A

INTERNSHIP REPORT
ON

TIRE MOULDING WORKSHOP

In the partial fulfilment of B. Tech. in Mechanical Engineering course of

Department of Electronics & Telecommunication Engineering

Lonere

2023-2024
 CERTIFICATE

This is to certify that the [Link] Industrial Traning in(Python-Udemy) and (Shree Shastha Tyre)
B. Tech 3rd year being submitted by
Parth Prakash Ubhare in the partial fulfilment of the requirements for the award of the degree
of Bachelor of Technology in Mechanical Engineering is a record of the student work carried by
they as prescribed in the syllabus of Dr. Babasaheb Ambedkar Technological University, Lonere
during the academic year 2023-2024.

Head Of Department
Guide
Dr. Hemant Warhatkar
Dr. R.S Pawade
Mechanical Engineering

[Link] Ambedkar Technological

University,Lonere-Raigad 402103

01
 Introduction

Retreading is a process through which we can use our old tyres. In this method, a worn casing of
a tyre that has a good structural quality is taken off and put through a process in which it gets a
completely renewed tread and sidewall rubber. After that, the revamped tyre is taken forward for
a curing process in which the new rubber is vulcanized to the original casing and hence, the tyre
gets a newly made tread pattern. Over the years, a lot of development has taken place in the tyre
manufacturing industry across the world. High standard tyres are being manufactured using
premium technologies, so that they could perform flawlessly not only in their ‘first life’, but also
in their second and even sometimes third life. So, along with that, the retreaded tyre industry is
also growing, as stronger tyre casings, enhanced re-manufacturing techniques and high quality
rubber compounds are being used.

A retreaded tyre commences its life as a worn out tyre. There is a need for retreading when you
find out that the tread is down to 2-3 mm or if it has been re-grooved earlier, or if your tyre has
puntures and needs a repair. In these cases, you need to take your tyre to an experienced technician
who will check and inspect the tyre to see whether it is in a condition to get retreaded. If the expert
finds it alright, then you can go for a retreading of your tyre.

Tyres are the only point of contact of the vehicle with the road. The intentions of the driver are
finally executed by the tyres only, hence the quality and design of the tyt important. The rubber
tube inflated with air supports the whole weight of the car, bu rubber tube cannot directly come
in contact with the road as it cannot resist wear and it strength. Tyre encases the rubber tube. Tyres
must perform a certain sumber of functions for the smooth functioning of the vehicle namely
stoering, carrying a load, cushioning, rolling, transmitting drive and long lasting life

Steering Tyres should steer the vehicle with precision irrespective of surface of the road, weather
conditions. The stability of a whicle's path depends upon ability of tyre to hold its course by
maintaining proper traction with the road. It should stand upto transversal forces without drifting
from its path.

Carrying load: Tyres should carry lot of weight usually more 50 times its own weight not only
when it is in motion hut also at rest. Car usually weight around 1.6 tonnes and the area of contact
of a single tyre with read is size of a post card. Hence each tyre experiences compressive stresses
of the order of few MPa

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Cushioning: Tyres absoth the shock due to obstacles or irregularities present on the surface of the
road, providing a comfort travel to the passenger as well as envaring long life of the vehicle. The
main characteristic of tyre is its ability to yield when stress is applied and return to its original
shape when stress is removed, with the tyre lasts, or in other words, keeps its optimum
performance level for millions of wheel revolutions. The tyre's wear depends on its conditions of
use [load, speed, condition of the road surface, state of the vehicle, style of driving, etc.) but above
all the quality of its contact with the ground. Pressure thorefore plays a major role, e stress cycle
occurring at very high frequencies.

Transmitting Drive: Tyres transmit drive namely the engine's usable power, braking effort with
the help of the friction. Superior quality and efficient design of the tyre helps in making complete
use of engine's power and braking facility.

Long Lasting Life: Tyres should be able to give optimum performance for millions of revolutions.
Life of a tyre depends on a variety of factors like quality of contact with the road, load, speed,
driving style etc..

Most of the functions of tyre can be achieved with proper maintenance of air pressure. Hence
ability to hold air without allowing it to diffuse is important.

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 Tire Retreading Process

1. Collection of Casings

Worn tyres are collected to select suitable casings for tyre retread.

2. Initial Inspection

Each tyre received in a retread plant is subjected to a rigorous visual inspection.

3. Buffing After inspection

The tyre’s old tread is mechanically removed on high speed buffers. Today’s buffers
are extremely accurate and will remove the proper amount of old rubber while
turning the tyre to an exact specified diameter and radius. Collaboration with
international leaders like MATTEUZZI enables Newera to build computerized
world class equipment under license for Asia.

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4. Section Repairs & Skiving

With advances in state-of-the-art repair materials and repair methods, many of these
tyres can be routinely repaired and in most cases can be retreaded when the original
tread is worn off. The repair station is where any surface injury is treated using
effective material and tools for grinding and patching.

5. Cementing and Filling

Even in small injuries it is critical that the injury is cleaned and filled. If this is not
done, severe rust, separation and steel cable looseness could take tyre out of service.
The injury should be inspected, and then cleaned out with a carbide cutter. After
cementing the injury, a vulcanizing rubber stem should be applied to “fill” the injury.
This would create a permanent repair that maximizes tyre life.

With Newera designed-and-built spray booth, your cementing operation can be

6. Building – Tread Rubber

In the pre-cure system, the tread rubber has already been vulcanized with the new
tread pattern design. The buffed tyre needs a thin layer of cushion gum to be wrapped
around its crown area. The pre-cured tread rubber is then applied with the building
machine. This is called the building process.

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7. a) Enveloping & Rim Mounting

The built tyres are then mounted with envelops and rims to prepare them for curing.

b) Double Envelope System

For enveloping, tyres are first fitted an outer envelope at the envelope-mounting
table before the inner envelope is fitted into them. The enveloped tyres are then
vacuumed out for preparation prior to curing. Modern plants have their casings
hoisted by monorail systems. With professional planning from Newera engineers,
you can be assured of workstations designed to maximize output and ease workflow.

8. Curing by Chamber

The tyre is then placed in a curing chamber and the pre-cured tread becomes adhered
to the tyre through a vulcanizing process.

Our wide engineering capabilities and experience enable Newera to build chambers
to suit our clients’ different preferences for size, steam heated, electric heated, or
double heating system, semi-automatic and automatic chambers.

The monorail & hook system increases productivity by cutting down on chances of
casings contamination and allows for faster loading and unloading of tyres. This
increases your work place safety and productivity.

9. Final Inspection & Painting

The retreaded tyre is subjected to a final inspection. This inspection insures that only
tyres that meet industry quality standards are allowed to leave the retread plant. All
retreaded tyres are encouraged to be returned with the sidewalls painted using a light
coat of black tyre paint.

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“HOT” retreading:
Hot retreading involves the vulcanisation of a tyre in a mould at a temperature of
around 150 °C. The tread and the sidewall veneer of the tyre are made up of non-
vulcanised rubber compounds. The shape and tread of the tyre are created in the
heating press.

Arguments in favour of hot retreading:

 Suitable for all tyre applications, including car and aircraft tyres.
 Material costs are lower than the more complex products required for
precure retreading.
 Hot retreading also allows extensive repairs to be carried out on the tyre
carcass (e.g. belt replacement).
 Even bias-ply carcasses can undergo hot retreading without any problems.

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COLD Retreading
Precure or “cold” retreading involves vulcanization without a mold at a
temperature of between 95 °C and 110 °C. The tire is put together using a pre-
vulcanized tread liner (= new tread) and a non-vulcanized bonding gum layer.
The bond between the carcass, the bonding gum and the precured tread is created
in an autoclave. Precure retreading has become fully established in the truck tires
sector since the introduction of radial tires in the mid-1960s.

Arguments in favor of precure retreading:

 Less investment is required on the part of the retreading plant (no expensive
molds) and lower follow-up costs, since it is the material supplier who updates
the range of molds.
 A wide range of tread types are available, allowing the optimum tread to be
selected for the tire application.
 The comparatively low investment costs involved mean that decentralised,
smaller production units can be operated. This means lower logistics costs and
makes the operator more flexible and closer to his customers.
 The precure retreading process is kind to the carcass, since vulcanisation
temperatures are lower and put less strain on the rubber-metal bonds in the
carcass. Heat build-up in the tyre, rolling resistance and other tyre properties
are often easier to assess than with hot retreading.
 With comparable tread geometries, the running performance of a precured
retread is often better than a hot retread and the same as an equivalent new
tyre.

08
Advantages of Retreading of tyre:
There are several advanges of retreading such as:

 Retreads are quite safe and are being used in all kind of vehicles nowadays.
May it be taxis or trucks, school buses or military vehicles, retreading is being
used in all of them.
 Retreading is highly environment friendly. When the existing tyres are made
ready for further use, the manufactures save landfill space. Also, it reduces
carbon dioxide emmission and saves millions of gallons of oil which is
required to manufacture new tyres. Therefore, when you get your old tyre
retreaded instead of buying a new one, you play a major role in saving the
precious natural resources.
 There are many economical benefits of retreading as the retreaded tyres are
less pricey in comparision with the new ones. This definitely helps you save
a considerable amount of money. You can retread your old tyre at least twice
or thrice and this helps you save upto 40% of your money every time because
if you go for a new set of tyres it will cost you almost double of the price of a
retread one.
 Retread process is not responsible for spreading large chunks of rubber on the
roads and highways. According to recent studies, it happens due to abuses like
tyre failure, caused by road hazards, tyre blasts and overloading to both new
tyres and retread ones.

09
Disadvantages of retreaded tyres:
 Retreaded tyres are generally a lot less expensive than the new ones, however,
after the budget tyres have come into play, the scenario has changed to a large
extent. Now, it seems that budget tyres are even less expensive than the
retreaded ones and as they are freshly made tyres, they obviously have better
quality than the retreaded tyres. Hence, a customer is more likely to prefer
budget tyres to the retreaded ones.
 In retreading, a new lease of rubber is put on the casing of a worn out tyre
without changing the cords of infrastructure. Hence, the quality of the
retreaded tyres always stays a lot down than that of the new tyres. No matter
how well it works after retreading, there has to be some issue with a retreaded
tyre.

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