fall 2010 elastomer engineering brochurerubber extrusion technology examine all aspects of the...

Elastomer EngineeringCUTTING-EDGE CONTINUING EDUCATION - FALL 2010

SCE-RUBBER.UWM.EDU

OptimizePerformance.InspireInnovation.Elastomer technology is permeating nearly every industry today. Toanswer increased demands, you must be at the forefront ofinnovation and efficiency.

Thankfully, you’ve found cutting-edge continuing education. Fromefficiency to extrusion, our comprehensive courses cover essentialtopics to help you maximize your knowledge, productivity andmarketable skills.

Each course is led by practitioner instructors who have the real-worldexperience to ensure your real-life success. They are teachers,innovators and most importantly they are engineers who understandthe field.

For more details and to learn how we can bring courses to you,contact me at 414-227-3121 or [email protected].

Sincerely,

Murali VedulaEngineering Program DirectorUWM School of Continuing Educationsce-eng.uwm.edu

MURALIVEDULAProgram [email protected] 414-227-3121

Dr. Murali Vedula worked in engineering atDow Chemical Company and StructuralComposites Industries for several years beforejoining UWM in 1997.

For the past 13 years, Dr. Vedula has used hisengineering knowledge and contacts toidentify professional development needs,including elastomer and plastics technology,electrical engineering, innovation, mechanicaland industrial engineering, and Six Sigma.In response to changing demographics, hehas restructured Six Sigma certificateprograms to meet the needs of the serviceindustry. In add ition, he recently began offeringan Office Lean certificate program and hasbeen involved with internal Lean training. Hislatest emphasis is on innovation. He currentlyserves on the Board of the Society of PlasticsEngineers Milwaukee Chapter.

DEBRAO’NEILProgram Associate [email protected]

Debra O’Neil has been with the School ofContinuing Education for over15 years, nineof which she was a program associate supporting public and corporate Engineeringprograms. She assists with the coordinationof course scheduling, materials assembly,program content, marketing, inquiries andbilling. She is customer service oriented andenjoys working with program participants.

TABLE OF CONTENTSRubber Technology

Molding of Rubber and Design of Rubber Molds ........................4 Rubber Extrusion Technology ......................................................5Rubber Compounding and Mixing for Performance ....................6Silicone Elastomers Technology and Fabrication ..........................7

Innovation

Accelerated Product Development - Using Product Realization............................................................8

Quality/BPI

Six Sigma Black Belt ....................................................................9

Instructors ....................................................................................10General Information ..................................................................11Onsite Training ............................................................................Back Cover

I COULD TAKE EVERYTHING BACK AND IMMEDIATELY

APPLY IT TO MY WORK."

- Engineering participant

"I LEARNED NEWMETHODOLOGIES THATRESULTED IN BOTH

HARD AND SOFT COSTSAVINGS AT MY JOB."

- Engineering participant

Interested in the following programs? Contact Murali Vedula at 414-227-3121or [email protected] for more information.

• Design of Resilient Products

• Dynamic Properties of Rubber Product Performance

• Rubber Adhesion: Principles & Practices

• Technical Creativity

ASK

US

Learn howto earn a

Rubber TechnologyCertificate 414-227-3121

or visit

sce-rubber.uwm.edu

4 sce-rubber.uwm.edu 414-227-3121

MOLDING OF RUBBER AND DESIGN OF RUBBER MOLDS Gain integrated insight into rubber molding beginning with the flow behavior ofthermoplastic and crosslinking materials, and finishing with the behavior of these materialsin molding processes. Review methods and equipment needed for successful molding andstudy current principles and techniques in the design of molds and molded parts. Focusis primarily on the design and molding of mechanical rubber goods with limited referenceto tire molding.

Who should attendMaterials and process engineers, rubber mold designers, quality control personnel andmanagers responsible for these functions. Attendees are encouraged to bring drawings orparts that experience problems in production for discussion by course instructors.

COURSE OUTLINE

Rubber.

Wed.-Fri., Oct., 13-15, 2010*8am-4:30pmInstructors: John Sommer, Terry Chapin,Richard Steiner, Van WalworthFee: $1190CEUs: 2.0 Program No. 4830-8304

*Same week as Rubber Mini EXPO

Rubber Materials- Description- Shrinkage- Types- Adhesion- Flow Behavior

Molding Methods- Compression- Blow- Transfer- Casting- Injection- RIM

Molds- Fouling- Cleaning

Mold Design- Design Process -

Information Gathering- Parting Line Considerations- Overflow Considerations- Part Feeding

• Sprues • Ring Feed • Pin Feed • Tab Feed • Submarine Gate- Cavity Spacing- Mold Construction • Mold Plates • Core Pin / Inserts • Leader Pins / Bushings • Material Selection • Durability • Spring Assists- Compression Molds- Transfer Molds- Injection Molds- Injection-Transfer- Additional Topics • CAD in Molds Design • Cold Runner Blocks

Designing of Parts for Manufacturability

- Rubber Part Tolerancing- Mold Debug - How to Solve Molding

Problems Through: • Part Redesign • Mold Redesign • Process Modification • Material Changes- Troubleshooting the Rubber

Molding Process

Versatile Mold Design for OptimizingDevelopment of Rubber Products

- Prototype Considerations- Initial Molding Methods- Use of CAD in Design- Combination Molds- Progressive Molds- Nesting- Special Features

sce-rubber.uwm.edu 414-227-3121 5

RUBBER EXTRUSION TECHNOLOGYExamine all aspects of the rubber extrusion process. Evaluate products from intricateprofile extrusions, to tires using composition ranging from a single thermoplastic elastomerto multiple dense and cellular compounds coextruded with carriers and reinforcements.

Who should attendMaterials and process engineers, die designers, quality control personnel, supervisors andmanagers responsible for these position.

Wed.-Fri., Apr. 20-22, 20118am-4:30pmInstructors: James Stevenson, John DickFee: $990CEUs: 1.8Program No. 4830-8302

COURSE OUTLINE

MATERIALSElastomer Properties

- Chemical Structure- Molecular Weight/Distribution- Morphology and Crystallinity- Viscosity (Flow)- Elasticity (Swell)- Scorch

Laboratory Tests for Extrudability- Mooney Viscometer- Processability Testers- Standard Dies (Garvey)- State of Cure Tests

Compound Ingredients- Elastomers- Fillers- Plasticizers and Process Aids- Cure Systems/Nitrosamines

Processing and Compounding- EPDM- Polychloroprene (Neoprene)- SBR/BR- Nitrile Rubber- Chlorosulfonated Polyethylene- Silicone Rubber - Fluoroelastomers

PUMPING EQUIPMENTScrew Extruder

- Types (Hot/Cold Feed)- Barrels and Screws- Vented Extruders- Continuous Mixers/Twin

Screw Extruders- Feed Devices

Ram (Preform) ExtrudersAuxiliary Devices

- Shear Head- Cavity Transfer Mixer- Gear Pump

Drives and TransmissionTemperature Control

SHAPING EQUIPMENTHeads

- Inline Heads- Crossheads- Tire Heads- Breaker Plates- Screen Changers

Dies- Types and Design Criteria- Flow - Drawdown- Sheet Dies, Profile Dies- Design Computations- Die Relief Strategies- Finite Element Simulation

DOWNSTREAM EQUIPMENTContinuous Cure (Low Pressure)Batch CureHose Manufacture

INSTRUMENTATIONInstrumented Extrusion LineTemperature SensorsPressure SensorsDimension SensorsWeight and Area SensorsProperty Sensors

OPERATIONS Extruder Dynamics

- Flow in Screw Pumps- Operating Curves

- Extrudate Temperature- Conveyor Operation- Extrudate Contraction- Extrudate Curvature

Productivity and Quality- Optimum Conditions- Feed Strip Geometry- Feed Mill Operation- Adjustments on Pin Barrels- Screw and Barrel Wear- Starved Operation- Die Drool

Process Variation and Control- Statistical Process Control - Feedback Control- Size Control- Shape Control- Online Measurement Guide- Commercial Controls

ADVANCED TECHNOLOGIESChanging Extrudate ShapeSwitching Feed StreamsDirected Flow Technology

- Rapid Die Change- Dimensional Control

Multiextruder ControlLow Resistance Dies

TROUBLESHOOTINGProduct GeometryExtruder OperationCompound

REFERENCESBooksPapers


RUBBER COMPOUNDING AND MIXINGFOR PERFORMANCEGet an intensive overview of rubber compounding and mixing as well as a review ofmethodologies for solving factory problems. Review latest developments in compoundingand mixing technology and procedures.

Who should AttendBoth entry-level and experienced rubber technologists, rubber chemists, process engineers,laboratory managers, supervisors, technicians, shop foreman, quality assurance managersand engineers, technical sales pers nnel, and rubber producers and users.

Wed.-Fri., Nov. 10-12, 20108am-4:30pmInstructors: John S. Dick, Peter C. Surette, Sr.Fee: $1290CEUs: 2.0Program No. 4830-8301

COURSE OUTLINE

Introduction- History- Basics of Formulating- Key Processability Characteristics- Common Factory Problems and

Possible Causes

Rubber Testing- Five Categories of Processability

Tests- Miniature Internal Mixers

and Extruders- Rotational Viscometers- Mooney Viscosity- Rheometers- Rotorless Curemeter- Assignable Causes of Variation • Rubber Process Analyzer • ASTM Standard Test Conditions • Rheological Profiles of Raw Rubber • Rheology and State of Mix • Stress Relaxation Tests

General Purpose Elastomers- Different Polymer Backbones- Crystallinity on Stretching- Natural Rubber; SBR;

Polybutadiene; EPDM- EPDM and Sponge Formulations

Unit 4 Specialty Elastomers- Curing Silicone Rubber with Peroxide- Advantages of Platinum Cures

Mixing- Tangential vs. Intermeshing- Rotor Design- Friction Ratios- Dispersive mixing vs. Distributive

Mixing- Importance of Order of Addition

of Ingredients

One Pass vs. Two Pass vs. Three PassDump Mill, Cooling Batches, Phase MixingCarbon Black Distribution in a Rubber BlendFiller and Oil Systems

- Plasticizer Performance- Carbon Black Oil Balance- Silica, Clay, Calcium Carbonate,

Titanium Dioxide

Rubber Chemicals- Rubber Cure Systems- Activators (Zinc Oxide and

Stearic Acid)- Sulfur Vulcanization- Blowing Agents- Activator Selection

Compounding for Dynamic Performance Properties

- The "Three Ps"- Rubber Compound Economics- The Selection of an Optimal Filler /

Oil System- Selection of an Optimal Cure Package

Lab DOEs and Field TrialsIntroduction to Factory ProblemsStatistics and Methodologies forSolving Factory Problems

- Basic Statistical Methods- Corrective Actions in the Short Term- Strategy for establishing long term so-

lutions to chronic problems- Six Sigma Techniques

Nature and Techniques for SolvingProblems in Rubber Compoundingand Processing

- Changing one-variable-at-a-timetechnique for improvement of a rub-ber compound

- Applying a Design of ExperimentInteractions

Case Studies of Rubber Compoundingand Processing Problems


SILICONE ELASTOMERS TECHNOLOGYAND FABRICATIONGet a comprehensive overview of silicone elastomers, including basic silicone chemistry,types of silicone elastomers, manufacturing processes, fabrication techniques, problemsolving, and application areas. Emphasis is on liquid injection molding (LIM/LSR) withdetailed information in the areas of material selection, dispensing methods, injectionmolding process, tool design, and bonding alternatives. This course is presented by a panelof experts in the silicones field, and time is allotted for discussion of specific projects of interest.

Who should AttendBoth entry-level and experienced rubber technologists, rubber chemists, process engineers,laboratory managers, supervisors, technicians, shop foreman, quality assurance managersand engineers, technical sales pers nnel, and rubber producers and users.

Mon.-Wed., Nov. 15-17, 20108am-4:30pmInstructors: Mel Toub, John Timmerman, RickFinnie, Juergen Giesow, Bob PelletierFee: $1090CEUs: 2.0Program No. 4830-8312

Silicone Elastomer Technology- Silicone Product Categories- Why Silicone?- Silicone Markets and Applications- Silicone Manufacturing Process- Nomenclature- HCE / HCR Technology- LIM / LSR Technology- Testing and Specifications- Elastomer Properties

Liquid Silicone Rubber (LSR / LIM)- Why Liquid Silicones?- Comparison with HCE And TPE- Process Overview- Dispensing Systems- Injection Equipment- Molding Parameters- Automation- Demolding- Troubleshooting

Tooling Design and Construction- Materials- Machining Methods- Hot Runner vs Cold Runner- Valve Gate vs Open Gate- Venting and Gating- Cavitation- Balanced Design- Do’s and Don'ts

Adhesion and Bonding of Silicone Rubber- Definition of Adhesion- Types of Adhesion- Measurement of Adhesion- Overmolding- Two Component Molding- Surface Modification- Troubleshooting

Project Planning- Material and Equipment Requirements- Prototyping- Enhanced Functionality- Cost Analysis- Debugging- Customer Communication

COURSE OUTLINE


ACCELERATED PRODUCT DEVELOPMENT - USING PRODUCT REALIZATIONLearn innovative approaches and design processes for developing new products with multi-disciplinary teams often located worldwide. Study strategies for optimizing multiple phasesof the product realization process including: requirements definition, concept generation,concept selection, prototype generation, design for manufacturing, testing and marketpenetration. Work on actual new product concepts and discover each phase of thenonlinear process to produce a working prototype.

Who should attendEngineers, researchers, scientists, managers and technical leaders of new product development,research and development, manufacturing, marketing and supplier management.

Mon.-Tue., Aug. 19-20, 20108am-4:30pmInstructor: Michael R. Lovell, Dean, College ofEngineering, UW–MilwaukeeFee: $790CEUs: 1.4Program No. 4830-8501

Introduction and OverviewCourse Objectives

- Global Landscape of Technology and Innovation- Overview of Product Realization Process- How new techniques were developed- Product Development Exercise

Creating Successful Teams- Team Building Exercise- Understanding teams- Roles of team members- Best Practices and Lessons Learned

Project Planning- Role and Rules for project planning- Project planning tools- Project Planning Exercise

Developing Project Requirements- Understanding internal requirements- Unique product orientations- Customer needs analysis

Concept Generation- What is a design concept?- Potential Failures

- Five Step Approach to generating innovative concepts- Concept generation exercise- Concept Selection- Potential Failures- Concept Screening- Concept Scoring- Concept Selection exercise

Design for Manufacturing- Understanding product realization from business perspective- Minimize costs while maximizing performance

Prototyping- Role of prototyping in design innovation- Prototyping processes- When to generate prototypes

Testing- Developing robust test plans- Role of failure in innovative design

Penetrating the Market- Making products to gain market niche- Ensuring product safety and reliability

Innovation.COURSE OUTLINE

COURSE OUTLINE


SIX SIGMA BLACK BELTSix Sigma is a highly disciplined improvement methodology that helps organizationsachieve optimal performance in all operations. Learn methods to identify how many“defects” you have in a process and systematically determine how to reduce them to get asclose to zero defect as possible.

Who should attendAnyone wanting to improve quality, identify and reduce sources of variation and reducethe rate of non-conformance in products or services.

Module I Tue.-Thu., Sept. 14-16, 2010Fee: $1295CEUs: 2.0Program No. 4830-8101

Module II Tue.-Wed., Oct. 5-6, 2010Fee: $1195CEUs: 1.4Program No. 4830-8102

Module III Tue.-Wed., Oct. 26-27, 2010Fee: $1195CEUs: 1.4Program No. 4830-8103

Module IV Tue.-Thu., Nov. 16-18, 2010Fee: $1295CEUs: 2.0Program No. 4830-8104

8am-4:30pmInstructor: Davis R. Bothe

Quality.

MODULE IDefine & Measure

- Overview of Process ImprovementStrategies

- Why Six Sigma? The DMAIC (Define, Measure, Analyze, Improve,Control) Roadmap

- Roles of Champions, Master BlackBelts, and Blak Belts

- Process mapping – flowcharts- Data collection and sampling

techniques- Basic statistics –

location versus variation- Control charges –

variable and attribute- Control charts for short

production runs- Subgroup statistics versus

process parameters- Rationale for the 1.5σ symbol

MODULE IIMeasure & Analyze

- Gage capability studies- Estimating process parameters- Short- versus long-term variation- Process and machine capability studies- Converting process performance

to a σ level- Effect of the 1.5σ shift on capability- Dealing with non-normal

distribution- Rolled throughput yield

MODULE IIIAnalyze & Improve

- Check sheets and matrix diagrams- Multi-vari analysis for families

of variation- Component swapping for large

assemblies- Brainstorming and cause-and-effect

diagrams- Multi-voting and decision-making

by consensus- Regression analysis and scatter

diagrams- Comparison testing between

“good” and “bad” parts- Analysis of means (ANOM)

MODULE IVImprove & Control

- Hypothesis testing and confidence intervals

- Analysis of variance (ANOVA)- Developing feasible solutions- Solution FMEAs and pilot studies- Mistake proofing – poka-yoke- Advanced control charting concepts- Corrective action plans –

work instruction- Preserving the process

knowledge gained- Kaizen for continuous improvement


Instructors.Rubber.Terry Chapin received his B.S.A.S. from Youngstown StateUniversity in Youngstown, Ohio in June 1980. He majored inMechanical Engineering and minored in Math and Civil Engineering.He is presently a Senior Rubber Technical and Cost Leader at Delphiand has worked as a Tool Engineer at Delphi Packard as well as inthe rubber industry for over 25 years. He has held previousengineering positions at Paxson Machine Company, EMCOWheaton and Commercial Shearing and holds two U.S. patents. Mr.Chapin has been an active technical speaker for universitycontinuing education and onsite locations for over 15 years and isreferenced in "Elastomer Molding Technology" by John G. Sommer.

John Dick has over 30 years of experience in the rubber industry.He was with BF Goodrich and later Uniroyal Goodrich Tire Co. asa Section Manager and Development Scientist in R & D until 1991when he joined Monsanto's Rubber Instruments Group (now AlphaTechnologies) as a Senior Marketing Technical Service Specialist.Mr. Dick has authored over 65 journal and magazine publicationsand four books on rubber technology.

John Sommer, a registered professional engineer in Ohio with anM.S. in polymer chemistry, Mr. Sommer has progressively gainedwide experience by working with many materials, processes andproducts over a 50-year career in the elastomers industry. Hisactivities resulted in 45 technical publications and 16 U.S. patents,one of which became the technology base for a new company.

Richard Steiner is a Wisconsin Certified Journeyman ToolDesigner, having served a four-year apprenticeship.He has workedat Quadra, Inc. for over 20 years and is currently VP of Engineering.Quadra is Wisconsin's largest rubber mold building job shop withcustomers in 13 states and Mexico.

James Stevenson has 35 years of experience in the processing ofrubber and plastic. He edited “Innovation in Polymer Processing:Molding” published in 1996. Prior to joining Honeywell in 1996,Mr. Stevenson held various technical and management positions atGenCorp (formerly General Tire) for 18 years and was Director ofResearch at Trexel, a start-up company commercializingmicrocellular foam technology. He earned his B.S. in ChemicalEngineering from Rensselaer Polytechnic Institute and M.S. andPh.D. degrees from the University of Wisconsin-Madison.

Peter Surette joined the rubber industry in 1969 after hegraduated from the University of Massachusetts, Lowell, with a B.S.Degree in Plastics Engineering. Mr. Surette has held variouspositions throughout his career involving laboratory management,compound design, process evaluation, process and productenhancement, laboratory design, compound specification development,procedural and MSDS writings, technical training as well astechnical sales and technical service. Pete owns his own consultingbusiness, Focused Solutions, which was established in 2002.

Mel Toub has worked in the silicone elastomers division ofMomentive Performance Materials (formerly GE Silicones) formore than 30 years. He has presented numerous technical papersto ACS, SAE, the International Silicones Symposium, and industryjournals and holds several patents in the area of silicone rubbertechnology. His academic background includes BE and ME degreesin Materials Engineering from Rensselaer Polytechnic Institute asa well as an MBA also from RPI.

Van Walworth is President of Research & Design Specialties, Inc.,based out of the Nashville, TN area. Mr. Walworth's professionalcareer spans over three decades as a practitioner of product R&D,tool & equipment design, process establishment and improvement,troubleshooting, project management, and spontaneous creativity.Over his career, Walworth held corporate engineering managementpositions with several companies including, Parker-Hannifin,Wynn's Precision, Ashtabula Rubber Company, and Thunderline Corp.

Innovation.Michael R. Lovell was hired as Dean of Engineering at theUniversity of Wisconsin-Milwaukee in August of 2008. Dean Lovellhas developed unique methodologies that increase the likelihoodof a team creating an innovative product from 50-80 percent.Utilizing his methodology, he mentored student teams thatdeveloped 224 new products and formed eight companies over afour-year period. He has launched an Institute for IndustrialInnovation at UWM.

Quality.Davis R. Bothe has over 30 years of experience working, teachingand consulting in the field of process improvement. His credentialsinclude: ASQ Fellow, IQI certified Master Black Belt, ASQ certifiedQuality Engineer, ASQ certified Reliability Engineer, member ofthe US Technical Advisory Group to the ISO Technical Committee69 on Applications of Statistical Methods. He is author of the qualityimprovement books "Industrial Problem Solving," "MeasuringProcess Capability," and "Reducing Process Variation."


General Information.REGISTRATIONPhoneMon.-Fri., 8am-5pm Central800-222-3623 (toll free)414-227-3200 (local)

Onlinesce-registration.uwm.edu

FeeThe fee includes program materials, continental breakfast, lunchand breaks. Lodging and other meals are not included.

LodgingYou may make your own lodging arrangement at the facility ofyour choice. Hotel information will be mailed with yourenrollment confirmation. When contacting the hotel, mentionthat you will be attending a University of Wisconsin–Milwaukeeseminar to receive a discounted rate.

CancellationsPlease call 414-227-4100 at least seven days before the coursestarts for a refund. Cancellations received less than seven daysbefore the start of the course will be subject to a late cancellationfee. You may enroll a substitute at any time before the coursestarts, or you may apply the enrollment fee to a future course.

In the event the School cancels a class, the University ofWisconsin–Milwaukee will reschedule, refund fees or apply thefee payment to any other School of Continuing Educationengineering program offered in the next 12 months. Liability ofcancellation is specifically limited to the amount of the pre-paidclass fee and excludes any incidental or consequential damages.

Continuing Education Units (CEUs)All programs in this catalog carry Continuing Education Units(CEUs). CEUs are a means of recognizing and recordingsatisfactory participation in nondegree programs. One CEU isawarded for each 10 contact hours (or equivalent) in anorganized continuing education experience. All CEUs earnedthrough the University of Wisconsin–Milwaukee School ofContinuing Education noncredit programs become a part ofyour permanent record.

ParkingParking is available in the Shops of Grand Avenue parkingstructure and other adjacent lots. The School of ContinuingEducation provides a parking discount for program participants.Inquire for details.

DirectionsFor the latest information on getting to and from the School ofContinuing Education, visit sce-directions.uwm.edu. Thewebpage includes access to printable color PDFs of currentmaps, information about parking and public transportation, andother details relevant to our location.

For Further InformationContact Murali Vedula at 414-227-3121 or [email protected].

RELATED PROGRAMS AND CERTIFICATESBusiness Process Improvementsce-businessimprovement.uwm.edu

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School of Continuing Education Business, Engineering & Technology161 W. Wisconsin Ave. Ste. 6000Milwaukee, WI 53203-2602

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ONSITE TRAINING Capitalize on our CapabilitiesAny program can be designed to meet your organization's unique and specificemployee development needs. Consider the advantages to partnering with UWM SCE.

Contain Costs by eliminating or reducing travel, food and lodging expenses.

Maximize Convenience by choosing your optimal dates, times and location.

Save Time with staff spending fewer hours away from work.

Build Teamwork through group brainstorming and shared learning experiences.

Custom Tailor Content to your needs to accomplish specific organizationalobjectives. Or, use the curriculum as-is.

For more information, contact Murali Vedula at 414-227-3121 or [email protected].

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fall 2010 elastomer engineering brochurerubber extrusion technology examine all aspects of the...

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