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Introduction
o History
o Basics of Formulating
o Key Processability Characteristics
o Common Factory Problems and Possible o Causes
Rubber Testing
o Five Categories of Processability Tests
o Miniature Internal Mixers and Extruders
o Rotational Viscometers
o Mooney Viscosity
o Capillary Rheometers
o Oscillating Rheometers
o Oscillating Disc Rheometer (ODR)
o Rotorless Curemeter
o Assignable Causes of Variation
o Rubber Process Analyzer
o ASTM Standard Test Conditions
o Rheological Profiles of Raw Rubber
o Rheology and State of Mix
o Stress Relaxation Tests
General Purpose Elastomers
o Different Polymer Backbones
o Molecular Weight Distribution Differences
o Crystallinity and Morphology
o Crystallinity on Stretching
o Natural Rubber; SBR; Polybutadiene; EPDM
o EPDM and Sponge Formulations
Unit 4 Specialty Elastomers
o Nitrile Rubber, HNBR , NBR / PVC
o Butyl Rubber, Halobutyl Rubber
o Polychloroprene, Epichlorohydrin
o Fluoroelastomer, Silicone Rubber, Curing Silicone Rubber with Peroxide
o Advantages of Platinum Cures
o Polyurethane Rubber
Mixing
o Tangential vs. Intermeshing
o Rotor Design; 2, 4, and 6 Wing Rotors, Rotor Speed
o Friction Ratios
o Dispersive mixing vs. Distributive Mixing
o Importance of Order of Addition of Ingredients
o Examples of Different Orders of Addition, Advantages and Disadvantages
One Pass vs. Two Pass vs. Three Pass
Dump Mill, Cooling Batches, Phase Mixing
Carbon Black Distribution in a Rubber Blend
Filler and Oil Systems
o Plasticizer Performance
o Carbon Black Oil Balance and Effects on Rubber Properties
o Silica, Clay, Calcium Carbonate,Titanium Dioxide
Rubber Chemicals
o Rubber Cure Systems
o Activators (Zinc Oxide and Stearic Acid)
o Sulfur Vulcanization
o Blowing Agents
o Activator Selection
Compounding for Dynamic Performance Properties
o The "Three Ps"
o Overview of Product Performance
o Rubber Compound Economics
o The Importance of Elastomer Selection to Meet Performance Needs
o The Selection of an Optimal Filler / Oil System
o Selection of an Optimal Cure Package
Lab DOEs and Field Trials
Introduction to Factory Problems
Statistics and Methodologies for Solving Factory Problems
o Basic Statistical Methods to identify special causes of variation
o Corrective Actions in the Short Term
o Develop a strategy for establishing long term solutions to chronic problems
o Six Sigma Techniques for Solving Chronic Rubber Factory Problems
Nature and Techniques for Solving Problems in Rubber Compounding and Processing
o Changing one-variable-at-a-time technique for improvement of a rubber compound
o Applying a Design of Experiment
Interactions
Case Studies of Rubber Compounding and Processing Problems
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Who Should Attend ▼
Both entry level as well as experienced rubber technologists, rubber chemists, process engineers, laboratory managers, supervisors, technicians, shop foremen, quality assurance managers and engineers, technical sales personnel, rubber producers and users.
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Benefits and Learning Outcomes ▼
- Learn about the five categories of rubber processability tests
- Understand the differences between general purpose and specialty elastomers and it affects compounding and mixing
- Gain an intensive overview of rubber compounding and mixing
- Review methodologies for solving factory problems
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