven across the warp cords.Provides means to interlace the twisted cords with filling yarns
20、to form a woven fabric.,DIP PROCESSING,Application of adhesive Enhance the physical properties of the fabric Stabilize the fabric for subsequent plant application Equalize differences between yarn sources,DIPPING PROCESS,APPLICATION OF ADHESIVE&TREATMENT OF FABRIC UNDER CONTROLLED CONDITIONSTIMETEMP
21、ERATURE TENSIONDIFFERENCES RESULTING FROM SOURCE OF SUPPLY&MILL PRODUCTION VARIANCES ARE REDUCEDADHESIONTENSILE PROPERTIESTHERMAL STABILITYDURABILITYFABRIC PROCESSING IMPARTS ABOVE CHARACTERISTICS BY CONTROLLING THE PHYSICAL STATE OF FIBREAMORPHOUS AREAS ARE PLASTICIZED BY MOISTURE&HEATTENSION IS AP
22、PLIED TO CREATE LINEAR ORIENTATION ALONG THE FIBER AXIS TIME,TEMPERATURE&TENSION RELATIONSHIPS ARE THUS CRITICAL.,DIP UNIT,MULTI STAGE DIP UNIT,DIPPING PROCES,EACH FIBRE TYPE&CORD CONSTRUCTION REQUIRES A UNIQUE PROCESSSPEED DIFFERENTIAL,BETWEEN PULL ROLLS,PROVIDE SPECIFIED STRETCH FOR EACH ZONE.HIGH
23、 TEMPERATURES REQUIRED TO ACTIVATE THE ADHESIVE&ESTABLISH DESIRED CORD PROPERTIESMULTIPLE ZONE PROCESS REQD FOR DOUBLE DIP SYSTEM FOR FIBERS SUCH A POLYESTER,NYLON&ARAMID.,TEMPERATURE VS SHRINKAGE,DIP PICK UP VS ADHESION,EFFECT OF TIME AND TEMP,PURPOSE OF DIP,Bond dissimilar materialsTransfer stress
24、es from high modulus fiber to low modulus rubberCushion fibers from fretting,SIMPLE DISPLAY,Wide array of compositions and application techniques available for fiber adhesivesFiber type,end use and production requirements define limits to designCoated fiber form(yarn,cord,or fabric)Mechanical requir
25、ements(coating thickness,penetration,flexibility)Chemical requirements(bonding to fiber and rubber matrix)Service requirements(temperature,fatigue,age),MECHANISM OF RFL DIP,DIP ON PLY ESTER,Polyester fiber has weaker interaction with RFL adhesives than nylon or rayonHydrogen bonding much weaker with
26、 polyesterEnergetics unfavorable for RF resin/polyester interactionEpoxy resins applied to fiber or combined with RFL adhesive to provide adhesionEpoxy resin selected for best compatibility with fiberResin components in RFL adhesive bond with epoxy,TENACITY,POLYESTER,NYLON,FIBERGLASS,ARAMID,CORD MOD
27、ULAS,POLYESTER,NYLON,FIBERGLASS,ARAMID,ADHESION,POLYESTER,NYLON,FIBERGLASS,ARAMID,DURABILITY,POLYESTER,NYLON,FIBERGLASS,ARAMID,SUMMARY,THE DEGREE OF FREEDOM AVAILABLE TO TIRE ENGINEER IN DESIGNING A TIRE COMPOSITE INCLUDE:1.CHOICE OF A MULTITUDE OF CORD MATERIALS(RAYON,NYLON,POLYESTER,FIBERGLASS,ARA
28、MID ETC)2.AN ARRAY OF CORD CONSTRUCTIONS-e g 2-ply,3-ply etc.3.CORD TWIST LEVEL(e g 315Zx315S,394Zx394S,etc.),balance vs.unbalanced etc.4.VARIETY OF LINEAR DENSITIES 5.SELECTION OF RIVET AND NUMBER OF REINFORCEMENT LAYERS FOR VARIOUS COMPONENTS e g#OF PLIES-10 Ply Actual,#OF BELTS,CHIPPERS,EPI COUNT etc.,SUMMARY,SELECTION OF REINFORCMENT MATERIAL/CONSTRUCTION KEY TO OPTIMIZING IN-TIRE COMPOSITE PERFORMANCE.,
