Technology of Forming of Elastomer Products

Major: Chemical Technologies of Polymeric and Composite Materials Processing
Code of subject: 7.161.06.E.021
Credits: 5.00
Department: Chemical Technology of Plastics Processing
Lecturer: Associate Professor Semenyuk Nataliya Bogdanivna
Semester: 2 семестр
Mode of study: денна
Мета вивчення дисципліни: Acquaintance of students with modern technologies of forming products from elastomers, classification of elastomers and the main methods of their production, mechanisms of vulcanization of rubbers, methods and methods of its implementation, classification and purpose of ingredients of rubber mixtures, as well as the main processes of rubber production, technology of processing waste from rubber production.
Завдання: The study of an educational discipline involves the formation of competencies in students of education: professional competences of a professional direction: - FCS1.2. The ability to use the mathematical apparatus and the results of experimental studies to master the theoretical foundations and practical use of the methods of physical and chemical research of polymer and composite materials. - FCS1.3. The ability to use professional knowledge and practical skills to design, control and manage the technological processes of forming products from elastomers.
Learning outcomes: As a result of studying the academic discipline, the student must be able to demonstrate the following learning outcomes: 1. To understand the mechanisms of vulcanization, methods and methods of its implementation. 2. Know the main processes of rubber production and be able to use them in practice. 3. Master the technology of processing elastomers into products. 4. Be able to design products from elastomers. 5. To master the principles of construction of technological schemes for the production of products from elastomers. 6. To be able to correctly plan and organize technological processes of manufacturing products from elastomers; 7. To be able to justify and choose optimal conditions for carrying out these processes and to be able to make decisions independently; 8. To be able to rationally select the components of rubber mixtures. Program learning outcomes: PR8. Critically understand the aspects of processing polymer and composite materials, master the methods of improving the technological process. PR10. Develop and modernize polymer and composite materials processing processes in accordance with modern innovative technologies. KOM 1. Clear and unambiguous presentation of one's own knowledge, conclusions and arguments to specialists and non-specialists, in particular, to students. AiV 1. Management of work or learning processes that are complex, unpredictable and require new strategic approaches. AiV 2. Responsibility for the contribution to professional knowledge and practice and/or evaluation of the results of the activities of teams and collectives.
Required prior and related subjects: • Polymer materials science • Fundamentals of chemistry and physico-chemistry of polymers • Technological processes of modification and processing of polymer and composite materials • Modern technological processes of processing polymer and composite materials
Summary of the subject: The discipline "Technology of forming products from elastomers" introduces students to the classification of elastomers, mechanisms of vulcanization of rubbers, modern concepts of methods of processing elastomers into products, and technologies for processing rubber production waste. As a result of studying this discipline, the student acquires relevant knowledge, abilities, skills and competences necessary for organizing the activities of enterprises processing elastomers and solving practical tasks to ensure the quality of products from them.
Опис: The content of the discipline and its importance for specialist training. Connection of the course with other general education and special disciplines. The contribution of domestic and foreign scientists to the development of the technology of synthesis and processing of elastomers. Status and prospects of elastomer processing in Ukraine. Concept of elastomers. Rubbers and rubbers. Natural and synthetic rubbers. Classification. Methods of production of elastomers. Polymerization in solution. Emulsion polymerization. Characteristics, advantages and disadvantages of methods. Vulcanization of rubbers. Stages of vulcanization. The main mechanisms of vulcanization: sulfuric, peroxide, radiation. Vulcanization of rubbers containing functional groups. Vulcanization in the presence of activators and process accelerators. The main parameters of the structural mesh, the effect on the properties. Composition of vulcanized systems. Classification and purpose of ingredients of rubber mixtures. The main processes of rubber production. Storage and preparation of ingredients and rubbers. Drying, grinding, sieving. Evaporation and plasticization of rubbers. Factors influencing the preparation of rubbers. Preparation of rubber mixtures. Requirements and production technology. Production of raw rubber blanks. Calendering. Operations that can be carried out with elastomers on calenders. Calender effect. Types of defects during calendering of rubber compounds and methods of their elimination. Calender productivity calculation. Products from rubber adhesives. General characteristics and classification of rubber adhesives. Thin-walled products from rubber adhesives, their production technology. Types of defects and methods of their elimination. Lubrication of fabrics on glue-lubrication machines. The main types of spreading machines and methods of applying thin layers of rubber mixture to fabric. Injection of rubber compounds. Vulcanization as the main and final process of rubber production. Vulcanization parameters. Plateau vulcanization, causes of its occurrence. Basic methods of vulcanization of rubber compounds. Press method. Determination of technological parameters during pressing. Types of defects and methods of their elimination. A typical technological scheme of forming products by the press method. Die casting. The essence of the method, advantages and disadvantages. Classification of molding machines for processing rubber compounds. Determination of technological parameters during injection molding. Types of defects and methods of their elimination. A typical technological scheme. Processing of rubber production waste. Regenerate. Rubber flour. Technological scheme of production. Safety techniques and environmental protection in the processing of elastomers.
Assessment methods and criteria: The main methods of knowledge diagnosis are: current (PC) and semester control (SC), which is carried out from educational material, the scope of which is determined by the work program of the discipline for the semester. Current control is carried out during the performance and protection of laboratory work, performance of сalculation and graphic work in order to check the level of assimilation of theoretical and practical knowledge and skills of the student. PC is conducted in the form of: oral control and defense of laboratory work reports and Calculation and graphic work. Semester control is conducted in the form of an exam (EC). The exam is a form of SC of the results of the student's studies in the academic discipline for the semester.
Критерії оцінювання результатів навчання: Current control (PC): Performance of laboratory work - 10 points Defense of laboratory reports - 10 points Calculation and graphic work - 10 b. Examination control (EC): written component - 60 p oral component - 10 points Together for the discipline (PC+EC) - 100 points
Порядок та критерії виставляння балів та оцінок: 100-88 points - certified with an “excellent” grade - High level: the student demonstrates an in-depth mastery of the conceptual and categorical apparatus of the discipline, systematic knowledge, skills and abilities of their practical application. The mastered knowledge, skills and abilities provide the ability to independently formulate goals and organize learning activities, search and find solutions in non-standard, atypical educational and professional situations. The applicant demonstrates the ability to make generalizations based on critical analysis of factual material, ideas, theories and concepts, to formulate conclusions based on them. His/her activity is based on interest and motivation for self-development, continuous professional development, independent research activities, implemented with the support and guidance of the teacher. 87-71 points - certified with a grade of “good” - Sufficient level: involves mastery of the conceptual and categorical apparatus of the discipline at an advanced level, conscious use of knowledge, skills and abilities to reveal the essence of the issue. Possession of a partially structured set of knowledge provides the ability to apply it in familiar educational and professional situations. Aware of the specifics of tasks and learning situations, the student demonstrates the ability to search for and choose their solution according to the given sample, to argue for the use of a particular method of solving the problem. Their activities are based on interest and motivation for self-development and continuous professional development. 70-50 points - certified with a grade of “satisfactory” - Satisfactory level: outlines the mastery of the conceptual and categorical apparatus of the discipline at the average level, partial awareness of educational and professional tasks, problems and situations, knowledge of ways to solve typical problems and tasks. The applicant demonstrates an average level of skills and abilities to apply knowledge in practice, and solving problems requires assistance, support from a model. The basis of learning activities is situational and heuristic, dominated by motives of duty, unconscious use of opportunities for self-development. 49-00 points - certified with a grade of “unsatisfactory” - Unsatisfactory level: indicates an elementary mastery of the conceptual and categorical apparatus of the discipline, a general understanding of the content of the educational material, partial use of knowledge, skills and abilities. The basis of learning activities is situational and pragmatic interest.
Recommended books: Basic 1. Skorokhoda V.Y. Fundamentals of elastomer technology and the formation of products from them: a study guide /V. Y. Skorokhoda, N. B. Semenyuk, Yu.Ya. Miller. – Lviv: Publishing House of Lviv Polytechnic, 2021. – 125 p. 2. Melnyk L.I. Elastomer processing technology: teaching. manual - Kyiv: NTU "KPI" named after Igor Sikorskyi, 2023. – 257 p. 3. Bhatia S.C. Rubber Technology: Two Volume Set. Woodhead Publishing India, 2019. - 688 p. 4. Rodgers B. Rubber Compounding: Chemistry and Applications 2nd ed. Taylor & Francis Group, LLC 2016. - 624 p. 5. Rubber compounding, principles, materials, and techniques // Eds. by F.W. Barlow, M. Dekker. – New York: Marcel Dekker, Inc. - 1988. - 325 p. Auxiliary 1. Gumenetskyi T.V., Levitskyi V.E., Suberlyak O.V. Physico-chemistry of polymers: textbook. - Lviv: Rastr-7, 2020. -420 p. 2. Suberlyak O.V. Theoretical foundations of chemistry and technology of polymers: Teaching. manual / O.V. Suberlyak, V.Y. Skorokhoda, N.B. Semenyuk – Lviv: Publishing House of Lviv Polytechnic, 2014. – 336 p. 3. Technology of production and processing of polymers for medical and biological purposes: teaching. manual / V. L. Avramenko, L. P. Pidgorna, H. M. Cherkashina, O. V. Bliznyuk. – Kharkiv: Publishing House and Printing House "Technological Center", 2018. - 356 p. Educational and methodological support: 1. Electronic educational and methodological complex "Technology of forming products from elastomers". Certificate No. 01717. Registration number: E41-217-113/2016 dated 07/06/2016. Authors: Skorohoda V.Y., Semenyuk N.B. 2. Skorohoda V.Y., Semenyuk N.B., Melnyk Y.Ya., Dudok G.D. Vulcanization of rubbers and structural parameters of the network of vulcanizates. Methodical instructions for laboratory works in the disciplines "Technology of forming products from elastomers", "Technology of synthetic rubber". – Lviv: NULP. -2024. -27 p. 3. Semenyuk N.B., Melnyk Y.Ya., Dudok G.D., Skorohoda V.Y. Physico-mechanical properties of elastomers. Methodical instructions for laboratory works in the discipline "Technology of forming products from elastomers", "Technology of synthetic rubber". – Lviv: NULP. - 2024. - 27 p. 4. Semenyuk N.B., Dudok G.D., Skorohoda V.Y. Synthetic latexes. Methods of obtaining, properties, processing. Methodical instructions for laboratory works in the disciplines "Technology of forming products from elastomers", "Technology of synthetic rubber production", "Technology of prosthetics and orthoses of limbs". - Lviv: NULP. -2024. - 27 p.
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