METALASTIK MANUFACTURING COMPANY PRIVATE LIMITED 891 Sarat Chatterjee Road, Flat G3 Kolkata 700 089

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  METALASTIK MANUFACTURING COMPANY PRIVATE
LIMITED89/1 Sarat Chatterjee Road, Flat
G3Kolkata 700 089AN ISO 90012000
COMPANY(With Design Activity)MANUFACTURES
MOULDED EXTRUDED RUBBER PRODUCTS FOR RAILWAYS,
DEFENCE, AEROSPACE, NAVAL AND OTHER SPECIALISED
SECTORS
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SUVRO CHATTERJEE Managing DirectorM.Tech,
DPRI(UK), AIM(UK), PGDOM Certified Auditor
for ISO 9000 Series. Member of ASTM
Technical Committee. Published more than 20
Technical papers in Indian
International Journals. Patent Holder on
Design of Elastomeric Pad. Experience of 20
years in RD, Production, QC,Management.
Specialisation in Rubber Engineering Metal
Bonding. Other products All Railway
Products, Footwear, Tyre, Hose, Belting
etc.
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• AN EFFORT TOWARDS
• IMPROVEMENT OF
• RUBBER PRODUCTS
• IN THE INDIAN RAILWAYS
• AN OVERVIEW

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ELASTOMER    VIRGIN
RECYCLED NATURAL SYNTHETIC  THERMOPLA
STIC RECLAIM
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WHY RUBBER IN ENGINEERING APPLICATI0NS

• RUBBER IS TOUGH, FLEXIBLE AND INCOMPRESSABLE.
• 2 RUBBER CAN STORE 150 TIMES HIGHER ENERGY (J/KG)
  COMPARED TO TEMPERED STEEL OF EQUAL WEIGHT.
• ELASTICITY IS A MATERIAL PROPERTY OF RUBBER AND
  CAN BE CHANGED EASILY.
• IT CAN WITHSTAND NORMAL EXPANSION AND CONTRACTION
  OF METAL STRUCTURE.
• RUBBER ABSORBS SHOCK LOAD PROTECTS THE SYSTEM.
• NO RUSTING NO LUBRICATION IS REQUIRED.
• LIGHTER IN WEIGHT AND EXTREMELY ECONOMIC.

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TYPE OF FAILUREMATURED FAILURE
PREMATURED FAILURENatural death due to
Accidentals death due to normal
degradation inhomogeneous
properties LIFE CAN BE LIFE CAN BE
SAVED AND INCREASED
ALSO BE INCREASED
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POLYMER DEGRADATION

• AEROBIC AGEING ANAEROBIC AGEING
• PHYSICAL CHEMICAL REVERSION
  MARCHING
• THERMAL MECHANICAL PHOTOCHEMICAL IONISING
• (Grinding, (UV Light) RADIATION
• Mastication) (X-Ray, ? Rad.)
• OXIDATIVE HYDROLYSIS ACIDALYSIS
  AMINOLYSIS
• (O2, O3) (H2O) (Carboxilic Acid)
  (Hexamethylene Tetramine)
• WITH MAIN CHAIN RUPTURE WITHOUT MAIN
  CHAIN RUPTURE

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PRODUCTWISE FAILURE

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REASONS OF PRE MATURE FAILURE OF ALL RUBBER
PRODUCTS

• 01 Surface Cracking (Tk. Matl)
• (1,2,3,4,5,7
• 02 Permanent Set
• (1,2,4,9)
• 03 Swelling
• (4,5,9)
• 04 Wear Tear
• (1,2,3,4,9)
• 05 Storage Hardening
• (6,7,8,9)

• 01 Over Stress Strain
• 02 Poor Compounding
• 03 Poor Weathering Property
• 04 Non Technical Curing
• 05 Wrong Grade of Elastomer
• 06 No Preservative
• 07 Poor Ageing Properties
• 08 Open Air Storing
• 09 Non Technical Blending

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REASONS OF PRE MATURE FAILURE OF METAL
BONDED PRODUCTS

• 01 Bond Failure
• (6,7,9,10)
• 02 Fatigue Failure (1,2,3,4,5,8,9)
• 03 Buckling
• (1,11)
• 04 Stress Relaxation
• (1,3,5,8)
• 05 Permanent Set
• (5,8)

• 01 Poor Design
• 02 Stress Concentration.
• 03 Poor thermal conductivity.
• 04 Poor heat resistance compound
• 05 Over stressing.
• 06 Non friendly compound to bonding
• 07 Metallic corrosion
• 08 Non uniform state of cure
• of thick article.
• 09 Different thermal expansion
• of metal and rubber
• 10 Jelled bonding agent
• 11 Lower Shape Factor

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• CORRECTIVE
• PREVENTIVE ACTIONS

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VISCO-ELASTICITY OF RUBBER

• ELASTICITY
• VISCOUS PHASE
• ELASTIC PHASE
• VISCO-ELATICITY

• ELASTICITY
• It is the ability of material to
• deform under load and resume
• almost completely when load is
• released. But it dose not follow
• Hooks Law.
• VISCO-ELASTICITY
• It is simultaneous dependence
• of Stress on Strain deformation
• and on the rate of deformation
• as well as on higher derivatives
• of deformation with respect to
• time.

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FAILURE MODE ANALYSIS

• AREA OF FAILURE
• IMPROPER SELECTION PROCESSING
  DESIGN OF METAL
• PRICING OF OF
  PRODUCTS TREATMENT
• ELASTOMER ELASTOMER
• OLD FITMENT STORAGE
• SPECIFICATION OF PRODUCTS CONDITION

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SELECTION OF ELASTOMER

• To identify application conditions correctly.
• (Polarity, Heat, Weathering etc.)
• To identify the need of minimum service life.
• To select proper grade of elastomer.
• To honour the availability of elastomer.
• To consider price of elastomer

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POLARITY OF ELASTOMER

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GENERAL PROPERTIES OF RUBBER
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PROCESSING OF RUBBER Failure Cause
Compounding Formula

• A Selection of correct ingredients.
• B Selection of pure ingredients.
• C Correct balancing of formula.
• D To consider processing application
  conditions.

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• TYPICAL FORMULA
• Ingredients phr
• 01 Rubber (NR) 100
• 02 Stearic Acid 1.0 2.0
• 03 ZnO 4.0 7.0
• 04 Carbon Black 30 80
• 05 Mineral Filler 30 100
• 06 Antioxidant 1.0 3.0
• 07 Antiozonant 1.0 2.0
• 08 Process Aid 2.0 5.0
• 09 Process Oil 5.0 30
• 10 Accelerator 0.5 3.0
• 11 Sulphur 0.5 3.0

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PROCESSING OF RUBBER
Failure Cause
Mixing Open Roll Mill/Internal
Mixer/Banbary/Dispersion Kneader

• A Scorched Compound
• B Batch to Batch Variation
• C Nonuniform Properties
• A Weighing
• B Temperature Control
• C Mixing Time Control
• D Dispersion Rating
• E Retention of Plasticity
• F Mixing as per Rubber Prop.

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PROCESSING OF RUBBER
Failure Cause
Moulding Compression / Transfer /
Injection

• A Bond Failure
• B Flow Marking
• C Poor Properties
• D Porosity
• F Over / Under Cure
• A Correct Temp. Control
• B Correct Moulding Pressure
• C Correct Compd. Plasticity
• D Good Rheological Property

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PROCESSING OF RUBBER
Failure Cause Extrusion Hot
Feed Extruder / Cold Feed Extruder

• Rough Extrusion
• Die Swell
• Porosity
• Void
• Nonuniform Dimension

• Variation in Viscosity Plasticity Value
• High Nerve Compound.
• Selection of incorrect ingredient rubber.
• Unskilled Operator

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PROCESSING OF RUBBER
Failure Cause Calendering Two Roll
Calender/Three Roll Calender/Four Roll Calender

• Rough Sheeting
• Crows Feet Marking
• Shrinkage
• Poor Properties
• Nonuniform Dimension

• Variation in Viscosity Plasticity Value
• High Nerve Compound.
• Selection of incorrect ingredient rubber.

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ENGINEERING DESIGN OF PRODUCT Failure Cause
Stress/Strain Limit

• 1 Max. Allowed Compression Stress 3.0 Mpa
• 2 Max. Vertical Deflection 15 of Th.
• 3 Max. Lateral Stress 3.0 Mpa, subject to
• Max. Lateral Deflection 50of Th.
• 4 Max. Tangential Rotary Shear 3.5 Mpa
  (Static)
• 4.2 Mpa (Dynamic)
• 5 Mechanical Loss Angle (tan ?) (3 - 7)

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ENGINEERING DESIGN OF PRODUCT Failure Cause
Stress Concentration
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ENGINEERING DESIGN OF PRODUCT Failure Cause
Buckling Instability

• SHAPE FACTOR
• Compressed Area
• SF
• Force Free Area
• Less SF means Buckling and Instability.
• SF directly relates to Fatigue Life

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ENGINEERING DESIGN OF PRODUCT Failure Cause
Loss of Energy

• 1 The loss of Energy is caused by internal
  friction within elastic body.
• 2 The residual deformation on loading unloading
  is caused by the partial disentanglement of the
  molecular chains with change in Entropy.
• 3 The area between loading unloading curve
  corresponds to the energy loss as heat between
  absorbed released energy

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FREQUENCY OF OSCILLATIONTRANSMISSIBILITY
CURVEFrequency Ratio (?) Exciting Freq. /
Natural Freq. If FRgt ?2, High Elastic Rubber is
preferred. If FRlt ?2, High Damping Rubber is
preferred

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SINUSOIDAL STRESS CYCLE
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SOME USEFUL DESIGNS
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MECHANISM OF BONDING - 1

• PROGRESS HARDER
• OF RESINOUS CHARACTER
• Inter
• Diffusion RUBBER Elastomer
• Internal COVER ADHESIVE Adhesive
• Crosslink Cover
• Adsorption PRIMER ADHESIVE
  Adhesive
• Primer
• Inter METAL
• Diffusion
• Adsorption Cross Brid

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MECHANISM OF BONDING - 2

• Adsorption depends on Cohesive Energy Density and
  Low/High Energy phenomenon.
• Mechanism includes chemical reaction at the
  Surface, Mechanical Interlocking, Van Der Waals
  Forces, H-Bonding Electrostatic Attraction.

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BOND FAILURE Failure Cause
Metal Preparation
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BOND FAILURE Failure Cause Blasted
Surface Study

• ADHESIVE CONTACT
• Low Energy Material High Energy Material

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BOND FAILURE Failure Cause Adhesive
Application
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BOND FAILURE Failure Cause Compounding
Vulcanization

• Selection of nonoily ingredients
• Higher Thermal Conductivity
• Good Rheological Properties
• Nonblooming ingredients
• Synchronization of curing between rubber
  adhesive
• Wiping of Adhesive
• Dual Temperature Curing

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UPGRADATION OF SPECIFICATION Failure Cause
Old Specification

• Regular upgradation of specification required
• 2 Incomplete specifications to be upgraded
• Introduction of more test parameters
• (Ageing, Acetone Extract etc.)

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FITMENT OF PRODUCT Failure Cause Improper
Fitment

• 1 THE LIFE OF THE PRODUCT ALSO DEPENDS ON THE
  STYLE OF PROPER FITMENT
• 2 IT MUST BE TRUE PARALLEL TO OTHER SURFACES OF
• THE SYSTEM.
• 3 AVOID SLACKNESS OR GAP WHEN FITTED IN THE
  SYSTEM.
• 4 MAINTAIN C.G. SAME BETWEEN THE PRODUCT AND
• SYSTEM.
• 5 PROPER TIGHTENING

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STORAGE CONDITIONFailure Cause Storage
Condition

• Should avoid direct sun light
• Should avoid moisture for metal component
• Special care for unsaturated elastomers as they
  are very much prone to be attacked by weathering
• Ambient temperature should be less than 30 C

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COST Vs QUALITYFailure Cause IMPROPER PRICIING

• THE RAILWAY
• SHOULD HAVE CLEAR IDEA ON CURRENT COST OF RAW
  MATERIAL AND OTHERS
• SHOULD HAVE CLEAR IDEA ON METHOD OF COSTING
• SHOULD CONSIDER THE KNOWLEDGE CAPABILITY ON
  FIRM
• 4 SHOULD CONSULT WITH EXPERTS (INTERNAL OR
  EXTERNAL) FOR ANY STRATEGIC DECISION

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METHOD OF COSTING For General Purpose Rubber

• 01 Cost of Compound/Kg A VG Compd.
  CostRubber Cost
• G C. Cost ? 1.5 R. Cost
• P C. Cost ? 2.0 R. Cost
• 02 Cost of Mixing/Kg Max. Rs 8.00
• 03 Cost of Moulding C Molding Cost /
  No. of products moulded
• 04 Cost of Extrusion/Kg Max. Rs 08.00
• 05 Cost of Calendering/Kg Max. Rs 15.00
• 06 Cost of Rejection Max. 10 of above.
• 07 Cost of Q.C. Max. 05 of above.
• 08 Cost of Extn. Inspection (02 05) of
  above.
• 09 Cost of Other Expenses Max. 02
• 10 Profit Min. 15

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INSPECTION OF PRODUCT

• Sampling as per SQC for no critical products
• 100 sampling for critical products checking on
  critical parameters
• Field sampling of Metal Bonded Products.

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FINISHED PRODUCT Vs TEST SAMPLE

• It is quite natural to have different test values
  between
• finished product and test samples (T.Sheet,
  Button, Cutting
• Sample etc.), though made from same compound.
• BECAUSE OF
• Different state of cure.
• Human error in sample preparation.
• Geometrical criteria for circular materials.
• RELAXATION
• 1 Normally 10 - 15 deviation is accepted
  internationally. SH Polymer Identification are
  excluded from this relaxation

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DETECTION OF NON-CONFORMING PRODUCT

• All tests cannot be carried out from the
  finished products due to its geometrical factors.
  In that case it is recommended to test from the
  Test Sheet and Button vulcanized at equivalent
  curing conditions. Check Points are
•  
• Sp. Gravity ? 0.05
• Acetone Extract ? 0.50
• Ash Content ? 1.00

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IDENTIFICATION OF POLYMER

• 1 Burn Test
• 2 Infrared Spectroscopy Study
• 3 Differential Scanning Calorimetry
• 4 Glass Transition Temperature Study
• 5 Scanning Electron Microscopy 
• 6 Transmission Electron Microscopy
• Pyrolysis Test (ASTM Colour Test) is not
  recommended in that case, because it has got some
  technical nonconformity in Indian Work Climate.
•  

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LIFE PREDICTION OR REUSE OF MATERIAL

• Sample collected from field can be analysed to
  detect service life or reuse of costly material.
• DYNAMIC TEST
•  Scrap Limit Max. 20 of Stress and
• Max. 30 of Strain
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• STATIC TEST
•  Scrap Limit Max. 30 of Stress and
• Max. 50 of Strain
•  
• No change in results of SG, ASH, ACETONE
  Extract.

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NEW GENERATION DAMPER

•  MAGNETO-RHEOLOGICAL FLUID is used in Dampers to
  obtain much higher damping properties compared to
  conventional dampers.
• Advantages of Rheonetic Systems
• Highly controllable by x-by-wire haptic
  feedbacksystems, millisecond control of energy
  dissipation and remote locking and position
  control.
• Eliminate the conventional damping system 
• Programmable
• Resonance vibration control can be maximized
  without compromising isolation over frequencies
  inputs.

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LATEST DEVELOPMENTS NEW PROCESS

• POLYCHLOROPRENE
• JACKET OVER
• NATURAL RUBBER
• MOUNTS.
• CR Jacket

• PROTECTION FROM OXIDATIVE DEGRADATION
• OIL FLAME RETARDANT
• IMPARTS gt 30 LIFE
• NO EXTRA COST

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DEVELOPMENTS LATEST NEW MATERIAL

• POLYMERIC COATING
• OVER BONDED
• PRODUCTS

• IT PROTECTS THE METAL PARTS FROM RUSTING AND
  CORROSION.
• IT PROTECTS THE METAL AND RUBBER INTERFACE FROM
  STARTING CORROSION.
• IT PROTECTS THE RUBBER FROM CONTAMINATING AGENTS.

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LATEST DEVELOPMENTS NEW MATERIAL

• COMPOSITE MATERIAL REPLACES METAL PLATE IN
  MOUNTS
• A COMPOUND MADE OF RESIN,
• NONASBESTOS FIBRE, FILLER,
• ADDITIVES, CURATIVES ETC.

• 1 ACCEPTABLE STRENGTH
• EXCELLENT IN-CITU BONDING
• LIGHTER WEIGHT
• 40 COST REDUCTION OVER METAL
• ACCEPTS MECHINING
• NO BREAKAGE UPTO 45 BENDING

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LATEST DEVELOPMENTS - NDT
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LATEST DEVELOPMENTS NEW ELASTOMERSENGAGE
(POLYOLEFIN ELASTOMER)

• ENGAGE IS A TRADE NAME OF POLYOLEFIN ELASTOMER
  HAVING ETHYLENE COPOLYMERS PRODUCED BY DUPONT
  DOW.
• EXCELLENT WEATHERABILITY gt EPDM
• SUPERIOR HEAT AGING PROPERTIES gt EPR
• COST Vs PERFORMANCE CHEAPER THAN EPDM
• EXCELLENT LOW TEMP. PROP. ( Workable at - 60C)
• VERY GOOD WEAR TEAR PROPERTIES
• APPLICATION ANY PRODUCT EXPOSED TO WEATHER

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LATEST DEVELOPMENTS NEW ELASTOMERSHYDROGENETED
NBR
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LATEST DEVELOPMENTS MODIFICATION OF MATERIAL
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LATEST DEVELOPMENTS NEW DESIGNAIR SPRING
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THANK YOU

•