vinay seh
Posts by vinay seh:
7 Important Facts You Should Check Before Choosing Your Rubber Part Supplier !!
Choosing a rubber parts manufacturer for your business can be a difficult process. Much like hiring an employee, selecting the right candidate to provide your company with high-quality parts is an investment that requires you to consider many factors. Enlisting the aid of a reliable parts manufacturer is a wise decision that could benefit your business, however, there are other considerations to be made before you commit to a particular supplier. Selecting a parts manufacturer is an important step in building the foundation for your long-term success. Finding the right supplier that can sufficiently meet your specific needs begins by first understanding how these companies can benefit you most. We’ve gathered the following facts that will help you identify the qualities of the ideal parts manufacturer.
1) Find A Supplier That Offers High Quality Product At Best Price With Effective Service
Your supplier should not compromise with quality as it serves the critical function of your product. To ensure quality of the Products manufactured & supplied your supplier should have a well defined quality monitoring system. Parts manufactured should be of high quality and comply with International standards & should be supplied to you at best price with on time delivery.
2) Should Have Enriched Experience In The Rubber Industry
Experience makes the difference. With maximum years of experience your supplier should hold a place amongst the top players in the Indian Rubber Industry. A Rubber Part manufacturer should have the experience of serving the rubber parts across a wide range of industries like Automotive, Electrical, Fluid Power, Home Appliances, Plumbing & Sanitary.
3) Should Offer Wide Product Range
Your supplier should be capable of manufacturing 100% high-quality rubber parts in a wide range such as in numerous materials, color, shapes & sizes by using different moulding techniques as per your requirement. With Intensive research and regular development it should ensure upgraded quality as per current industry standards. The ideal supplier should work with it’s customers closely and offer them a wide range of products in advance to meet their challenges & demands on time.
4) Should Have Quality Management Systems (QMS)
Your supplier should be an ISO 9001:2018 and IATF 16949 certified company. To ensure the quality of the Products manufactured & supplied it should emphasize on development of a process-oriented quality management system that provides continual improvement, defect prevention & waste reduction while manufacturing high-quality rubber components that comply with international standards.
5) Should Have Well Defined & Customer Focused Work Flows & Processes-
It should believe in a predefined workflow process that has a significant impact on the organization’s efficiency, productivity & customer experience. Pre-defined processes enable us to constantly step towards innovation & next-level performance to continually meet the ever increasing buyer standards.
6) Should Have High Precision Testing Equipment To Ensure Absolute Quality-
A Supplier should ensure that their products are developed from the latest technology for best product finish therefore it should have all the modern facilities, state of the art equipment & world class manufacturing facilities at its plant, which should have sophisticated technology to produce 100% quality parts. Its in-house tooling facilities should include mould designing & mould development software along with High speed CNC & VMC machines. For more accurate inspection and speed, the latest Automated Online Inspection System should be installed to avoid manual inspection errors & to ensure absolute quality.
7) Should Offer Customized & Standard Products To Suit Your Applications-
Your product is unique and requires unique rubber parts to fit well. Hence your supplier should be specialized in offering customized products as per the drawing, sample and application. It should have a dedicated development & tooling department to develop the exact products as per your concept and fitment. As the right fitment will enhance product performance and ensure 100% leak proof solution.
Kesaria Rubber Industries is a leading manufacturer & exporter of Rubber, TPE & PTFE components with enriched experience of more than 30 years & is specialized in providing absolutely flashless rubber parts with high accuracy as per international standards. We have a complete in-house facility with an amazing production capacity of more than 2.5 million parts per day to fulfill our customer’s requirements on time so that they can achieve their business goals. We ensure absolute quality, safety & durability of our products & have always met the ever growing demands of our customers as per changing technologies & market trends to exceed global standards.
5 Most Suitable Materials For High-Temperature Sealing Applications !!!
Industrial Rubber Seals are designed to prevent leakage, while helping to combine systems or mechanisms together. While seals created for ambient and low temperatures are not extremely difficult, creating seals for high temperature applications is a challenge. This is because standard sealing materials cannot perform well in such conditions for long periods of time. As excessive heat can gradually degrade rubber materials, leading to deteriorating performance and premature failure. This can result in leakage & high-temperature applications require high-temperature-resistant rubber products that offer dependable performance no matter what. Hence, it is important to choose the right manufacturing materials to ensure prolonged seal performance in high temperature applications.
Applications with high temperatures can include ethylene production, steam and gas turbines, solid oxide fuel cells, and industrial exhaust systems. Such applications comprise immense levels of heat, aggressive chemicals, and strong transfer fluids. Due to these elements, the temperatures can be of at least 400⁰F or above. Traditional sealing materials like mica or graphite lose their physical integrity, and their performance diminishes quickly in such environments. This can result in total leakage, which can lead to a shutdown, and downtime.
Silicone Rubber
A rubber-like polymer, Silicone Rubber has a high temperature resistance up to 230⁰. It offers outstanding high-temperature resistance, with some compounds able to withstand temperatures up to 305 °C. The material is resistant to UV rays, ozone, and oxygen. It has great electrical insulation properties, and high gas permeability. It is mainly used to manufacture aerospace seals, and automobile gaskets.
Silicone is not a high strength material and tears easily. Having said that, we have special compound grades that deliver better tear resistance than standard silicone. Fluorosilicone elastomer material combines high liquid resistance of fluorocarbon, and extreme temperature stability of silicone. With a temperature above 400⁰F, fluorosilicone O-rings can be exposed to sunlight, and will not degrade due to air, ozone, aromatic, or chlorinated hydrocarbons.
PTFE
Polytetrafluoroethylene is one of the reliable polymer materials. It can resist strong industrial chemicals, and maintain its integrity in temperatures above 500⁰F for long time periods.PTFE provides the least amount of friction when compared to other options. In addition, PTFE is tremendously nonwetting and acts as an excellent electrical insulator. PTFE is also unfazed by the majority of chemicals. It is extremely resistant to high temperatures, contain outstanding electrical properties, have excellent release surfaces and superior chemical resistance. PTFE is widely used across various industrial applications like Plumbing, HVAC, Electronic Appliances, Pharmaceutical, Automotive & many more.
FKM (Viton)
FKM is a family of fluoroelastomers commonly referred to by DuPont’s Viton® brand name. FKM is an excellent high-temperature-resistant rubber that can resist the temperature above, which retains its good mechanical properties and chemical resistance (oils, fuels, lubricants and most mineral acids), even at extremely high temperature up to 225⁰F. Due to its wide temperature range, chemical compatibility, low compression set, and excellent aging characteristics, fluorocarbon elastomers (FPM, Viton®) have grown to major importance in the seal industry. Fluorocarbon elastomers are highly fluorinated carbon-based polymers used in applications to resist harsh chemical and ozone attack. Fluorocarbon O-ringsshould be considered for use in aircraft, automobile and other mechanical devices requiring maximum resistance to elevated temperatures and to many fluids such as mineral oils and greases, non-flammable hydraulic fluids, silicone oil, fuels etc. Whilst not recommended for use with brake fluids, ammonia solvents, strong acids or superheated steam.
EPDM
EPDM – also known as ethylene propylene diene monomer – is an extremely versatile material used in a variety of applications, from automotive products to HVAC parts. This type of rubber also acts as a less expensive alternative to silicone, as it can endure weather conditions, abrasion, and other challenges for long periods of time with proper use. EPDMis a copolymer of ethylene, propylene and diene monomers. This synthetic high-temperature-resistant rubber offers excellent heat resistance, performing optimally up to +150°C. It has good resistance to UV exposure, ozone, aging, weathering, and many chemicals – great for outdoor applications. Can be fabricated in a variety of ways, which includes custom molded and extruded partsLong-term part lifespan allows for fewer replacement parts, saving money in the long run.
Also Read: What Are The Advantages Of EPDM O Rings?
HNBR
HNBR elastomers are changing the game for sealing and manufacturing companies. Made from hydrogenated acrylonitrile butadiene rubber (NBR), the compound meets higher temperatures, retains better resistance and has become widely known for its physical strength. It is a unique elastomer that is derived from conventional nitrile rubber through the hydrogenation of unsaturated bonds in the butadiene. HNBR is an exceptionally high-temperature-resistant rubber that can withstand much higher temperatures than conventional nitrile up to +150 °C. It also offers good abrasion resistance. It is resistant to mineral oil-based hydraulic fluids, animal and vegetable fats, diesel fuel, ozone, sour gas, dilute acids and bases. HNBR also resists new bio-oils (biological oils). Typical applications include gaskets and seals, especially for the oil and gas industry, and accumulator bladders, and diaphragms. It is compatible with automotive oils, gases and fuels such as aliphatic hydrocarbons, hydraulic fluids and dilute acids. However, HNBR is not recommended for use with chlorinated hydrocarbons, polar solvents or strong acids. Also note that it has limited resistance to brake fluids.
How To Check The Material Grade/ Impurities/ Quality etc. !!!
When it comes to predicting the durability or performance of a given material for use in a specific application, it’s crucial to evaluate chemical and physical properties as well as environmental compliance and quality control. At Kesaria Rubber we understand the real-world service-life and environmental challenges polymer materials face. Our experts can help you predict, manage and improve the performance of your polymer-based material or product whilst ensuring its safety and compliance. We provide independent rubber material analysis to clients operating in a wide range of industries.
We help clients understand, manage and improve the performance of their materials and products using a range of analytical techniques together with expert interpretation of results, guidance and advice. We go through a comprehensive range of chemistry, physical testing, and technical consulting stages to support the development of polymer based materials and end products.
Chemical Characterization
When working with new compounds and sustainable, recyclate-based material formulations – gaining full confidence in their performance requires accurate assessment of not only physical and mechanical properties but also the identification and mitigation of any contaminants.
How we check the Material grade/Polymer Identification
Proper material selection is at the heart of any product or development project. Material characteristics and performance can determine the success or failure of the productand consistency of the rubber materials from lot to lot plays a significant role. Below are a few tests by which we can check the material/ identify the material and check the consistency of the quality of the rubber material. Following are the methods we use for chemical testing-
1.0Chemical methods ( ASTM D 297 )
- Burning Test: The piece of sample is heated in a flame and the odor and the color of the flame is noted.
- Acid degradation test:
- Action of 80% H2SO4 and heated slowly in the flame. The change in sample condition is observed.
- Action of Concentrated Nitric Acid: A small piece of width approximately 2-3 mm is taken in the test tube containing 1-2 ml of concentrated HNO3 and heated slowly in the flame. The change in sample condition is observed.
3. Beilsten test (Cu Wire test): The copper wire is heated till red hot; the sample is taken on the red-hot wire and heated in the flame. The color of the fame is then noted.
2.0 Instrumentation methods
- FTIR: Fourier Transform Infrared Spectroscopy (FTIR)
- GCMS: Gas Chromatography Mass Spectrometry (GCMS)
Physical Testing
Rubber material formulations can be greatly affected by a wide range of environmental conditions and physical forces. From adhesives to a variety of rubber compounds, Kesarias’ physical testing experts can provide guidance and test data to support your material evaluation needs. Our environmental exposure capabilities include variables such as temperature, humidity & UV Arc chambers to test in the harshest of lab conditions. Physical properties can be studied extensively through a myriad of internationally recognized standard test protocols. While data from any combination of these material property tests can provide you with a good picture of a given material’s expected performance.In addition, Kesarias’ laboratories are able to not only excise samples from most whole products, but our internal small batch mixing and molding capabilities can assist you in providing the most appropriate samples for your testing purpose.
How we check impurities and quality of rubber
Density: ASTM D297
The specific gravity of any elastomer is important for its identification and providing an approximate measurement of its physical properties. Rubber density determines the specific gravity of the material and Generally the S.G. of rubber is used in place of density which is measured with respect to water. Specific Gravity is normally abbreviated to SG and is the ratio of the weight of a given substance to the weight of an equal volume of water at a specified temperature. If the Specific Gravity increases from its standardized value then it seems that rubber material has impurities or fillers which will affect material properties.
Procedure:
The most common method of determining the density of a rubber material is to weigh a test piece in air and water. Weighing in air provides the actual weight and weighing in water provides the volume. The density is then calculated by dividing the weight by the volume.
Ash content (ASTM D297_Filler Analysis)
The quality of rubber varies widely due to the percentage of ash content into it. Rubber materials having Inorganic impurities like Silica, Zinc Oxide, Clay etc. and high concentration of these impurities or high ash content % may initiate the oxidative degradation of rubber and may affect the quality of the final product. The percentage of these impurities can be found out by an ash content test. This test method is used by the rubber industry to ensure purity of the ingredient as per standard specification.
Lower Ash Content (Virgin Materials/Lower Impurities) | Longer service life.
Higher durability. Lower after sales services. |
Procedure:
Ash % is determined by taking an accurately weighed sample in a properly cleaned porcelain crucible and heating in a muffle furnace at 550 + / 25 °C for 1 hrs. The crucible is then cooled to room temperature and final weight is taken after getting constant weight. The mass of residue in the crucible represents the Ash Content. The ash content is calculated as per given formula i.e.
Ash content % = Weight of the ash
_________________ x 100
Weight of sample taken
Life Prediction & Accelerated Ageing
Life prediction and accelerated aging studies to help you make significant, safe and effective material choices, supported by material analysis for your intended end-use application. Life prediction and accelerated aging can be assessed throughout the product cycle from material evaluation, product development, and material qualification through to prototype design and final product stages. As service conditions become increasingly more demanding there is a need to demonstrate material durability and ensure a material is fit for purpose. Testing materials and products exposed to accelerated high temperature aging enables product service life predictions to be evaluated.
Prediction of expected product life time
Kesaria Rubber Industries helps generate data to drive product improvements. Polymer material performance is dependent on time, temperature, stress and environmental factors which can all be investigated with the following testing:
- Mechanical (creep, fatigue, stress relaxation, impact, environmental stress cracking (ESC) and wear)
- Thermal (degradation, dimensional stability, fire)
- Oxidative (oxygen, ozone and metal catalyst)
- Chemical (fluids, gases, water and steam)
- Radiation (sunlight, ultraviolet light and atomic radiation)
- Biological (microorganisms)
- Electrical (arcing, electrostatic build up, dielectric breakdown)
5 Essential Considerations Before Designing Rubber Products !!!
Designing rubber parts means taking multiple requirements into consideration. A design engineer wants to get the part that will work in their assembly. Purchasing Managers want to make sure they can meet the timetable and get the most cost-effective part. The quality engineer needs all the documentation to satisfy quality standards and information to pass regulatory reviews. Designing the ideal rubber part for all the industrial applications, there are several rubber product design features worth bearing in mind.Here are five ways to make sure that part will meet those requirements and get to market on time.
1. Using The Right Material
With new material regulations being introduced, making sure you have the right material is critical. Many design engineers use common rubber sealing material in prototype concept work. It’s the easiest to get and they may believe all rubber materials are the same. Before the product goes to market, a company’s regulatory department may find the material not acceptable or requires a high level of testing to determine if the material is qualified for use.
Letting a rubber molder know about what material is going to be used in a particular application will allow the molder to select the correct material. This will help streamline compliance and may eliminate future testing if the material is already tested. Rubber compounds are typically made up of 20 or so individual ingredients, compared with plastic compounds that might only have three or fewer. Formulating rubber products requires an extensive review of these ingredients, including the purity level of each. To know more about choosing the right material check our material selection guide-
https://www.kesaria.com/blog/how-to-choose-which-rubber-is-best-for-my-application/
2. Evaluation Of Chemical Compatibility
No rubber material is perfect. When designing the perfect sealing product It’s important to use the right material to match the application & the environment in which it will operate. When working with chemical substances we majorly face challenges in handling & processing of various chemical substances. Hence, it is very important to check the chemical compatibility of these substances & select the most appropriate elastomeric material that can withstand any type of environment & media therefore we would recommend a range of chemical resistant materials such as NR, SBR, NBR, CR, EPDM, HNBR, ACM, CSM, Silicone & FKM (Viton) with our technical experts to guide you in selecting the right material as per your application.
3. Review Of Hardness In Rubber Compound
Shore Hardness measures the resistance a material has to indentation. The Shore durometer is used to compare & measure the hardness of a material, typically of polymers, elastomers & rubbers using a spring-loaded steel rod by compressing the surface of the material. A shore hardness of 0 equates to the maximum amount of indentation possible, while A shore hardness of 100 is indicative of an extremely high resistance to indentation. To know more about hardness of your product check out our hardness comparison chart-
https://www.kesaria.com/products/o-rings/
4. Observe The Permissible Tolerances
It is essential to observe the rubber tolerance in your design process as almost all the elastomers undergo a certain degree of shrinkage. The ingredients in a rubber formulation are mixed at a given tolerance. This can cause variations in the amount of shrinkage from batch to batch. In addition, molds are heated. The tolerance on a mold temperature profile can also cause shrinkage variations apart from these other factors are like tool design, geometry, hardness etc. are also responsible for shrinkage hence considering all these factors it is important to get a guidance at the earliest stage from our technical experts to ensure the most optimum solution for your particular application requirement.
5. Review The Geometry To Avoid Stress / Strain
Determining the geometry is very essential to check viscoelastic properties, stress-strain properties, rebound resilience & tear strength of rubber raw materials as it includes essential chemical-analytic and physical structure of carbon atom also called geometric factor i.e. highest possible level to bear stress. The simpler and more symmetrical the geometry of your design, the easier it will be to produce. It is worth bearing in mind that complicated geometries can often cause stress to the product that in turn could decrease it’s durability hence causing the product to be less durable & only for a shorter period of time.
With a little work during the design phase, rubber parts can have a smooth sailing right through production. We make sure our customers get the perfect product as per their application requirement to achieve their business goals.