Materials and Process Selection for the Manufacturing of a

Automobile Tire

Because there are several different materials that are involved in the process of manufacturing a tire. We have decided to concentrate on the selection of the rubbers for this process. This includes the Tread Area, and the side walls.

Materials Selection Parameters

Cost Density

Yield

Strength (elastic limit) Fatigue Strength at 10^7 cycles

List of Materials that may be suitable for tire production

Butadiene Rubber Natural Rubber Polyisoprene Rubber Polyurethane Rubber Styrene Butadiene Rubber

Materials Comparison Chart

Material Cost $ Density Yield Strength Fatigue Strength Butadiene Rubber (unreinforced) Min Max Avg 0.95 $ 1.05 $ 1.00 $ 0.0329 0.034 0.03345 0.218 1.02 0.619 0.087 0.406 0.2465 Natural Rubber (unreinforced) Min Max Avg 0.79 $ 0.86 $ 0.82 0.0336 0.035 0.0343 3.05 4.06 3.555 1.22 1.62 1.42

Polyisoprene Rubber (unreinforced) Min Max Avg Cost $ 1.32 $ 1.45 $ 1.39 $ Density 0.0336 0.035 0.0343 Yield Strength 3.34 3.74 3.54 Fatigue Strength 1.33 1.5 1.415

Material

Polyurethane Rubber (unfilled) Min Max Avg 2.20 $ 2.42 $ 2.31 0.043 0.0437 0.04335 5.8 7.4 6.6 2.32 2.96 2.64

Material Cost Density Yield Strength Fatigue Strength

Styrene Butadiene Rubber (unreinforced) Min Max Avg $ 0.95 $ 1.05 $ 1.00 0.034 0.0347 0.03435 0.203 0.435 0.319 0.0812 0.174 0.1276

Passenger Tire Composition

Natural rubber 14 % Synthetic rubber 27% Carbon black 28% Steel 14-15% Fabric, fillers, accelerators, etc. 16 - 17% Average weight: 25 lbs

Polyisoprene Rubber will be used for the synthetic rubber because its mechanical properties and cost fit our needs the best. Passenger Tire Composition by Weight and Cost

25 lbs * 14% Natural Rubber = 3.5 lbs 25 lbs * 27% Synthetic Rubber = 6.75 lbs 3.5 lbs * 0.82 $/lbs Natural Rubber = $ 2.87 6.75 lbs * 1.39 $/lbs Polyisoprene Rubber = $ 9.38

Truck Tire Composition

Natural rubber 27% Synthetic rubber 14% Carbon black 28% Steel 14-15% Fabric, fillers, accelerators, etc. 16-17% Average weight: New 120 lbs

Truck Tire Composition by Weight and Cost

120 lbs * 14% Polyisoprene Rubber = 16.8 lbs 120 lbs * 27% Natural Rubber = 32.40 lbs 16.8 lbs * 1.39 $/lbs Polyisoprene Rubber = $ 23.35 32.40 lbs * 0.82 $/lbs Natural Rubber = $ 26.57

Typical Tire production

1.
2. 3.

4.

Raw Materials (various types of rubber) are placed into a mixer and evenly combined. Then this mix is heated and rolled to form a ply (rubber strip) The plys along with wire bundles and other composites are formed into the typical tire shape creating a green tire Then the green tire is placed into a mold where a balloon (bladder) is filled with steam and cause the treads to form on the walls of the tire.

Process Selection Parameters

Mass Range Range of section Thickness Tolerance Capital Cost (cost of avg machine)

Tire Process Selection Limits

Rolling Process
Raw Data

Molding Process
Raw Data

Process Selection Chart

Rolling Vacuum Molding min Mass Range (lb) Range of section thickness (mil) Tolerance (mil) Capital Cost ($) 0.22 78.7 3.94 $164,000.00 max 4140 9840 19.7 $1,640,000.00 avg 2070.11 4959.35 11.82 $902,000.00 min 1.76 78.7 31.5 $32,800.00 max 4410 236 47.2 $82,000.00 avg 2205.88 157.35 39.35 $57,400.00

Cost Analysis
Rolling Machine = $902,000.00 Vacuum Molding Machine = $57,400.00 Total Capital Cost $959,400.00

Manufacturing Processes Rolling

Rolling is an integral part of tire manufacturing. It produces different sections such as sidewalls, treads and other parts of the tire. Rolling is also responsible for securing all sections of the tire together before curing and inspection.

Manufacturing Processes Molding

Molding: Tread shape Engraved with tread pattern and sidewall markings required by D.O.T.

Manufacturing Processes Curing

Curing: Final step in production Tires get final shape and tread pattern
Vulcanization: Adds strength to tires Stronger molecular bonds

How a tire is made

http://www.youtube.com/watch?v=If5t783NZFY