The Study Of Optimum Condition To Produce Rubber Induced Polymer (Polyethylene).

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THE STUDY OF OPTIMUM CONDITION TO

PRODUCE RUBBER INDUCED POLYMER

(POLYETHYLENE)

AHMAD FARIZ BIN FAIZAL LIM

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UTeM Library (Pind.1/2007)

THE STUDY OF OPTIMUM CONDITION TO PRODUCE RUBBER INDUCED

POLYMER (POLYETHYLENE)

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FAKULTI KEJURUTERAAN PEMBUATAN

Rujukan Kami (Our Ref) : 15 May 2008 Rujukan Tuan (Your Ref):

Pustakawan

Perpustakawan Universiti Teknikal Malaysia Melaka

UTeM, No 1, Jalan TU 43,

Taman Tasik Utama, Hang Tuah Jaya,

Ayer Keroh, 75450, Melaka

Saudara,

PENGKELASAN TESIS SEBAGAI SULIT/TERHAD

- TESIS SARJANA MUDA KEJURUTERAAN PEMBUATAN (FAKULTI

KEJURUTERAAN PEMBUATAN): AHMAD FARIZ BIN FAIZAL LIM

TAJUK: THE STUDY OF OPTIMUM CONDITION TO PRODUCE RUBBER

INDUCED POLYMER (POLYETHYLENE)

Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk

“

THE STUDY OF

OPTIMUM CONDITION TO PRODUCE RUBBER INDUCED POLYMER

(POLYETHYLENE)

”

mohon dikelaskan sebagai terhad untuk tempoh lima (5) tahun dari

tarikh surat ini memandangkan ia mempunyai nilai dan potensi untuk dikomersialkan di

masa hadapan.

Sekian dimaklumkan. Terima kasih.

“BERKHIDMAT UNTUK NEGARA KERANA ALLAH”

Yang benar,

………..

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Karung Berkunci 1200, Ayer Keroh, 75450 Melaka

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DECLARATION

I hereby, declared this thesis entitled “The Study of Optimum Condition to Produce Rubber

Induced Polymer (Polyethylene)” is the results of my own research

except as cited in references.

Signature

:

Author’s Name

:

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APPROVAL

This PSM submitted to the senate of UTeM and has been as partial fulfillment of the

requirements for the degree of Bachelor of Manufacturing Engineering (Material

Engineering). The members of the supervisory committee are as follow:

PN. ZURINA BINTI SHAMSUDIN

(Main Supervisor)

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ABSTRACT

The purpose of this study is to find the optimum condition to produce rubber induced

polymer polyethylene (PE). In this research, the used waste rubber was taken from

the old tires and the polyethylene, PE are use to produce new polymeric material that

enhance their properties. The polymer blending that involved in this study was melt

blending of two polymers which mixed up in their molten state. The methodology of

this study is prepare the raw material, mixing process by using internal mixer,

crashing process and lastly forming process of the polyethylene mix with waste

rubber. The main concern of the mixing process is the parameter such as

temperature, time and rotor speed of the mixer. The produced material of

polyethylene (PE) and waste rubber are tested for its flexural strength using the

Universal Testing Machine (UTM). The standard of the flexural strength used this

study is ASTM D790. Based on the result of the flexural testing, the best

composition for optimum condition of the polyethylene (PE) and waste rubber

produced was 90wt% polyethylene with 10wt% waste rubber. It is found out that the

rubber induced polymer polyethylene (PE) produced which is new polymeric

material do enhances the properties. Besides that, by adding some homogenizing

agent to the mixing process of the polyethylene (PE) and waste rubber can enhance

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ABSTRAK

Tujuan kajian ini dikendalikan adalah untuk mencari keadaan optimum untuk

menghasilkan getah yang teraruh dengan polimer, politena. Dengan menggunakan

getah terpakai daripada tayar lama dan juga politena untuk menghasilkan bahan

polimer yang baru. Di dalam kajian ini, pengunaan getah terpakai yang diambil

daripada tayar terbuang dan juga politena, PE digunakan untuk menghasilkan bahan

polimer baru yang dapat mengubah sifat-sifatnya. Campuran polimer yang terlibat

dalam kajian ini ialah campuran cair bagi dua polimer yang dicampurkan dalam

keadaan cair. Kaedah yang digunakan dalam kajian ini ialah menyediakan bahan

mentah, proses pembancuh iaitu mesin pembancuh, proses penghancuran dan juga

proses pembentukan politena dengan getah terpakai. Bahan yang telah terhasil

daripada politena dan juga getah terpakai telah diuji kekuatan lenturannya dengan

menggunakan mesin bebas ujikaji. Piawai ujian kekuatan lenturan yang digunakan

dalam kajian ini ialah ASTM D790. Di dalam proses pencampuran, parameter

memainkan peranan penting seperti suhu, masa dan juga kelajuan pemutar.

Berdasarkan keputusan daripada ujian kekuatan lenturan, komposisi optimum yang

diperolehi yang paling bagus adalah 90wt% politena dengan 10wt% getah terpakai.

Politena dan juga getah terpakai akan menghasilkan bahan polimer yang baru yang

dapat mengubah sifat. Dengan menambahkan agen penghomogenan di dalam proses

pencampuran politena dengan getah terpakai dapat menggubah sifat mekanikal dan

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DEDICATION

To my family and my friends, thank you very much for your support and effort

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ACKNOWLEDGEMENT

I would like to express my gratitude and appreciation to the individuals who involve

in ensuring a successful occurrence and flow of activities throughout my final year

project. My appreciation and gratitude towards my supervisors, Mr Muhammad

Zaimi Bin Zainal Abidin, Mrs Pn Zurina Binti Shamsudin and also to my second

examiner Mr Edeerozey Abd. Manaf for their encouragement and support and for

spending time with me by providing a lot of guidance and ideas for my project

research. With their knowledge and experience really inspired and spurred myself to

learn a lot of things from them. I’m lucky to have an opportunity to work with them

and not least, my appreciation to Hairulhisham Bin Rosnan, and Azhar Shah Bin Abu

Hassan for their time and guidance to complete my research at the laboratory.

Finally, my sincere appreciation is dedicated to my parents Mr Faizal Lim Bin

Abdullah, Mrs Alawiyah Binti Ghazali and as well as the friends for their assistance

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2.1.2 Advantages of Polymer………...

5

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2.1.3.1 Linear Polymer………

5

2.1.3.2 Branched Polymer………

6

2.1.3.3 Cross-Linked Polymer………

7

2.1.3.4 Network Polymer………

7

2.1.4 Thermoplastic……….

8

2.1.5 Thermoset…………...……….

9

2.1.6 Elastomer……….

9

2.2 Polyethylene………...………..

10

2.2.1 Classification of Polyethylene………..……...………

10

2.2.2 Properties of Polyethylene………...………

10

2.2.3 Application of Polyethylene……….………...………

11

2.3 Rubber………..………

12

2.3.1 Classification of Rubber………..

12

2.3.2 Natural Rubber………

12

2.3.3 Vulcanization………...………

13

2.3.4 Mechanical Properties of Rubber………

14

2.4 Polymer Blending..………..

15

2.4.1 Classification of Polymer Blending……….

15

2.4.2 Importance of Polymer Blending ………

15

2.4.3 Mechanical Properties of Polymer Blending..……….

16

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2.4.4.1 Melting Blending……….……….

16

2.4.4.2 Solution Blending……...……….……….

17

2.4.4.3 Latex Blending……….………

17

2.4.4.4 Interpenetrating Networks..………….……….

17

2.5 Processing method of polymer………

18

2.5.1

Internal mixer………...

18

2.6 Flexural Testing Standard………

18

2.7 Flexural Strength………..

19

2.7.1 Classification of Flexural Strength………..

19

2.7.2 Three Point Flexural Strength ………

19

2.7.3 Calculation of Flexural Strength……….

20

2.7.4 Calculation of Flexural Modulus….………

20

3. METHODOLOGY………..

21

3.1 Introduction ……….

21

3.2 Raw material………

23

3.2.1

Preparation of rubber………..

23

3.2.2

Preparation of polyethylene resin………...

23

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3.3.1 Internal Mixer……….

24

3.3.1.1 Material preparation……….

25

3.3.1.2 Parameter setting for internal mixer………

26

3.4 Crashing process………..

27

3.4.1 Crashing machine………...……….

27

3.5 Forming process……..……….

28

3.5.1 Hot press………...………...

28

3.5.2 Parameter of hot pressing………

29

3.6 Flexural test………...………...

30

3.6.1 Flexural test configuration………..

30

3.6.2 Specimen preparation….……….

31

3.6.3 Run flexural test

32

4. RESULTS………..………...………

33

4.1 Flexural testing………

33

4.1.1 Data collection……….

33

4.1.2 Result calculation of flexural strength………

35

4.1.3 Result calculation of flexural modulus………

36

4.1.4 Max force………

38

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4.1.6 Max strain………

40

5. DISCUSSION ………...………..

41

5.1 Introduction………..

41

5.2 Flexural strength………..

41

5.3 Flexural modulus……….

42

5.4 Effect of internal mixer………

43

5.5 Homogenizing agents………..

44

6. CONCLUSION AND RECOMMENDATION…..………..

45

6.1 Conclusion………...

45

6.2 Future work………..

46

7. REFERENCE………..

47

8. APPENDICES

A

Pressure standard of hot press

B

Control panel of hot press parameter

C

Calculation of flexural test

D

Calculation of flexural test 2

E

Procedure of internal mixer

F

Process flow chart of internal mixer

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LIST OF FIGURES

2.1

Polymer categories……….

5

2.2

Linear chain structure………

6

2.3

Branches chain structure………

6

2.4

Cross-linked chain structure………..

7

2.5

Network chain structure……….

7

2.6

Recycle symbols………

8

2.7

Basic Structure of polymer molecules: (a) Ethylene molecules;

(b) Polyethylene, a linear chain of many ethylene molecules………...

12

2.8

Polymerization of polyisoprene……….

13

2.9

‘cis’ configuration………..

13

2.10 ‘trans’ configuration………...

13

2.11 Vulcanization process………

14

2.12 Flexural test………

19

3.1

Flow chart of research methodology………..

22

3.2

Particles of rubber………..

23

3.3

Particles of polyethylene resin………..

24

3.4

Thermo HAAKE PolyLab Mixer OS………

24

3.5

The weighting process: (a) weight polyethylene; (b) weight waste rubber...

25

3.6

Crusher machine………

27

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3.8

Schematic of hot press………..

29

3.9

Specimen of testing material: (a) polyethylene with 10wt% rubber, (b)

polyethylene with 20wt% rubber and (c) polyethylene with 30wt% rubber.

30

3.10 Specimen for flexural test……….

31

3.11 The position of specimen before run flexural test……….

32

3.12 The position of specimen after run flexural test……...……….

32

4.1

Graph of force (kN) versus stroke strain (%) for specimen PE/20% rubber

(sample 5)………...

36

4.2

The bar graph max force of polyethylene with waste rubber………

38

4.3

The bar graph max stress of polyethylene with waste rubber………..

39

4.4

The bar graph max strain of polyethylene with waste rubber………

40

5.1

The graph flexural strength of polyethylene and waste rubber……….

41

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LIST OF TABLES

2.1 Application of polyethylene………

11

3.1 The composition of polyethylene and waste rubber………

25

3.2 The internal mixer parameter for polyethylene and waste rubber…………..

26

3.3 Parameter of hot press……….

29

4.1 Data of flexural testing………

33

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NOMENCLATURE

° C

- Degree celcius

m

- Meter

mm

- Milimeter

N

- Newton

rpm

- Rotor per minute

Pa

- Pascal

Avg

- Average

Tg

- Glass Transition Temperature

Mpa

- Mega Pascal

Max

- Maximum

min

- Minutes

SEM

- Scanning Electron Microscope

ASTM

- American Standard Testing Material

PE

- Polyethylene

HDPE

- High Density Polyethylene

LDPE

- Low Density Polyethylene

UHMWPE

- Ultra High Molecular Weight Polyethylene

PP

- Polypropylene

PVC

- Polyvinyl chloride

PS

- Polystryene

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CHAPTER 1

INTRODUCTION

1.1

Introduction of rubber induced polymer

The use of recycled rubber taken from old tires into polymer, polyethylene and other

types of common use polymer to produce various type of characteristic polymer.

These waste rubbers from old tires suggested to be crushed into tiny bits before

mixing it with polymer resin. Polymer blend or mixing is a mixture of two or more

polymers with improvement in the properties. The important of mixing two or more

polymers are to achieve enhanced properties such as toughness, strength,

processability, chemical resistance, weatherability, heats stability, and flow behavior.

The optimum condition to produce polymer blend can be determined by studying the

mechanical properties of the blend. It depends on the composition of blend elements

and method of producing it such as internal mixer. Main components that are needed

to be consider in producing Rubber-polyethylene, PE polymer are the ratio of

material (waste rubber and polyethylene, PE), particle size, process parameter

(temperature and time) and method of producing it such as internal mixer, machine

and hot press for forming the rubber induced polymer. After the polymer blend has

been produce, flexural test is conducted to determine the best composition and

process parameter in producing the waste rubber induce polypropylene polymer

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1.2

Statement of purpose

The purpose of this research is to study and analyzed the flexural strength of the

optimum condition to produce waste rubber induced polymer (Polyethylene, PE) that

depends on the composition of the material, the process of blend and the parameter

setting during blending process.

1.3

Problem statement

Rubber and commonly used polymer such as polyethylene (PE) have different

characteristics for example elasticity, heat resistance and also durability. By

combining these various characteristics of the both material hope to get a new

polymeric material that have a good flexural strength based on the composition of the

material. The correct method of mixing the both material need to be determine so

that the suitable process and parameter would create a new polymeric material.

1.4

Objectives

The objectives of this study are:

i) To study the method of producing the waste rubber induced polymer,

polyethylene (PE).

ii)To analyze the flexural strength of the waste rubber induced polymer,

polyethylene (PE).

iii)To find the optimum condition of waste rubber induced polymer, polyethylene

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1.5

Scope of study

The polymer material (Polyethylene, PE) induced the waste rubber only will be cover

in this study. By doing mixing process on both materials based on the composition,

the ideal temperature and mixing time are obtain to produce new polymer. The

process that involve in the study is the mixing process by using internal mixer

machine, where else there are forming process such as hot press involved in this

study concerning about the optimum condition to produce waste rubber induced

polymer (Polyethylene, PE). The mechanical testing that involve in this study is

flexural testing that based on ASTM D790. This study does not cover the others

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CHAPTER 2

LITERATURE REVIEW

2.1

Polymer

2.1.1

General view of polymer

The word polymer is derived from the classical Greek words poly meaning “many”

and meres meaning “parts” (Joel R. Fried, 2003). Simply stated, a polymer is a

long-chain molecule that is composed of a large number of repeating units of identifical

structure. Certain polymers, such as proteins, cellulose, and silk, are found in nature,

while routes. Polymers naturally can be produced synthetically. Polymers that are

capable of high extension under ambient conditions find important application as

elastomers. Others polymer may have characteristics that permit their formation into

long fibers suitable for textile applications.

In the contrast to the usage of the word polymer, those commercial materials other

than elastomers and fibers that are derived from synthetic polymers are called

plastics. A typical commercial plastic resin may contain two or more polymers in

addition to various additives and fillers. These are added to improve a particular

property such as process ability, thermal or environmental stability, or modulus of

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[image:23.612.141.518.75.189.2]

Figure 2.1: Polymer categories

2.1.2

Advantages of polymer

The advantages of the polymer that have been widely used in the application today in

term of the following characteristics:

1. Corrosion resistance and resistance to chemicals

2. Low density

3. Low electrical and thermal conductivity

4. High strength-to-weight-ratio, particularly when reinforced

5. Noise reduction

6. Wide choice of colors and transparencies

7. Ease to manufacturing and complexity of design possibilities

8. Relatively inexpensive

2.1.3

Structure of polymer

2.1.3.1

Linear polymer

Linear structure (Refer Figure 2.2) has a sequential structure based on the properties

of the polymer that depends on the monomers and the arrangement of the molecular

structure. A linear molecular is not necessarily straight in shape. Generally, a POLYMER

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polymer may consist of more than one type of structure; a linear polymer may

contain some branched and linked chains. As a result of branching and

[image:24.612.257.408.160.262.2]

cross-linking, the polymer’s properties might change (R.A Higgins, 1998).

Figure 2.2: Linear chain structure

2.1.3.2

Branched polymer

Branched polymer is determined by the properties of the polymer that depends on the

type of monomers and the arrangement of the molecular structure. The branched

polymers are side-branch chains that attach to main chain during the synthesis of the

polymer. The branching interferes with the relative movement of the molecular

chains as for the result, deformation resistance and stress crack are increased (R.A

Higgins, 1998). The density of the branched polymer might also effect the efficiency

of the packing polymer chains. The entanglement of the branches makes the

movements more difficult, a phenomenon akin to increased strength.

[image:24.612.256.407.553.653.2]

The Study Of Optimum Condition To Produce Rubber Induced Polymer (Polyethylene).