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    Calander Thickness Measurement and Analysis PDF

    Uploaded by

    Gayashan Kulathunga
    finding reasons for a issue of thickness variation issue of calendaring process in tire manufacturing process.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Calander Thickness Measurement and Analysis PDF

    Uploaded by

    Gayashan Kulathunga
    237 views22 pages
    finding reasons for a issue of thickness variation issue of calendaring process in tire manufacturing process.

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    Calander thickness measurement and Analysis.pdf

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    © © All Rights Reserved

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    finding reasons for a issue of thickness variation issue of calendaring process in tire manufacturing process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    237 views22 pages

    Calander Thickness Measurement and Analysis PDF

    Uploaded by

    Gayashan Kulathunga
    finding reasons for a issue of thickness variation issue of calendaring process in tire manufacturing process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    CALENDAR THICKNESS MEASUREMENT

    and
    ANALYSIS

    SECOND PROGRESS

    Presented by:
    ALAWATHTHAGE G.C.
    KULATHUNGA H.G.G.
    RATHNAYAKA R.M.P.P.K.

    (RU/E/2009/004)
    (RU/E/2009/095)
    (RU/E/2009/148)

    PRESENTATION OUTLINE

    CALENDARING PROCESS

    INTRODUCTION TO THE PROBLEM

    LITERATURE REVIEW

    MEASURING AND ANALYSIS OF CALENDAR LAYER THICKNESS

    MEASURING AND ANALYSIS OF CALENDAR ROLLER SURFACE

    CONCLUSIONS OF INVESTIGATIONS

    REASONS FOR ISSUE

    AMOUNT OF MATERIAL WASTE

    SOLUTION

    CALENDARING PROCESS IN TYRE


    MANUFACTURING
    Why Calendaring in Tyre Manufacturing?

    For making inner liner & calendar layer

    What is Calendaring Process?

    Calendaring process

    INTRODUCTION TO THE PROBLEM


    Research Problem

    Cross Section of Calendar Layer

    There is no any scientific investigation carried out to related to the


    issue
    project targets to find a most suitable solution and improve the
    productivity, working efficiency as well as saving of valuable material

    LITERATURE REVIEW
    similar type of issue in metal strip manufacturing, but in that case,
    metal strip thickness is varying along length of the metal strip.

    Research is done by T. Widmaier, T. Salmela, P. Kuosmanen, J.


    Juhanko, P. Karha and J. Uusima.

    Try to understand the phenomena behind the rolling force variations


    seen in the rolling force measurements.

    The aim was to reduce the periodic rolling force variation and to
    study how this affects the thickness variations of the steel strip.

    Thickness Variation Along Length of Metal Strip

    RESEARCH METHODOLOGY
    1. Measuring the calendar thickness.
    2. Data analysis and calendar surface mapping.
    3. Measuring the calendar roller surface variation.

    4. Data analysis and calendar roller surface mapping.


    5. Impact of the side cutters to the issue.
    6. Effect of tension variation and sagging of the calendar layer.
    7. Cost estimation for the material waste.
    8. Finding a most affordable solution to solve the issue.

    RESEARCH METHODOLOGY
    Calendar Thickness Measurement, Data Analysis and
    Surface Mapping
    Specifications of Obtained a inner liner
    Thickness

    Width

    Length

    2mm

    1500mm

    4250mm

    Preparations for the Taking Measurements

    Decided to measure the thickness of the calendar from the distance


    of 5cm.
    To achieve that firstly we divide the layer in widthwise in to 5cm

    partitions and then lengthwise.

    RESEARCH METHODOLOGY
    Calendar Thickness Measurement, Data Analysis and
    Surface Mapping

    5cm square divisions

    Measuring the Layer Thickness

    Used Microsoft excel and MATLAB software


    packages for Data Analysis and Surface Mapping

    Thickness Gauge

    RESEARCH METHODOLOGY
    Calendar roller surface variation Measurement, Data
    Analysis and Surface Mapping
    A special methodology for roller surface measurement.
    Measuring process
    Marking Measuring Coordinates on the roller and reference edge

    Reference Edge with Coordinates System

    Paper Strip with Coordinates pasted on the roller

    RESEARCH METHODOLOGY
    Calendar roller surface variation Measurement, Data
    Analysis and Surface Mapping
    Measuring process
    The Reference edge mounted to the machine using brackets.
    Adjust the distance by moving the reference edge through the slots.

    Measure the distance between reference edge & roller surface by


    using two feeler gauges sets.

    Feeler Gauge Set

    Reference Edge Mounting to the Machine

    RESEARCH METHODOLOGY
    Calendar roller surface variation Measurement, Data
    Analysis and Surface Mapping
    Used Microsoft excel and MATLAB software packages for Data
    Analysis and Surface Mapping

    Impact of the side cutters to the issue


    visually inspected the surfaces of both calendar rollers.

    Compare the surfaces.

    Effect of tension variation and sagging of the calendar layer


    Based on the pattern of thickness variation.

    RESEARCH METHODOLOGY
    Cost estimation for the material waste
    Measure the weight of a sample.

    Calculate the density.


    Calculate the excess material per unit length.
    Estimate the annual loss.

    Finding a most affordable solution to solve the issue


    Changing the order of roller location.

    Roller grinding or refurbishment.


    Improvement for cutter mounting.
    Roller replacement.

    OBSERVATIONS, RESULTS & DISCUSSION


    Calendar Thickness Measurement, Data Analysis and
    Surface Mapping
    Surface Plot of Calendar Layer Third Measurement
    Surface Plot of Calendar Layer Second Measurement

    Surface Plot of Calendar Layer First Measurement

    2.9

    2.9

    2.9

    2.8

    2.8

    3
    2.5
    2
    1.5

    2.6
    2.5

    2.7

    2.7

    2.5
    2

    2.6

    1.5
    30

    2.5

    THICKNESS(mm)

    THICKNESS(mm)

    2.7

    THICKNESS(mm)

    2.8

    3
    2.5
    2
    1.5

    2.6
    2.5

    30

    30
    2.4

    25

    2.4

    2.4
    25

    25
    2.3
    20

    20

    2.3

    2.3
    20

    30
    25

    15
    20
    10

    30

    2.2

    2.2

    15
    30

    2.1

    10

    25

    15
    5
    5

    LENGTH

    0 0

    20

    10

    1.9
    WIDTH

    15

    15
    20

    2.1

    15

    2
    1.9

    5
    0

    2.1

    10

    LENGTH

    0
    WIDTH

    Surface Plots of Calendar Layer

    Similar pattern of variation along the width.

    Thickness vary from 1.9mm to 2.7mm.


    No any considerable variation along the length

    10

    10

    LENGTH

    2.2

    25

    1.9
    WIDTH

    OBSERVATIONS, RESULTS & DISCUSSION


    Calendar roller surface variation Measurement, Data
    Analysis and Surface Mapping

    Roller Surface Plot

    Significant variation along the length of the calendar roller

    OBSERVATIONS, RESULTS & DISCUSSION


    Comparison of results
    Defected Areas of Calendar
    Layer

    Surface Plot of Calendar Layer

    Defected Areas of Calendar


    Roller

    Surface Plot of Calendar Roller

    Defected Areas are similar in both calendar surface and roller surface

    variation.

    OBSERVATIONS, RESULTS & DISCUSSION


    Comparison of results

    Difference of Roller Surface and Calendar thickness

    Difference of the calendar roller surface and the average calendar


    thickness is having a linear relationship.
    It is proven that the issue is occurred due to the surface variation of
    the roller surface

    OBSERVATIONS, RESULTS & DISCUSSION


    Impact of the side cutters to the issue
    Damaged area of
    roller

    Roller Contact
    with cutters

    Side Cutter

    Direct Contact of Cutter Roller

    Roller without
    Contact cutters
    Impact of Cutters

    The roller which is directly contact with cutters are severely damaged
    while other one in good condition.

    Effect of tension variation and sagging of the calendar layer


    No variation along the length of the calendar layer.

    No impact of tension variation or calendar layer sagging.

    OBSERVATIONS, RESULTS & DISCUSSION


    Cost estimation for the material waste
    Density of compound

    1207.79Kgm^(-3)

    Actual Weight in 1m length

    3.648Kg

    Expected Weight in 1m length

    3.503Kg

    Material Waste

    0.145Kg

    It is average loss per day 580kg and average cost of it is 350Rs.


    580*350 = Rs. 203000

    Think About loss

    OBSERVATIONS, RESULTS & DISCUSSION


    Finding a most affordable solution to solve the issue
    1. Changing the order of roller location
    Three roll mill machine.
    only two rollers are using.

    replace the defected roller with non used roller.

    2. Roller grinding or refurbishment


    cost is around Rs.85000 to Rs.145000.

    3. Roller replacement with a new one


    Cost is around $2000 to $5000 must imported.

    4. Improvement for cutter mounting.


    Only above 1 or 2 or3 solutions are not enough.
    To avoid the issue permanently need to avoid direct contact of cutters and roller.
    Modification is compulsory with a above solution.

    OBSERVATIONS, RESULTS & DISCUSSION


    Modification for Machine

    New roller

    Modified Design

    Conclusion
    Project

    targets to measure and analysis of the calendar thickness

    variation

    Identified the amount of variation and the pattern of the variation


    Studied

    and investigate the impact of the most related facts to the

    issue of the thickness variation

    To avoid that issue it is suggesting the following solutions


    Changing the order of roller location
    Roller grinding or refurbishment

    Roller replacement with a new one


    Modification for cutting process

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