A tyre manufacturing process involves using various components. It is necessary to take precise steps to manufacture tyres to maintain quality and performance.
The following are the manufacturing process involved in the production of tyres:
- Blend : There are about 30 kinds of rubber and other ingredients which are used during the manufacturing of a tyre. The ingredients are mixed in a giant blender like machine. The gummy product that is created after mixing the ingredients will be sent on for milling.
- Mill: The rubber is later cooled and is cut into strips which will form the basic structure of the tyre. In this state of the rubber, many other elements of the tyre are prepared and then they are coated with a different type of rubber.
- Build: Now that the components are ready for the major stage of the manufacturing process- a tyre is made from the inside out. The textile elements, steel belts, ply, tread, beads and other components are placed on a machine which manufacturers tyres.
The product that we get after using the components is a green tyre and after this, different processes are conducted to bring out the finished goods. - Cure: The green tyre has to be vulcanised in a machine which is generally called a curing machine, which compresses all of the parts of the tyre together producing the proper circular shape of the tyre. This includes tread patterns and the sidewall markings.
The next step involves using special machinery by the inspectors who will carefully check each tyre for imperfections. If the product passes the test, then it is shipped to be sold by the dealers and markets.
Quality control engineers check randomly the tyres off the production line to see and find damage. In addition to this, tyres are taken from the production line and a X-raying process is done to see for any damages.
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There are various components involved in tyre manufacturing which are explained in the following:
- Ply: The skeleton of the tyre consists of different layers made of fabric known as plies. The function of the plies is to reduce elasticity and it also keeps the tyre flexible at the same time. plies are normally made of rubber- coated cords which are formed by the woven fibers. The tyre becomes strong with a layer known as a carcass ply. It is laid above the inner liner of a tyre which adds on to the strength of the tyre.
- Belt: Steel wires which looks like woven sheets are coated in rubber and is placed around the tyre. The function of belt is to reinforce and offer rigidity to the tyres. For adding durability and to enhance the tyre to be puncture resistance, the tyres has to be included with Kevlar cord.
- Shoulder: There is a slight angle or beveled edge between the tread and the sidewall of a tyre. It has an important function which is providing cornering stability and control.
- Sipe and groove: The tyre disperses water due to the deep grooves that seperate block like structure called tread. The groove which are smaller, found in the tread blocks are called Sipes which are important for grip while driving on snow and ice in winter.
- Beads: The airtight seal between the rim of the wheel and the tyre is known as beads. They are made from braided high strength steel that is coated in rubber.
- Sidewall: The outside of the tyre's sidewall consists of information that we need to know about the tyre. The sidewall runs from the bead to the tread. This part of the tyre has extra thick rubber which provides lateral stability.
- Tread: The rubber which meets the road is where the tread is found. The purpose of tread is to give grip and cushioning or smoothness. A tyre's rubber compound and design depends on the tread for giving a comfortable ride.
- Rib: The rib is a reinforcing element used in some tyres. It runs down the centre as it is the weakest portion of the tyre.
