METHOD FOR IMPROVING PRODUCTION PROCESS FOR WIDE-BASE TRUCK RADIAL TIRE

Abstract

The present patent provides a method for improving the construction process of a wide-base radial truck tire, and the improvement of the tire construction process is realized by the design of carcass ply, the tire belt drum and the tire semi-finished components. The patent solves the problem of carcass bending, and provides theoretical guidance and technical support for improving the performance of wide-angle radial tires. The design method of the belt drum of the tire molding machine effectively controls the cords elongation of the belt. In addition, the problem of uneven force in the cords of the belt is eliminated, which dispels the abnormal flow of the wide-base tire shoulder rubber to the center of the crown during the shaping process, thus improving the durability and operability of the tire. The proposed semi-finished components design method in this patent can accurately design the tire semi-finished parts material distribution map, significantly improve the finished tire and the theoretical design of tire material distribution consistency, thus reducing tire development cycle and development costs.

Description

INTRODUCTION

The current patent refers to the wide-base truck radial tire production process. The patent aims to propose an improved method for wide-base radial truck tire building. By adjusting the building process of the wide-base radial truck tire, the proposed method can help improve the quality of tire manufacturing as well as quality of the finished tire.

BACKGROUND

Low-carbon economy demands in recent years continue to push tire manufactures to produce tires with fuel-savings, low emissions and improved driving safety. One of the important ways to meet this demand is tire broadening to produce a wide-base radial truck tire. Wide-base radial truck tires refer to tires with an aspect ratio of 0.65 and below. The distinguishing feature of the wide-base radial truck tire is its flat nature without tubing but wide rims. Wide-base radial truck tire has been widely used for trucks, such as drive wheel, trailer wheel and semi-trailer wheel.

A technical characteristic feature of the Michelin X-one wide-base radial truck tire is its 0° belt crown part that is, 400 m of non-joint wires to 0° angle continuous winding on the crown. This feature guarantees tread stability, even distribution of stress, better clutching performance, and uniform tread wear and extended mileage.

Compared with conventional tires and dual tires, wide-base radial truck tire is lighter in weight, with larger load carrying capacity and requires less installation space. However, their manufacturing process is more complex, and it requires high precision. In the actual building process of wide-base radial truck tires, carcass ply bending is one of the most common defects, which directly affects tire performance. The “trial and error method” is used to optimize design parameters with the object of solving the carcass ply bending problem in the design process. Yueyao Ping effectively solved the carcass ply bending problem by controlling the building design parameters. Zhe Pu reduced the carcass ply bending problem by adjusting tire components laminating strength in the building process The above methods have drawbacks of large test numbers with usually low precision, as well as narrow scope of application, and scanty obtainable information.

There are three building drum in the tri-drum single stage building machine for all steel heavy truck tire: the carcass drum (main drum), which is bonding the components of the sidewall, the inner, the bead, the abrasion, and the carcass; the belt drum (auxiliary drum), which is joining the components of belts and tread. After gluing the carcass drum components and the belt drum components, and these components are translated to the building drum by transferring ring, the building drum, which complete the stereotype, compaction, and form a green tire.

The drums are generally composed of several arc blocks, and the drum diameter of the belt is adjusted by replacing the segments or adjusting nuts. The drums are usually cylindrical, which results in different rates of belt elongation at different locations for the duration of the building process. The crown's elongation rate is high, but that of the sidewall is short. Nevertheless, the width of the belt of wide-base radial truck tire is wider, and the force of the cord is not uniform when the tire belt/crown is glued, especially in the case of 0° cap plies winding technology. FIG. 16 presents the cross section of a wide-base radial truck tire with 0° cap plies winding technology. In the center of the crown, the band tightening effect is stronger than at the belt ends. In the vulcanized tire stereotypes, since the radial tire carcass cord angle is set to 90°, the cord is assembled by rubber material implying that, a slight stretch will deform the belts, leading to the rubber flow to the shoulder, and this in turn will result in uneven tires, affecting the tire structure and uniformity.

Since tire building design acts as a bridge between tire semi-finished components design and the finished tire, the accuracy of building design directly affects the qualities of finished tire. The reason why it is prudent to control the large rubber flows in tire building process. In order to manage the rubber large flow during the building process by way of ensuring tire manufacturing accuracy and improve product consistency, tire designers usually use trial and error method to adjust the building design. However, this method is costly and time consuming. Consequently, a more precise design method of semi-finished components is essential.

In the past decades, tire CAE technology has developed rapidly, and the wide use of numerical methods to simulate the tire building process is predominant. The patent document of CN101923589A discloses a simulation technique for constructing a wide-base radial truck tire. Du Xaiowei conducted the finite element simulation of a 385/55 R22.5 steel-wide base radial tire using ABUQUS software. The simulated structure was in good agreement with the actual structure each other. Gao Ming, from Triangle Tire Co., Ltd., is employed to simulate the building process of 215/35R18 tire, as well as the influence of design process parameters on the shape of tire were analyzed. The numerical simulation of the tire building processes is mainly used to visualize the building process of tires outside the vulcanization tank. It is mostly as well employed to analyze the effects of different tire design and building parameters on the finished tires in conventional models of non-wide base radial tires.

Again, the determination method of the carcass bending for the wide-base radial truck tire, the analysis for the rubber flow abnormalities and control method have not yet been publicly reported. Moreover, there is no relevant research on semi-finished tire parts to improve the quality of finished tires.

The Contents of the Patent

Based on the numerical simulation of the building process of the wide-base radial truck tire, the shape of the carcass ply is determined by the carcass rebar force value during the building process. In other words, if the carcass rebar force has negative value, the carcass ply is bending; if the carcass rebar force is all positive value, there is no bending. The building parameters are adjusted until, until the carcass rebar force is all positive, that is, there is no bending in carcass ply.

Based on the numerical simulation of the building process of the wide-base radial truck tire, the structural parameters of the belt drum of the tire building machine are determined based on the anomalous phenomenon of the crown rubber flow in the building process.

The design method of the semi-finished components is determined by numerical simulation of the building process of the wide-base radial truck tire. Through applying the opposite boundary to tire building process, the shape and design parameters of the semi-finished components are determined. The boundary conditions include the roll pressure, the inflation pressure in building process, the friction coefficient among the rubbers and the drums.

The present patent is achieved by the technical means described as below:

The method of the present patent utilizes the positive and negative of the carcass rebar force value at the crown of the finished tire to determine whether or not the carcass ply is bending. The patent has the advantages of wide application range, high precision and generalization ability, and can overcome the shortcomings of the traditional trial and error method, thus effectively improving rubber flow and solving the bending problem of the carcass ply of the wide-base radial truck tire, and improving the tire building quality.

In addition, the proposed method, which is control rubber anomalous flow, is feasible in the tire production process, since only the original drum is coated with a curved film which satisfies the outer surface shape parameter of the curved drum.

The patent also has the advantages of wide application range and high precision, which can overcome the defects of the traditional method and design the material distribution map of the tire semi-finished components accurately, greatly improve the consistency of the tire distribution of the finished tire and the theoretical design tire, reduce the number of tire test, reduce tire manufacturing costs and rise productivity.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart of the present patent.

FIG. 2 shows the uniaxial tensile test and data fitting.

FIG. 3 presents the rubber shear relaxation test and data fitting.

FIG. 4 is the fitting of relaxation modulus using generalized Prony series expansion.

FIG. 5 presents a finite element model tire components, FIG. 5(a) shows the carcass drum components; FIG. 5(b) shows the belt drum components; Figure5(c) shows the triangular rubber components.

FIG. 6 presents the gluing process of the carcass drum components. FIG. 6(a) shows the components before the gluing; FIG. 6(b) shows the components after the gluing.

FIG. 7 presents the gluing process of the auxiliary drum components. FIG. 7(a) shows the components before the gluing; FIG. 7(b) shows the components after the gluing.

FIG. 8 illustrates the green tire building process. FIG. 8(a) is tire fixation; FIG. 8(b) is bead move, FIG. 8(c) is inflation, FIG. 8(d) is sidewall anti-packet, FIG. 8(e) is green tire in two dimensions; FIG. 8(f) is green tire in threedimensions.

FIG. 9 presents the building process of the green tire in vulcanization machine. FIG. 9(a) shows the assembly of tire and vulcanized molds, and FIG. 9(b) is building process, FIG. 9(c) is the finished tire.

FIG. 10 shows the thickness of different position in the finished tire.

FIG. 11 shows the carcass rebar force between C-C and F-F.

FIG. 12 shows the carcass ply is bending in the actual sample tire.

FIG. 13 shows the carcass rebar force during the shoulder and crown (C-C to F-F) after optimum building parameters.

FIG. 14 shows the carcass ply shape after optimizing the building parameters. FIG. 14(a) is the sample tire I; FIG. 14(b) is the sample tire II.

FIG. 15 shows the technology of 0° cap plies winding in wide-base radial truck tire.

FIG. 16 shows the inner unevenness in tire cavity.

FIG. 17 presents building process of the green tire in vulcanization machine with the plane belt drum. FIG. 17(a) is closed mold; FIG. 17(b) is vulcanization.

FIG. 18 shows the position change of the belt 3 using the plane surface drum

FIG. 19 shows the expectant expansion ratio of the belt 3 with using 0° cap plies winding.

FIG. 20 presents the design parameters of the curved surface belt drum.

FIG. 21 shows the gluing process of the tread components using the curved surface belt drum. FIG. 21(a) is the position of tread components; FIG. 21(b) is the gluing process of tread components.

FIG. 22 shows the building process of the green tire in vulcanization machine with the curved surface drum. FIG. 22(a) is closed mold; FIG. 22(b) is vulcanization.

FIG. 23 is the position change of the belt 3 using the curved surface drum.

FIG. 24 is the comparison results of belts rebar force when using the plane surface drum and the curved surface drum. FIG. 24(a) is belts rebar force using curved surface drum; FIG. 24(b) is belts rebar force using plane drum.

FIG. 25 is the cross-section of a sample tire when using the curved surface drum.

FIG. 26 shows the schematic distribution of the theoretical material distribution.

FIG. 27 shows the shape determination of the tread subsystem. FIG. 27(a) is tread subsystem position, FIG. 27(b) is the shape of semi-finished tread subsystem, FIG. 27(c) is the shape of semi-finished tread subsystem after modified.

FIG. 28 shows the shape determination of the carcass subsystem. FIG. 28(a) is carcass subsystem position, FIG. 28(b) is the shape of semi-finished carcass subsystem; FIG. 28(c) is the shape of semi-finished carcass subsystem after modified.

FIG. 29 shows the shape determination of the triangular subsystem. FIG. 29(a) is triangular subsystem position; FIG. 29(b) is the shape of semi-finished triangular subsystem; FIG. 29(c) is the shape of semi-finished triangular subsystem after modified.

FIG. 30 shows the tire components comparison between the simulation section and the theoretical section. FIG. 30(a) shows the shape and distribution of thecomponents of the simulation section, and FIG. 30(b) shows the shape and distribution of the components of the theoreticalsection.

Where:

1—Tire theoretical structure; 2—Part I: tread sub-system; 3—Part II: carcass sub-system; 4—Part III: triangular sub-system; 5—auxiliary; 6—tread; 7—carcass drum; 8—bead; 9—strength; 10—inner; 11—carcass; 12—shoulder; 13—soft-apex; 14—hard-apex.

DETAILED DESCRIPTION

The present patent will now be described in further detail with reference to the accompanying figures and specific examples, but the scope of the present patent is not limited thereto.

As shown in FIG. 1, the improved method for wide-base radial truck tire production process according to the present patent comprises the following three steps:

Based on the numerical simulation of the building process of the wide-base radial truck tire, the shape of the carcass ply is determined by the direction of carcass rebar force in the tire crown during simulation process. In other words, if the carcass rebar force value is all positive value, it means there is no bending in carcass ply; if the carcass rebar force value has negative value, it means there is bending in carcass ply. The building parameters are adjusted until the carcass rebar force value is all positive, then the carcass ply is no bending.

Based on the numerical simulation of the building process of the wide-base radial truck tire, the structural parameters of the belt drum of the building machine are determined based on the anomalous phenomenon of the crown rubber flow in the manufacturing process.

Based on the numerical simulation of the building process of the wide-base radial truck tire, applying the opposite boundary to tire building process, the shape of the semi-finished components is reversal design. Consider of the extrusion die of the rubber, the shape of the semi-finished components are modified, thus the design method of the semi-finished components of the tire is presented.

To illustrate the specific implementation steps, Firstly, the building process of a 385/55R22.5 wide-base radial truck tire is taken as the example, and the building method is verified by test tire components sizes at different positions;

Secondly, based on the simulation method, the carcass ply shape of the 385/55R22.5 wide-base radial truck tire is determined. By optimizing the belt drum circumference and the bead width, the two new sample tires are simulated and analyzed, to make sure the carcass rebar force value are all positive. By the comparison of the sample tires carcass ply shape, it is show that there is no bending in the crown.

Thirdly, the curved surface belt drum is provided to solve rubber abnormal flow problem of the 435/50 R19.5 wide-base radial truck tire, which result into the difference of material distribution between the real manufacture structure and the theoretical structure. From the comparison results of the tire using the plane belt drum and the curved surface belt drum respectively, it is show that the rubber abnormal flow is disappeared.

Fourthly, the reversal design process of a 385/55R22.5 wide-base radial truck tire is taken as the example; by the comparison of the original design method of the tire semi-finished components, it is show that the reversal design method of the tire semi-finished components has a great influence on improving tire product uniformity.

Simulation of Building process of Wide-Base Radial Truck Tire

S1: Tire Rubber Mechanical Test and Constitutive Model Choose

The shear relaxation modulus and stress-strain curve of each rubber of tire were obtained by shear test and the uniaxial tensile test. The reference standards of the shear test and uniaxial tensile test are ISO 289-1:2005 and ISO 37:2005 respectively.

The generalized Maxwell model and Marlow hyper-elastic model were used to characterize the viscous behavior and hyper-elastic property of the unvulcanized rubber. Because there are many type rubbers in tire components, taking the tread rubber and the inner rubber as the examples, it is used to examine the validity of rubber mechanical test and constitutive model. FIG. 2 shows the uniaxial tensile test curves for the tread rubber and the inner rubber. FIG. 3 shows the shear relaxation test curve of the tread rubber and the inner rubber.

ABAQUS assumes that the viscoelastic material is defined by a Prony series expansion of the dimensionless relaxation modulus. For the uncured rubber component investigated, three Maxwell elements result in satisfying results. Thus, the viscous parameters g₁, g₂, g₃ and t₁, t₂, t₃ in Prony model can control the influence of the three Maxwell elements. As shown in FIG. 4, the test data curve is in good agreement with the curve fitted by the generalized Prony model, which suggests that the generalized Prony could express the viscoelasticity mechanical properties of the rubber component properly. The tread and inner rubber parameters for the generalized Prony model are represented in Table 1.

TABLE 1
Material parameters for the generalized Prony model
	Tread		Inner
	gj	τj	gj	τj
1	0.279	0.0023	0.299	0.0029
2	0.248	0.375	0.328	0.415
3	0.121	9.957	0.175	8.539

S2: Establishment of Finite Element Model for Tire Components

(1) According to the build process of the tri-drum single stage building machine, the 385155R22.5 wide-base radial truck tire mainly comprises three components: the carcass drum components, the belt drum components and the triangular rubber components. The carcass drum components comprise a sidewall rubber, an abrasion rubber, a plastic, an inner layer, a strength layer, and a carcass layer and shoulder rubber. While the belt drums components are provided with thebelt1, belt2, belt3, belt0, and tread rubber; the triangular rubber components comprise a bead, a hard-apex rubber and a soft-triangular rubber, and a rubber plastic. To reduce the computing time, half of the model is chosen to simulate the tire building process. According to the building requirements, the finite element model of all the tire components is established. But because of the hard-apex rubber and the soft-apex rubber were co-extruded by two rubber extruder group, the contact relationship of the triangular rubber components is established directly in the Hypermesh Software. The wide-base radial truck tire is simplified as an axisymmetric model. The rubber s components are discredited with CGAX3H and CGAX4H element which model incompressible rubber behavior, Reinforcement materials in the carcass, the belts and enhancement plied are modeled with SFMGAX1 elements that carry rebar layers, which is embedded in continuum rubber components elements. The bead is defined as isotropic material described by C3D8R element; the carcass drum and the belt drum are modeled by the analytical rigid body respectively. All the finite element model of tire components was meshed by using Hypermesh software. All the finite element model of tire components was imported into Abaqus Software to the simulate analysis. FIG. 5(a) shows the finite element model of the carcass drum components, FIG. 5(b) shows the finite element model of the belt drum components, and FIG. 5(c) shows the finite element model of the triangular rubber components. The mesh size is controlled within the range of 3-5 mm in the carcass drum components. The mesh size is controlled within the range of 3-7 mm in the belt drum components. The mesh size is controlled within the range of 4-8 mm in the triangular rubber components.

(2) Contact simulation: during tire building process, the adhesion between the various components is very strong, so the direct constraint method of coulomb friction is used to simulate the contact behavior between the different tire components.

S3: Tire Building Process Simulation

(1) Gluing of Components on the Carcass Drum

The tire sidewall, abrasion, filler, inner, down inner, strength, carcass, shoulder pad are glued sequentially on the carcass drum. The purpose of this process is to bond different components using the cohesive property of rubber components. In the process of gluing, the finite element model of each component is established according to the tire construction design. The uniform pressure is sequentially applied on the surface of each rubber component to simulate the gluing process. The results are shown in FIG. 6(a) and FIG. 6(b).

(2) Gluing of Components on the Belt Drum

The components, including belt1 lay, belt2 lay, belt3 lay, belt0 lay and tread are glued sequentially on the belt drum. During the process of simulation, each component is analyzed in turn. The process of attaching is realized by exerting two-stage uniform pressure when the tread is glued. Firstly, the crown components are glued using Pressure 1, then the shoulder components are glued by Pressure 2. The pressure in the shoulder pad location (Pressure 2) is larger than that of in the center of tread (Pressure 1), which is determined by the practical manufacturing pressure. The results are shown in FIG. 7(a) and FIG. 7(b).

(3) The Building Process of the Green Tire

The building process of the green tire is performed in three stages: inflation, stitching and sidewall turn-up. First, the components on both the carcass drum and belt drum, and the bead are positioned as shown in FIG. 8(a); coinciding with increasing inflation pressure P (0.1 MPa-0.2 MPa) applied on the tire inner, the beads are displaced (L_m) (FIG. 8(b)). Secondly, when the contact between the carcass and belts is attained, the stitching pressure (L_r) acts on the tread, and the belts complete gluing (in FIG. 8c). Third, the turn-up bladder pressure P (0.2 MPa-0.4 MPa) is stepwise applied on the surface from the abrasion to the sidewall until the turn-up process is finished (FIG. 8(d)). Finally, the inflation pressure is reduced to zero. The two-dimensional final shape of the green tire is presented in FIG. 8(e), and the three-dimensional final shape of the green tire is presented in FIG. 8(f)

(4) The Building Process of the Finished Tire

The molding process of the tire curing is carried out in the capsule vulcanizing machine. The green tire is a deformable body, and the curing mold is simulated as rigid body (FIG. 9(a)). First, the bladder is evacuated, the green tire is then set outside of the bladder with an inflated pressure of 0.9 MPa (Pressure P1), and the green tire and bladder are held together by rubber friction. Second, the molds are closed, and then, the internal pressure of the inner surface is increased to 2.5 MPa (Pressure P2) until the process of tire curing complete, as indicated in FIG. 9(b) and FIG. 9(c). To simplify the analysis, the influence of the curing bladder is neglected, and the uniform pressure P1 and P2 are directly applied on the inner surface of the green tire.

(5) Experimental Verification of Tire Building Simulation

To validate the tire building simulation, the thickness of tire components in five locations ((A-A, B-B, C-C, D-D and E-E)) (FIG. 10) are selected for checking simulation results, and the analysis of thickness of the five locations are presented in Table 2, 3, 4, 5 and 6 respectively. The simulation error is defined as the thickness difference between the simulated structure and that of the real structure. Similarly, the manufacture error is defined as the thickness difference between the real structure and the theoretical structure.

As shown in Table 2-6, the analysis of thickness indicates that the simulation structure material distribution is particularly similar to the real structure, which proves that the tire building process simulation method is effective. However, the error between the real structure and the theoretical structure is relatively large, especially in the tread, tire shoulder and apex. Moreover, the shapes of these components have a great influence on the material distribution of the finished tire.

TABLE 2
Thickness comparison of A-A location
	Thickness	Thickness	Thickness
	of simulation	of real	of theoretical	Simu-	Manu-
	structure	structure	structure	lation	facture
A-A	[mm]	[mm]	[mm]	error/%	error/%
tread	18.53	20.00	17.65	7.4	13.31
Belt1	2.65	2.40	2.32	10.4	3.44
Belt2	2.87	2.60	2.45	10.3	6.12
Belt3	1.81	2.00	2.05	9.5	2.44
carcass	1.78	2.00	3.05	11.0	34.43
inner	3.38	3.80	3.20	11.1	18.75

TABLE 3
Thickness comparison of B-B location
	Thickness	Thickness	Thickness
	of simulation	of real	of theoretical	Simu-	Manu-
	structure	structure	structure	lation	facture
B-B	[mm]	[mm]	[mm]	error/%	error/%
tread	17.07	16.80	14.43	1.61	16.42
Belt0	3.62	3.50	3.18	3.43	10.06
Belt1	1.93	2.05	2.00	5.85	3.50
Belt2	2.23	2.50	2.00	8.92	12.5
carcass	2.02	2.00	3.05	1.00	34.43
inner	2.90	3.05	3.20	4.92	9.38

TABLE 4
Thickness comparison of C-C location
	Thickness	Thickness	Thickness
	of simulation	of real	of theoretical	Simu-	Manu-
	structure	structure	structure	lation	facture
C-C	[mm]	[mm]	[mm]	error/%	error/%
tread	24.01	24.50	22.00	2.00	11.36
shoulder pad	7.82	7.80	6.11	0.26	27.66
carcass	2.15	2.50	3.05	14.0	18.03
inner	3.17	3.10	3.20	2.26	3.12

TABLE 5
Thickness comparison of D-D location
	Thickness	Thickness	Thickness
	of simulation	of real	of theoretical	Simu-	Manu-
	structure	structure	structure	lation	facture
D-D	[mm]	[mm]	[mm]	error/%	error/%
sidewall	6.05	6.40	6.20	5.4	3.22
carcass	2.66	2.50	3.05	6.4	18.03
inner	3.49	4.00	3.20	12.5	25.00

TABLE 6
Thickness comparison of E-E location
	Thickness	Thickness	Thickness
	of simulation	of real	of theoretical	Simu-	Manu-
	structure	structure	structure	lation	facture
E-E	[mm]	[mm]	[mm]	error/%	error/%
abrasion	5.25	6.50	4.70	19.23	38.30
strength	3.05	2.90	3.00	5.17	3.33
carcass	2.62	2.50	3.05	4.80	8.19
apex	18.22	17.50	14.21	4.11	23.15

Determination Method of the Carcass Ply Shape

S4: Carcass Rebar Force in the Finished Tire Analysis

The carcass rebar force of the finished tire 385/55R22.5 at the crown is derived from simulation process, and if the carcass rebar force value is all positive value, the carcass ply is no bending; if the carcass rebar force has negative value, the carcass ply is bending.

Specifically, a node path is created for extracting the carcass rebar force at the crown of the finished tire, as shown in FIG. 10. The rebar force distribution along the width of the CC-FF segment within the carcass is shown in FIG. 11. It can be seen from FIG. 11 that the carcass rebar force at the center of the crown is negative. According to the method of the present patent, it is determined that the carcass ply at the finished tire crown should be bending. The actual tire is split and the carcass ply shape is shown in FIG. 12. It can be seen that the carcass ply is bending at the tire crown, which is consistent with the predicted result of the method described in the present patent.

In order to put the proposed method into practice to guide actual tire building, the building design parameters of the belt drum circumference and the bead width are adjusted. By optimizing the belt drum circumference and the bead width, the new two sample tire are simulated and analyzed, to make sure the carcass rebar force are all positive. For the sample tire I, the belt drum circumference is 2674 mm, which add 4 mm for the original size, and the bead width is 786 mm, which decrease 4 mm for the original size. For the sample tire II, the belt drum circumference is 2674 mm, which add 4 mm for the original size, and the bead width is 782 mm, which decrease 8 mm for the original size. The carcass rebar force in the sample I and the sample II are shown in the FIG. 13.

As seen in the FIG. 13, the carcass rebar force value in the two sample tires are all positive, which means that the carcass ply in the two sample tires will be no bending. According to the adjusted building parameters, the two sample tires are manufactured and split. The shapes of the carcass ply in the two sample tires are shown in FIG. 14, which shows that the carcass ply does not exist bending, and basically consistent with the predicted results. This shows that the method of determining the bending of the carcass ply in the finished tire is accurate, which can meet the demand of the actual engineering application, and can be popularized in the tire industry to provide guidance for the building process of wide-base radial truck tire.

Design Method of Belt Drum of Tire Building Machine

S5: Design of the Curved Surface Belt Drum

The crown of a wide-base tire (435/50R19.5) has five cord layers, and the belt 3 is made using the 0° cap plies winding technology (FIG. 15). In other words, the successive belts have 0° winding in the tire crown so that the 0° cap plies winding technology can maintain the tire ground pressure distribution uniformity and improve the grip and wear performances. However, because of the particularity of the 0° cap plies windings technology, the belt 3 ply is tied severely, and it has larger stiffness. During the actual tire building process, the crown component does not flow easily from the middle to the side, and this results in the inner unevenness in the tire cavity such that the abnormal crown is generated (which is shown in FIG. 16), which leads to inner unevennes.

The simplified building process of the 435/50R19.5 green tire with the plane drum in the vulcanizer is shown in FIG. 17. It can be seen from FIG. 17 that the shoulder component is in contact with the mold; however, the center of the crown component is not. The belt 3 location in the building process and its actual position in the tire are shown in FIG. 18. During the building process, the shoulder contacts the mold firstly, and thus, the building pressure is mostly born by the shoulder; the middle of the crown is offset to the mold, and the belt ply bears the building pressure. If the building pressure increases, the belt ply will not move to the actual assigned position. Furthermore, in order to fill the gap between the crown and mold, the tread component rubber will flow from the shoulder to the middle crown due to the high dynamic flow property of the unvulcanized rubber. Thus, the abnormal crown present in FIG. 16 is generated.

FIG. 19 shows that the comparison of the material distribution between the green tire and the theoretical tire. It can be seen from FIG. 19 that the distance between the belt3 in the green tire and in the theoretical tire is Δr in warp direction, the elongation ratio of belt3 is

$\delta =\frac{\Delta r}{R_1}=\frac{R_0-R_1}{R_1}\times 100\%,$

where R₁ and R₀ is the belt 3 radials in the green tire structure and in the theoretical tire respectively.

To solve the abnormal inner unevenness problem (FIG. 16), the curved surface belt drum design method is provided. The surface of the belt drum is not a plane but is instead curved. By virtue of the curved surface belt drum, the extensional quantity of 0° cap plies winding belt at different positions will keep in uniformity extended ratio during the green tire building process, and thus guarantee equal force in the middle crown.

The cross-sectional profile of the belt drum consists of two straight lines and an curved line, which are shown in FIG. 20. The width d of the curved line is 80%-120% of the width of the belt3 in the tire theoretical material distribution; the radius of curvature R of the curved line is 70% -130% of the radius of curvature of the belt 3; the diameter of the belt drum is D, and the length of the two straight segments are l₁ and l₂ respectively:

$D=\frac{D_1}{1+\delta }$ $l_1=l_2=\frac{L-d}{2}$

Where L is the total width of belt drum, and D₁ is the radius of curvature of the belt3 measured in the tire theoretical material distribution; the elongation ratio δ of belt3 is 0.2-1.0%;

The width of the curved line width d, the radius of curvature of the curved line R and the diameter of the belt drum D can be adjusted to meet the belt 3 expected elongation ratio within 0.2-1.0%.

In order to better determine the shape parameters of the curved surface belt drum, it is preferable to determine the main design parameters of the curved surface belt drum by the simulation of tire building process S3.

The tire building process using the curved surface belt drum is presented via the simulation method in S3. The gluing of the tire crown components on the belt drum is shown in FIG. 21. It can be seen from FIG. 21 that the belts are arcshaped after gluing is completed. The building process in the vulcanizer is shown in FIG. 22. As shown in FIG. 22, the arc-shaped belts are in accord with the curvature of the mold, the crown components directly contact the mold, and the extensional ratios of the tire belt at different positions are the same. As seen from the simulation results shown in FIG. 22, the abnormal crown problem disappears.

The location change of the belt 3 is shown in FIG. 23. It can be seen from FIG. 23 that the extensional ratios in different positions are the same, and the position of the belt 3 in the vulcanizer is in accordance with the theoretical material distribution. The comparison of rebar force of the belt1, belt2, belt3, belt4, belt5 using the curved surface drum and the plane drum is shown in FIG. 24, which shows that the rebar force of the five belts using the curved surface drum in the middle of the crown decreases significantly, and the rebar force gradient reduces in the meridian direction.

S6: To Validate the Accuracy of the Curved Surface Belt Drum

According to the design parameters in FIG. 20, the curved surface drum is made by sticking arc-shaped rubber on the surface of the plane drum. The sample tire section made by the curved surface drum is shown in FIG. 25. From the comparison results of FIG. 16 and FIG. 25, the sample tire has a good section and the abnormal inner unevenness problem does not appear. In addition, the material distribution of the sample tire is consistent with the theoretical material distribution.

Reversal Design Method of Tire Semi-Finished Components

Tire semi-finished components design method including test rubber mechanical property, choose constitutive model, and establish finite element model, semi-finished components reversal design and building simulation verification.

S7: Tire Rubber Mechanical Test and Constitutive Model Choice

The shear relaxation modulus and stress-strain curve of each rubber were obtained by shear test and the uniaxial tensile test. The reference standards of the shear test and uniaxial tensile test are ISO 289-1:2005 and ISO 37:2005 respectively. The generalized Maxwell model and Marlow hyper-elastic model were used to characterize the viscous behavior and hyper-elastic property of the unvulcanized rubber. Because there are many type rubbers in tire components, taking the tread rubber and the inner rubber as the examples, it is used to examine the validity of rubber mechanical test and constitutive model. The choice method of the rubber constitutive model is consistent with S1.

S8: Establishment of Finite Element Model for Tire Components

According to the building requirements, the finite element model of all the tire components is established. The wide-base radial truck tire is simplified as an axisymmetric model. The rubber components are discredited with CGAX3H and CGAX4H element, which present incompressible rubber behavior; Reinforcement materials in the carcass, the belts and enhancement plied are modeled with SFMGAX1 elements that carry rebar layers, which is embedded in continuum rubber components elements. The bead is defined as isotropic material described by C3D8R element.

The tire theoretical marital distribution is divided into three parts for rubber components reversal design, as shown in FIG. 26, which are named as tread subsystem Part I, carcass subsystem Part II, and triangular subsystem Part III. The tread subsystem Part I only comprises a tread (6); the carcass subsystem Part II comprises a carcass, a strength, an inner and a shoulder, the triangular subsystem Part III comprising a bead (8), a soft apex (13) and a hard apex (14). The three Parts are meshed with element size is 3-6 mm. All the finite element model of tire components was meshed by HYPERMESH software.

(2) Contact simulation: during tire building process, the adhesion between the various components is very strong, so the direct constraint method of coulomb friction is used to simulate the contact behavior between different tire components.

S9: Reversal Design for Tire Semi-Finished Components

(1) Reversal Design of Tread Subsystem Part I

The shape and position of the tread (6) obtained from the tire theoretical material distribution, which is shown in FIG. 27(a). The tread (6) is formed into plane as a rigid body (5) by means of the simulation method, the shape of the tread (6) is reduced to the shape of the semi-finished part of the green tire (1).

The specific process in the simulation is: a plane rigid body (5) is provided on the inside of the tread (6), and the rigid body (5) is moved to outside of the tread (6), at the same time, a uniform pressure P is applied to the tread (6) outside. The rigid body move and the uniform pressure work together to obtain the shape of the tread (6) by the reverse simulation. The shape of the tread (6) is shown in FIG. 27(b). Synthesizes considering the shape of tread in FIG. 27(b) and extruding die size of the tread (6), and the reverse shape of the tread (6) of the semi-finished part is shown in FIG. 27(c). It should be pointed out that the present method ignores the pattern groove. It should be noted that the present method ignores the pattern groove. If the pattern groove is considered, according to the principle of rubber volume invariably, and the groove relative position and groove volume in the theoretical material distribution, the shape of the semi-finished part of the tread (6) is obtained by subtract the shape of the pattern groove.

(2) Reversal Design of Carcass Subsystem Part II

The radial extension ratio of inner (10) and carcass (11) is not uniform at different position, where the maximum extension ratio occurs at the crown of tread (6), the minimum occurs at the bead (8). Although, the thickness of each of them at different position after inflation is inequality, the volume remains unchanged before and after expansion. The shoulder rubber (12) will appear radial extension and bending during tire building process, but its volume is invariant. In the reversal design simulation, the shape of the carcass (11), the inner (10) and the shoulder (12) are determined according to the shape and position of the theoretical material design. A uniform pressure is applied to the outside of the carcass (11) as shown in FIG. 28(a), and the bead (8) moves to two sides, thus the carcass (11) and the inner (10) are spread on the carcass drum (7), and the reversal simulation result is shown in FIG. 28(b). According to the extrusion die of each component, the shape of the modified tire semi-finished components of Part II is shown in FIG. 28(c).

(3) Reversal Design of Triangular Subsystem Part III

During tire building process, the hard apex and the soft apex are rotated around the bead (8) (as shown in FIG. 29(a)), and the radial expansion ratio is small. In the reversal building simulation, the shape of the triangular subsystem components is determined according to the shape and position in the theoretical material design. The bead (8) is fixed and a uniform pressure is applied to the outside of the hard-apex (as shown in FIG. 29(b)). According to the extrusion die of the triangular rubber, the shape of the modified semi-finished parts of Part III is shown in FIG. 29(c).

(4) Determination of the Shape of Other Tire Components

During the sidewall anti-package process, the capsule squeezes the sidewall and the abrasion, but these deformations are very small. Besides, the shape, width and thickness of the belt ply remains unchanged, so the shape of belt ply can be directly determined from the tire theoretical material design.

(5) Tire Building Simulation Verification

The semi-finished components obtained from step S9 are subjected to the forward building simulation of step S3, and the simulation results of the shape and distribution of each component are shown in FIG. 30(a). FIG. 30(b) shows the shape and distribution in the theoretical material design. The comparison result from FIG. 30 shows that the consistency of the two is very good. In other words, the reversal design method for tire semi-finished components has a great influence on improving tire product uniformity.

The example presented above are preferred practice of the present patent, however, the patent is not limited to the practice described above. Any modifications, substitutions of the patent are subject to the patent protection.

Claims

1. A method for wide-base radial truck tire production comprising the following three steps: (A) based on a numerical simulation of the building process of the wide-base radial truck tire, the shape of the carcass ply is determined based on the positive and negative of the carcass rebar force value during the finished wide-base radial truck tire; finite element method was used to improve the tire building process parameters, and to adjust the tire production process parameters, until the carcass rebar force is positive, which means, there is no bending in carcass ply;(B) based on the numerical simulation of the building process of the wide-base radial truck tire, the structural parameters of the belt drum of the tire molding machine are determined based on the anomalous phenomena of the crown rubber flow in the manufacturing process of the wide-base radial truck tire; and(C) through the numerical simulation of the building process of the wide-base radial truck tire, the design parameters of the semi-finished components of the tire are determined by judging the shape of the semi-finished components of the manufacturing process of the wide-base radial truck tire.

2. The method, according to claim 1, further comprising the steps of: applying the determined structural parameters of the tire manufacturing process and the belt drum of the tire molding machine in the actual production of the wide-base radial truck tire; from the comparison results of the carcass ply shape, rubber flow in crown between the simulation and the actual production, it is showed that the feasibility of improved production process for the wide-base radial truck tire.

3. The method, according to claim 1, the design method of the semi-finished components is determined by numerical simulation of the building process of the wide-base radial truck tire; through applying the opposite boundary to tire building process, the shape and design parameters of the semi-finished components are determined; from the comparison results of tire components shape and material distribution between the simulation and theoretical design, it is showed that the feasibility of improved production process for the wide-base radial truck tire.

4. The method, according to claim 1, the numerical simulation of the building process of the wide-base radial truck tire includes the following steps: (A1) tire rubber mechanical test and constitutive model selection:the shear relaxation modulus and stress-strain curve of each rubber were obtained by shear test and the uniaxial tensile test; the generalized Maxwell model and Marlow hyper-elastic model were used to characterize the viscous behavior and hyper-elastic property of the unvulcanized rubber;(A2) establishment of finite element model for tire components,(A2a) according to the build process of the tri-drum single stage building machine, the 385/55R22.5 wide-base radial truck tire are mainly composed of three components: the carcass drum components, the belt drum components and the triangular rubber components; the carcass drum components comprise a sidewall rubber, an abrasion rubber, a plastic, an inner layer, a strength layer, and a carcass layer and shoulder rubber; while the belt drums components are provided with thebelt1, belt2, belt3, belt0, and tread rubber; the triangular rubber components comprise a bead, a hard-triangular rubber and a soft triangular rubber, and a rubber plastic; to reduce the computing time, half of the model is chosen to simulate the tire building process; according to the building requirements, the finite element models of all the tire components are established; the wide-base radial truck tire is simplified as an axisymmetric model; the rubber components are discredited with CGAX3H and CGAX4H element which model incompressible rubber behavior; reinforcement materials in the carcass, the belts and enhancement plied are modeled with SFMGAX1 elements that carry rebar layers, which is embedded in continuum rubber components elements; the bead is defined as isotropic material described by C3D8R element; the carcass drum and the belt drum are modeled by the analytical rigid body respectively; all the finite element model of tire components was meshed by using HYPERMESH software; all the finite element model of tire components was imported into ABAQUS Software for further analysis;(A2b) the mesh size is controlled within the range of 3-5 mm in the carcass drum components; the mesh size is controlled within the range of 3-7 mm in the belt drum components; the mesh size is controlled within the range of 4-8 mm in the triangular rubber components;(A2c) according to the tire drum structure parameters of the tire molding machine, the analytical rigid body is used to simulate the mechanical characteristics of the belt drum structure;(A2d) during tire building process, the adhesion between the various components is very strong, so the direct constraint method of coulomb friction is used to simulate the contact behavior between the different tire components;(A3) simulation of tire building process.,(A3a) according to the build process of the tri-drum single stage building machine, the tire sidewall, abrasion, filler, inner, down inner, strength, carcass, shoulder padare glued sequentially on the carcass drum, and form the carcass drum components; the components, including belt1 lay, belt2 lay, belt3 lay, belt0 lay and tread are glued sequentially on the belt drum, and form the belt drum components because of the hard-apex rubber and the soft-apex rubber were co-extruded by two rubber extruder group, the contact relationship of the triangular rubber components is established directly in the HYPERMESH Software;(A3b) the three components models of the carcass components, the belt drum components and the triangular components in (A3a) are respectively introduced into the ABAQUS software; according to the tire construction schedule, the carcass components and the belt drum components are successively assembled on the building drum and triangular rubber components is positioned on the building drum; the inflation process is realized by acting 0.1 MPa-0.2 MPa uniform pressures on the tire inner; the beads are displaced to stereotype location; the turn-up process of the sidewall is carried out by applying 0.2 MPa-0.4 MPa uniform pressure on the surface from the abrasion to the sidewall until the turn-up process is finished, and the green tire is presented;(A3c) The-the green tire obtained in (A3b) is put into the vulcanizing tank, and it is located by applying a uniform pressure P1 0.9 MPa on the inner surface; then the molds are closed, and then, the internal pressure of the inner surface is increased to P2 2.5 MP until the process of tire curing complete, and the finished tire is presented.

5. The method, according to claim 4, wherein the method for determining the tire carcass ply shape includes the following: after the finished tire (A3c) is obtained, the shape of the carcass ply is determined by the direction of carcass rebar force in the tire crown during simulation process; if the carcass rebar force value is all positive value, it means there is no bending in carcass ply; if the carcass rebar force value has negative value, it means there is bending in carcass ply.

6. The method, according to claim 2, wherein the steps of obtaining the curved surface parameters of belt drum includes the following steps: (A) preliminary determination of the structural parameters of the tire drum: the middle section of the belt drum is designed as a convex curved surface structure, and the cross-sectional profile of the belt drum consists of two straight lines and acurved line; the radius of curvature of the curved line is defined as R, and the width of the curved line is defined as d; the diameter of the belt drum is D, and the length of the two straight segments is l1 and l2 respectively:

7. The method, according to claim 6, wherein the structural parameters of the belt drum are initially determined in the step (B); the width d of the curved line is 80%-120% of the width of the belt3 in the tire theoretical material distribution; the radius of curvature R of the curved line is 70%-130% of the radius of curvature of the belt 3.

8. The method, according to claim 4, the reversal design method of tire semi-finished components is as follows: (A) the tire theoretical marital distribution is divided into three parts for rubber components reversal design, which are named as tread subsystem Part I, carcass subsystem Part II, and triangular subsystem Part III; through applying the opposite boundary to tire building process in the claim 4, the shape and design parameters of the semi-finished components are determined; the boundary conditions include the roll pressure, the inflation pressure in building process, the friction coefficient among the rubbers and the drums; consider of the extrusion die of the rubber, the shape of the semi-finished components are modified, thus the design method of the semi-finished components of the tire is presented:(B) tire building simulation verification: the determined shape and design parameter of the semi-finished components is used to tire building simulation of the claim 4; analyzing and contrasting the components shape and material distribution of simulation design and theoretical design; it is used to present that the reversal design method of tire semi-finished components is a practical way.

9. The method, according to claim 8, wherein the three subsystem models in tire semi-finished components design method include a plurality of rubber models and a rebar-rubber composite material.

10. The method, according to claim 8, wherein the three subsystem models in tire semi-finished components design method are axisymmetric models.

11. The method, according to claim 1, wherein the rubber model employs a viscoelastic constitutive model, and comprising at least stress-strain data, Poisson's ratio and relaxation modulus.

12. The method, according to claim 1, wherein the rebar-composite material is characterized by a rebar model, and comprising at least the density, the cross-sectional area and the angle of the steel-cord in belt ply and carcass ply.