MANUFACTURING PROCESS (BMCG 2323)

GROUP I

PRODUCT: TIRE

No Nama Matrix Number

1 Nur Ezarina Binti Muhammad Shyfri Sudhanandan B061710067

2 Nor Hazim Bin Nor Razali B061710059

3 Muzhafar Bin Mustaffa B061710221

4 Nur Imanny Natassya Binti Zaidon B061710331

5 Nor Amirah Binti Mohamed @ Md Isa B061710131

LECTURER NAME: DR CHENG SEE YUAN

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 CONTENT

Section Topic Page Number

1.0 Introduction 3

2.0 Manufacturing processes 3-4

3.0 Assembly process / packing 4-6

4.0 Manufacturing issues / aspect 6-7

5.0 Alternative manufacturing processes 7-9

6.0 Summary 9

7.0 References 10

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1.0 INTRODUCTION

A tire (American English) or tyre (British English) is a ring-shaped component that surrounds
a wheel's rim to transfer a vehicle's load from the axle through the wheel to the ground and to
provide traction on the surface travelled over. Most tires, such as those for automobiles and
bicycles, are pneumatically inflated structures, which also provide a flexible cushion that
absorbs shock as the tire rolls over rough features on the surface. Tires provide a footprint that
is designed to match the weight of the vehicle with the bearing strength of the surface that it
rolls over by providing a bearing pressure that will not deform the surface excessively. The
materials of modern pneumatic tires are airtight synthetic rubber liner, carcass ply, beads,
sidewall, crown plies and tread. Objective of tire are to quantify the problem, identify all the
parameters that can influence tire life, determine the impact of each parameters on tire life,
investigate the operational practises and determine the impact of the proposed changes.

2.0 MANUFACTURING PROCESSES

Steel Chemical Rubber Textile

Industries Industries Plantation Industries

Wire Fabric
Bead, Belt, Banbury
Calendar Manufacture
Carcass Wire Mixer
Manufacture

Fabric
Extruders Calendar
Bead
Construction

Wire Tire Building Fabric Bias Cutter

Treatment Machine and Sheet Calendar
Cutter

Curing Press Nd.P.C.I Final Inspection

Final Force
x-Ray Balance
Product Variation

Figure 1: The manufacturing process to make tire

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This process contain a few main elements to make the product run smoothly without any
disruptions which is Street Industries, Chemical Industries, Rubber Plantation and also Textile
Industries. For the early stage, there must collect a rubber from Rubber Planting and for the
processing of rubber solidification, it should be associated with Chemical Industries to be
processed in banbury mixer. Street Industries will be processed to bead, belt and carcass wire
and it can be a wire calendar after combine with banbury mixer.

The next stage for textile industry is it can also run fabric manufacture so banbury mixer will
exist to bead construction and fabric calendar while it can exist an extruders process. For make
a tire building machine, there must have a wire treatment cutter which is by wire calendar
process and the fabric calendar because it is important to make sure the tire building machine
can proceed without any mistaken. After that we should have a curing press Net P.C.I. This
solution eliminates any movement or rotations of the PCI body itself and greatly reduces the
amount of moving mechanical components and maintenance.

Next stage after we curing press, the final inspection process is done to ensure the product is
in good condition when the customer used the product. Hence, the tire must have a balance in
terms of physical tires, sizes and so on. In order to ensure that the tire is in perfect condition
and quality, the force variation process should be carried out to increase the level of tire
performance during the next use of any party.

After the variation process is carried out, the resulting tire should be x-ray. This means that if
the tire produced does not comply with the prescribed standards, it can be identified before it
becomes a finished product. If the tire being tested does not have any defects or damage, it will
be the final finished product to be marketed both locally and internationally.

3.0 ASSEMBLY PROCESS/PACKAGING

Tires Packaging Machines

The FPT series tire packaging machine is mainly used in the packaging of the tire, for example
is hose reel, tube roll and others material. There are many advantages of the packaging that is
efficient, saving labour and cost of material. The machines are waterproof, rustproof, dustproof,
anti-aging affect and effectively protect the normal operation of the machine. This design not
only helps to save the labour, save the warehouse space, improve the productivity and also
decorate the product effectively.

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 Figure 2: Tire Packing Machine FPT-200. Source from
https://www.fhopepack.com/Tyre_packing_machine.html

The tire packaging machine for motorcycle tires, which can be packed with lightweight tires to
avoid shaking. With the help of cylinder bracket to support the roller, it is easier to operate the
packing. It replaces the labour of manual tyre packaging. The feature of the machine is there
are different material that can be used in the tyre wrapper, then the auto and semi-auto mode
for easy the operation. Besides, the material is fix on the ring for packing, the different tyres
OD and ID adjustment and also packaging tension is adjustable by special breaker. This kind
of packaging machine is designed for motorcycle tire is satisfied with the convenience of the
tire packaging. Optional onboard programs control system is provided touch screen
instructions. The complete technical documentations, videos and images simplify maintenance
and maximize the normal running time.

Figure 3: Tire Packing Machine FPT-300. Source from

https://www.fhopepack.com/Tyre_packing_machine.html

The tire packaging machine contain a strong frame. A rotating ring is placed around the frame
to wrap the material roll. The opening rotary ring is used for eye cross wrapping. This tire of
machine can perfectly pack to the overall surface of tires and make the outer of packing more
beautiful. The features of the machine are efficient tyre packing with different materials, the
automatic material cutting, then can easily adjust for different tyres size from small to bigger.
Besides, packing tension is adjustable by special breaker and also the trouble of the tyres can
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be shown automatically when indicator of alarms is sound. This kind of packaging machine is
designed for motorcycle tire is satisfied with the convenience of the tire packaging. Optional
onboard programs control system is provided touch screen instructions. The complete technical
documentations, videos and images simplify maintenance and maximize the normal running
time.

Figure 4: Tire Packing Machine PFT-400. Source from

https://www.fhopepack.com/Tyre_packing_machine.html

The tire packaging machine is for large tire and large roll. The packaging machine is fixed
besides the packaging table which also can calculate the length for the tire packaging. The
machine automatically cuts of the material. The feature of the machine is using the different
material in the tyre wrapper, the materials is fix on the ring for packing, then the packing
tension is adjustable by a special breaker. Besides, the auto and semi-auto for the easier
operation and also logo tape device for wrapping logo at the same time is used. This kind of
packaging machine is designed for motorcycle tire is satisfied with the convenience of the tire
packaging. Optional onboard programs control system is provided touch screen instructions.
The complete technical documentations, videos and images simplify maintenance and
maximize the normal running time.

4.0 MANUFACTURING ISSUE

Tires are among the biggest and the most problematic sources of waste and because of their
large shape and volume they also occupy a lot of space. However, used tires are also one of the
most reusable waste. Disposal of waste tire rubber has become one of the major environmental
issues in the world. Every year millions of tires are discarded, thrown away or buried all over
the world, representing a very serious threat to the ecology. Also, the illegal dumping of tires
is a serious threat to public health through the release of chemicals and pollutants into
surrounding soil, groundwater and rivers.

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The worn tire contains a number of chemicals with energy potential, but it is also a source of
secondary raw material. The tires are made of flexible elastomeric rubber material, the structure
of which is reinforced with textile and metallic materials. Thus, used tires pose problems even
for the most sophisticated waste management systems. The tires are made up of complex
polymeric materials with a large addition of various other components, the recovery of this
added value being a dangerous operation and leading to high energy consumption.

5.0 Alternative Manufacturing Process

The alternative manufacturing process for tire is 3D printing. The manufacturing industry is
always looking at new and innovative ways of working and in recent years, 3D printing has
been at the forefront. Advancements in the 3D printing technology, equipment and materials
has resulted in the costs being driven down, making it a more feasible option to general
manufacturing use.

5.1 Steps in 3D Printing

Step 1: CAD

Produce a 3-D model using computer-aided design (CAD) software. The software may provide
some hint as to the structural integrity you can expect in the finished product too, using
scientific data about certain materials to create virtual simulations of tire of how the tire will
behave under certain conditions.

Step 2: Conversion to STL

Convert the CAD drawing to the STL format. STL, which is an acronym for standard
tessellation language, is a file format developed for 3D Systems in 1987 for use by its
stereolithography apparatus (SLA) machines. Most 3-D printers can use STL files in addition
to some proprietary file types such as ZPR by Z Corporation by Object Geometries.

Step 3: Transfer to AM Machine and STL File Manipulation

A user copies the STL file to the computer that controls the 3-D printer. There, the user can
designate the size and orientation of tire for printing. This is similar to the way you would set
up a 2-D printout to print 2-sided or in landscape versus portrait orientation.

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Step 4: Machine Setup

Each machine has its own requirements for how to prepare for a new print job. This includes
refilling the polymers, binders and other consumables the printer will use. It also covers adding
a tray to serve as a foundation or adding the material to build temporary water-soluble supports.

Step 5: Build

Let the machine do its thing; the build process is mostly automatic. Each layer for the tire is
usually about 0.1 mm thick, though it can be much thinner or thicker. Depending on the tire’s
size, the machine and the materials used, this process could take hours or even days to
complete. Be sure to check on the machine periodically to make sure there are no errors.

Step 6: Removal

Remove the printed object (or multiple objects in some cases) from the machine. Be sure to
take any safety precautions to avoid injury such as wearing gloves to protect yourself from hot
surfaces or toxic chemicals.

Step 7: Post processing

Many 3-D printers will require some amount of post-processing for the printed object. This
could include brushing off any remaining powder or bathing the printed object to remove
water-soluble supports. The new print may be weak during this step since some materials
require time to cure, so caution might be necessary to ensure that it doesn’t break or fall apart.

Step 8: Application

Make use of the newly printed object or objects. The new 3D printed tire is produced.

Figure 5: Michelin 3D Printed Tire. Source from:

https://www.google.com/amp/s/www.engadget.com/amp/2017/08/07/michelin-vision-
biodegradable-3d-print-airless-tire/

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5.2 Comparison between 3D Printing and Existing Process

3D Printing Existing Process

Advantage Disadvantage

 Up to 70% savings on  Higher cost of manufacturing and

shipping
prototype costs

Disadvantage Advantage

 Less innovative designs due  Offers easy, inexpensive design

techniques and innovation
to cost constraints

Disadvantage Advantage

 Longer build time required,  Thanks to the compressed design

with greater margin for error cycles, far less time to build

Disadvantage Advantage

 Create greater waste; process  Higher precision with layered

manufacturing process
disallows ultimate design and production

6.0 SUMMARY

Materials of modern pneumatic tires are airtight synthetic rubber liner, carcass ply, beads,
sidewall, crown plies and tread which have a few processes to make sure the product run
smoothly without any disruptions which is Street Industries, Chemical Industries, Rubber
Plantation and also Textile Industries. There are also three types of Tire Packing Machines
such as Tire Packing Machine FPT-200, Tire Packing Machine FPT-300 and Tire Packing
Machine PFT-400. However, there are a lot of environmental issues, threat to the ecology,
threat to public health and being a dangerous operation and leading to high energy
consumption. There are 8 steps in 3D printing of tire start with CAD, conversion to STL,
transfer to AM Machine and STL file manipulation, machine setup, build, removal, post
processing and application.

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7.0 REFERENCE

1) Tirebuyer, (2009). Tirebuyer.com. America. Retrieved from

https://www.tirebuyer.com/education/tire-anatomy-and-construction#

2) Wikipedia, (2019). Wikimedia Foundation Inc. Retrieved from

https://en.wikipedia.org/wiki/Tire

3) G.C. Lindeque, (2016). Journal of the Southern African Institute of Mining and Metallurgy.
University of Pretoria, South Africa. Retrieved from
http://www.scielo.org.za/scielo.php?script=sci_arttext&pid=S2225-62532016000400006

4) SlideShare, (2011). Department of Metallurgical Engineering and Materials Science.

Indian Institute of Technology, Bombay. Retrieved from
https://www.slideshare.net/sateeshin/manufacturing-processes-tyre

5) Mark, James E. et. al. (1994). Science and Technology of Rubber. Academic Press. San
Diego, CA. Retrieved from
http://wwwcourses.sens.buffalo.edu/ce435/2001ZGu/Firestone_Tires/FirestoneTiresReport.ht
m

6) Fhope Machinery Co., Ltd (2019). Retrieved from

https://www.fhopepack.com/Tyre_packing_machine.html

7) Batayneh M, Marie I and Asi I (2007). Use of selected waste materials in concrete mixes,
Waste Management. Retrieved from https://iopscience.iop.org/article/10.1088/1757-
899X/294/1/012064/pdf

8) Cherlynn Low, (2019). Verizon Media. United State. Retrieved from

https://www.engadget.com/2017/08/07/michelin-vision-biodegradable-3d-print-airless-tire/

9) Lucie Gaget, (2018). Sculpteo. France. Retrieved from

https://www.sculpteo.com/blog/2018/07/13/3d-printing-in-the-automotive-industry-discover-
the-3d-printed-tires/

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