Elastomer Engineering CUTTING-EDGE CONTINUING EDUCATION - FALL 2010 SCE-RUBBER.UWM.EDU

Transcription

1 Elastomer Engineering CUTTING-EDGE CONTINUING EDUCATION - FALL 2010 SCE-RUBBER.UWM.EDU

2 Optimize Performance. Inspire Innovation. Elastomer technology is permeating nearly every industry today. To answer increased demands, you must be at the forefront of innovation and efficiency. Thankfully, you ve found cutting-edge continuing education. From efficiency to extrusion, our comprehensive courses cover essential topics to help you maximize your knowledge, productivity and marketable skills. Each course is led by practitioner instructors who have the real-world experience to ensure your real-life success. They are teachers, innovators and most importantly they are engineers who understand the field. For more details and to learn how we can bring courses to you, contact me at or Sincerely, Murali Vedula Engineering Program Director UWM School of Continuing Education sce-eng.uwm.edu MURALI VEDULA Program Director Dr. Murali Vedula worked in engineering at Dow Chemical Company and Structural Composites Industries for several years before joining UWM in For the past 13 years, Dr. Vedula has used his engineering knowledge and contacts to identify professional development needs, including elastomer and plastics technology, electrical engineering, innovation, mechanical and industrial engineering, and Six Sigma. In response to changing demographics, he has restructured Six Sigma certificate programs to meet the needs of the service industry. In add ition, he recently began offering an Office Lean certificate program and has been involved with internal Lean training. His latest emphasis is on innovation. He currently serves on the Board of the Society of Plastics Engineers Milwaukee Chapter. DEBRA O NEIL Program Associate oneil@uwm.edu Debra O Neil has been with the School of Continuing Education for over15 years, nine of which she was a program associate supporting public and corporate Engineering programs. She assists with the coordination of course scheduling, materials assembly, program content, marketing, inquiries and billing. She is customer service oriented and enjoys working with program participants.

3 I COULD TAKE EVERYTHING BACK AND IMMEDIATELY APPLY IT TO MY WORK." - Engineering participant "I LEARNED NEW METHODOLOGIES THAT RESULTED IN BOTH HARD AND SOFT COST SAVINGS AT MY JOB." - Engineering participant TABLE OF CONTENTS Rubber Technology Molding of Rubber and Design of Rubber Molds...4 Rubber Extrusion Technology...5 Rubber Compounding and Mixing for Performance...6 Silicone Elastomers Technology and Fabrication...7 Innovation Accelerated Product Development - Using Product Realization...8 Quality/BPI Six Sigma Black Belt...9 Instructors...10 General Information...11 Onsite Training...Back Cover Learn how to earn a Rubber Technology Certificate or visit sce-rubber.uwm.edu ASK US Interested in the following programs? Contact Murali Vedula at or mvedula@uwm.edu for more information. Design of Resilient Products Dynamic Properties of Rubber Product Performance Rubber Adhesion: Principles & Practices Technical Creativity

4 Rubber. MOLDING OF RUBBER AND DESIGN OF RUBBER MOLDS Gain integrated insight into rubber molding beginning with the flow behavior of thermoplastic and crosslinking materials, and finishing with the behavior of these materials in molding processes. Review methods and equipment needed for successful molding and study current principles and techniques in the design of molds and molded parts. Focus is primarily on the design and molding of mechanical rubber goods with limited reference to tire molding. Who should attend Materials and process engineers, rubber mold designers, quality control personnel and managers responsible for these functions. Attendees are encouraged to bring drawings or parts that experience problems in production for discussion by course instructors. Wed.-Fri., Oct., 13-15, 2010* 8am-4:30pm Instructors: John Sommer, Terry Chapin, Richard Steiner, Van Walworth Fee: $1190 CEUs: 2.0 Program No *Same week as Rubber Mini EXPO COURSE OUTLINE Rubber Materials - Description - Shrinkage - Types - Adhesion - Flow Behavior Molding Methods - Compression - Blow - Transfer - Casting - Injection - RIM Molds - Fouling - Cleaning Mold Design - Design Process - Information Gathering - Parting Line Considerations - Overflow Considerations - Part Feeding Sprues Ring Feed Pin Feed Tab Feed Submarine Gate - Cavity Spacing - Mold Construction Mold Plates Core Pin / Inserts Leader Pins / Bushings Material Selection Durability Spring Assists - Compression Molds - Transfer Molds - Injection Molds - Injection-Transfer - Additional Topics CAD in Molds Design Cold Runner Blocks Designing of Parts for Manufacturability - Rubber Part Tolerancing - Mold Debug - How to Solve Molding Problems Through: Part Redesign Mold Redesign Process Modification Material Changes - Troubleshooting the Rubber Molding Process Versatile Mold Design for Optimizing Development of Rubber Products - Prototype Considerations - Initial Molding Methods - Use of CAD in Design - Combination Molds - Progressive Molds - Nesting - Special Features 4 sce-rubber.uwm.edu

5 RUBBER EXTRUSION TECHNOLOGY Examine all aspects of the rubber extrusion process. Evaluate products from intricate profile extrusions, to tires using composition ranging from a single thermoplastic elastomer to multiple dense and cellular compounds coextruded with carriers and reinforcements. Who should attend Materials and process engineers, die designers, quality control personnel, supervisors and managers responsible for these position. Wed.-Fri., Apr , am-4:30pm Instructors: James Stevenson, John Dick Fee: $990 CEUs: 1.8 Program No COURSE OUTLINE MATERIALS Elastomer Properties - Chemical Structure - Molecular Weight/Distribution - Morphology and Crystallinity - Viscosity (Flow) - Elasticity (Swell) - Scorch Laboratory Tests for Extrudability - Mooney Viscometer - Processability Testers - Standard Dies (Garvey) - State of Cure Tests Compound Ingredients - Elastomers - Fillers - Plasticizers and Process Aids - Cure Systems/Nitrosamines Processing and Compounding - EPDM - Polychloroprene (Neoprene) - SBR/BR - Nitrile Rubber - Chlorosulfonated Polyethylene - Silicone Rubber - Fluoroelastomers PUMPING EQUIPMENT Screw Extruder - Types (Hot/Cold Feed) - Barrels and Screws - Vented Extruders - Continuous Mixers/Twin Screw Extruders - Feed Devices Ram (Preform) Extruders Auxiliary Devices - Shear Head - Cavity Transfer Mixer - Gear Pump Drives and Transmission Temperature Control SHAPING EQUIPMENT Heads - Inline Heads - Crossheads - Tire Heads - Breaker Plates - Screen Changers Dies - Types and Design Criteria - Flow - Drawdown - Sheet Dies, Profile Dies - Design Computations - Die Relief Strategies - Finite Element Simulation DOWNSTREAM EQUIPMENT Continuous Cure (Low Pressure) Batch Cure Hose Manufacture INSTRUMENTATION Instrumented Extrusion Line Temperature Sensors Pressure Sensors Dimension Sensors Weight and Area Sensors Property Sensors - Extrudate Temperature - Conveyor Operation - Extrudate Contraction - Extrudate Curvature Productivity and Quality - Optimum Conditions - Feed Strip Geometry - Feed Mill Operation - Adjustments on Pin Barrels - Screw and Barrel Wear - Starved Operation - Die Drool Process Variation and Control - Statistical Process Control - Feedback Control - Size Control - Shape Control - Online Measurement Guide - Commercial Controls ADVANCED TECHNOLOGIES Changing Extrudate Shape Switching Feed Streams Directed Flow Technology - Rapid Die Change - Dimensional Control Multiextruder Control Low Resistance Dies TROUBLESHOOTING Product Geometry Extruder Operation Compound REFERENCES OPERATIONS Books Extruder Dynamics - Flow in Screw Pumps Papers - Operating Curves sce-rubber.uwm.edu

6 RUBBER COMPOUNDING AND MIXING FOR PERFORMANCE Get an intensive overview of rubber compounding and mixing as well as a review of methodologies for solving factory problems. Review latest developments in compounding and mixing technology and procedures. Who should Attend Both entry-level and experienced rubber technologists, rubber chemists, process engineers, laboratory managers, supervisors, technicians, shop foreman, quality assurance managers and engineers, technical sales pers nnel, and rubber producers and users. Wed.-Fri., Nov , am-4:30pm Instructors: John S. Dick, Peter C. Surette, Sr. Fee: $1290 CEUs: 2.0 Program No COURSE OUTLINE Introduction - History - Basics of Formulating - Key Processability Characteristics - Common Factory Problems and Possible Causes Rubber Testing - Five Categories of Processability Tests - Miniature Internal Mixers and Extruders - Rotational Viscometers - Mooney Viscosity - Rheometers - Rotorless Curemeter - Assignable Causes of Variation Rubber Process Analyzer ASTM Standard Test Conditions Rheological Profiles of Raw Rubber Rheology and State of Mix Stress Relaxation Tests General Purpose Elastomers - Different Polymer Backbones - Crystallinity on Stretching - Natural Rubber; SBR; Polybutadiene; EPDM - EPDM and Sponge Formulations Unit 4 Specialty Elastomers - Curing Silicone Rubber with Peroxide - Advantages of Platinum Cures Mixing - Tangential vs. Intermeshing - Rotor Design - Friction Ratios - Dispersive mixing vs. Distributive Mixing - Importance of Order of Addition of Ingredients One Pass vs. Two Pass vs. Three Pass Dump Mill, Cooling Batches, Phase Mixing Carbon Black Distribution in a Rubber Blend Filler and Oil Systems - Plasticizer Performance - Carbon Black Oil Balance - Silica, Clay, Calcium Carbonate, Titanium Dioxide Rubber Chemicals - Rubber Cure Systems - Activators (Zinc Oxide and Stearic Acid) - Sulfur Vulcanization - Blowing Agents - Activator Selection Compounding for Dynamic Performance Properties - The "Three Ps" - Rubber Compound Economics - The Selection of an Optimal Filler / Oil System - Selection of an Optimal Cure Package Lab DOEs and Field Trials Introduction to Factory Problems Statistics and Methodologies for Solving Factory Problems - Basic Statistical Methods - Corrective Actions in the Short Term - Strategy for establishing long term solutions to chronic problems - Six Sigma Techniques Nature and Techniques for Solving Problems in Rubber Compounding and Processing - Changing one-variable-at-a-time technique for improvement of a rubber compound - Applying a Design of Experiment Interactions Case Studies of Rubber Compounding and Processing Problems 6 sce-rubber.uwm.edu

7 SILICONE ELASTOMERS TECHNOLOGY AND FABRICATION Get a comprehensive overview of silicone elastomers, including basic silicone chemistry, types of silicone elastomers, manufacturing processes, fabrication techniques, problem solving, and application areas. Emphasis is on liquid injection molding (LIM/LSR) with detailed information in the areas of material selection, dispensing methods, injection molding process, tool design, and bonding alternatives. This course is presented by a panel of experts in the silicones field, and time is allotted for discussion of specific projects of interest. Who should Attend Both entry-level and experienced rubber technologists, rubber chemists, process engineers, laboratory managers, supervisors, technicians, shop foreman, quality assurance managers and engineers, technical sales pers nnel, and rubber producers and users. Mon.-Wed., Nov , am-4:30pm Instructors: Mel Toub, John Timmerman, Rick Finnie, Juergen Giesow, Bob Pelletier Fee: $1090 CEUs: 2.0 Program No COURSE OUTLINE Silicone Elastomer Technology - Silicone Product Categories - Why Silicone? - Silicone Markets and Applications - Silicone Manufacturing Process - Nomenclature - HCE / HCR Technology - LIM / LSR Technology - Testing and Specifications - Elastomer Properties Liquid Silicone Rubber (LSR / LIM) - Why Liquid Silicones? - Comparison with HCE And TPE - Process Overview - Dispensing Systems - Injection Equipment - Molding Parameters - Automation - Demolding - Troubleshooting Tooling Design and Construction - Materials - Machining Methods - Hot Runner vs Cold Runner - Valve Gate vs Open Gate - Venting and Gating - Cavitation - Balanced Design - Do s and Don'ts Adhesion and Bonding of Silicone Rubber - Definition of Adhesion - Types of Adhesion - Measurement of Adhesion - Overmolding - Two Component Molding - Surface Modification - Troubleshooting Project Planning - Material and Equipment Requirements - Prototyping - Enhanced Functionality - Cost Analysis - Debugging - Customer Communication sce-rubber.uwm.edu

8 Innovation. ACCELERATED PRODUCT DEVELOPMENT - USING PRODUCT REALIZATION Learn innovative approaches and design processes for developing new products with multidisciplinary teams often located worldwide. Study strategies for optimizing multiple phases of the product realization process including: requirements definition, concept generation, concept selection, prototype generation, design for manufacturing, testing and market penetration. Work on actual new product concepts and discover each phase of the nonlinear process to produce a working prototype. Mon.-Tue., Aug , am-4:30pm Instructor: Michael R. Lovell, Dean, College of Engineering, UW Milwaukee Fee: $790 CEUs: 1.4 Program No Who should attend Engineers, researchers, scientists, managers and technical leaders of new product development, research and development, manufacturing, marketing and supplier management. COURSE OUTLINE Introduction and Overview Course Objectives - Global Landscape of Technology and Innovation - Overview of Product Realization Process - How new techniques were developed - Product Development Exercise Creating Successful Teams - Team Building Exercise - Understanding teams - Roles of team members - Best Practices and Lessons Learned Project Planning - Role and Rules for project planning - Project planning tools - Project Planning Exercise Developing Project Requirements - Understanding internal requirements - Unique product orientations - Customer needs analysis Concept Generation - What is a design concept? - Potential Failures - Five Step Approach to generating innovative concepts - Concept generation exercise - Concept Selection - Potential Failures - Concept Screening - Concept Scoring - Concept Selection exercise Design for Manufacturing - Understanding product realization from business perspective - Minimize costs while maximizing performance Prototyping - Role of prototyping in design innovation - Prototyping processes - When to generate prototypes Testing - Developing robust test plans - Role of failure in innovative design Penetrating the Market - Making products to gain market niche - Ensuring product safety and reliability 8 sce-rubber.uwm.edu

9 Quality. SIX SIGMA BLACK BELT Six Sigma is a highly disciplined improvement methodology that helps organizations achieve optimal performance in all operations. Learn methods to identify how many defects you have in a process and systematically determine how to reduce them to get as close to zero defect as possible. Who should attend Anyone wanting to improve quality, identify and reduce sources of variation and reduce the rate of non-conformance in products or services. COURSE OUTLINE MODULE I Define & Measure - Overview of Process Improvement Strategies - Why Six Sigma? The DMAIC (Define, Measure, Analyze, Improve, Control) Roadmap - Roles of Champions, Master Black Belts, and Blak Belts - Process mapping flowcharts - Data collection and sampling techniques - Basic statistics location versus variation - Control charges variable and attribute - Control charts for short production runs - Subgroup statistics versus process parameters - Rationale for the 1.5σ symbol MODULE II Measure & Analyze - Gage capability studies - Estimating process parameters - Short- versus long-term variation - Process and machine capability studies - Converting process performance to a σ level - Effect of the 1.5σ shift on capability - Dealing with non-normal distribution - Rolled throughput yield MODULE III Analyze & Improve - Check sheets and matrix diagrams - Multi-vari analysis for families of variation - Component swapping for large assemblies - Brainstorming and cause-and-effect diagrams - Multi-voting and decision-making by consensus - Regression analysis and scatter diagrams - Comparison testing between good and bad parts - Analysis of means (ANOM) MODULE IV Improve & Control - Hypothesis testing and confidence intervals - Analysis of variance (ANOVA) - Developing feasible solutions - Solution FMEAs and pilot studies - Mistake proofing poka-yoke - Advanced control charting concepts - Corrective action plans work instruction - Preserving the process knowledge gained - Kaizen for continuous improvement Module I Tue.-Thu., Sept , 2010 Fee: $1295 CEUs: 2.0 Program No Module II Tue.-Wed., Oct. 5-6, 2010 Fee: $1195 CEUs: 1.4 Program No Module III Tue.-Wed., Oct , 2010 Fee: $1195 CEUs: 1.4 Program No Module IV Tue.-Thu., Nov , 2010 Fee: $1295 CEUs: 2.0 Program No am-4:30pm Instructor: Davis R. Bothe sce-rubber.uwm.edu

10 Instructors. Rubber. Terry Chapin received his B.S.A.S. from Youngstown State University in Youngstown, Ohio in June He majored in Mechanical Engineering and minored in Math and Civil Engineering. He is presently a Senior Rubber Technical and Cost Leader at Delphi and has worked as a Tool Engineer at Delphi Packard as well as in the rubber industry for over 25 years. He has held previous engineering positions at Paxson Machine Company, EMCO Wheaton and Commercial Shearing and holds two U.S. patents. Mr. Chapin has been an active technical speaker for university continuing education and onsite locations for over 15 years and is referenced in "Elastomer Molding Technology" by John G. Sommer. John Dick has over 30 years of experience in the rubber industry. He was with BF Goodrich and later Uniroyal Goodrich Tire Co. as a Section Manager and Development Scientist in R & D until 1991 when he joined Monsanto's Rubber Instruments Group (now Alpha Technologies) as a Senior Marketing Technical Service Specialist. Mr. Dick has authored over 65 journal and magazine publications and four books on rubber technology. John Sommer, a registered professional engineer in Ohio with an M.S. in polymer chemistry, Mr. Sommer has progressively gained wide experience by working with many materials, processes and products over a 50-year career in the elastomers industry. His activities resulted in 45 technical publications and 16 U.S. patents, one of which became the technology base for a new company. Richard Steiner is a Wisconsin Certified Journeyman Tool Designer, having served a four-year apprenticeship.he has worked at Quadra, Inc. for over 20 years and is currently VP of Engineering. Quadra is Wisconsin's largest rubber mold building job shop with customers in 13 states and Mexico. James Stevenson has 35 years of experience in the processing of rubber and plastic. He edited Innovation in Polymer Processing: Molding published in Prior to joining Honeywell in 1996, Mr. Stevenson held various technical and management positions at GenCorp (formerly General Tire) for 18 years and was Director of Research at Trexel, a start-up company commercializing microcellular foam technology. He earned his B.S. in Chemical Engineering from Rensselaer Polytechnic Institute and M.S. and Ph.D. degrees from the University of Wisconsin-Madison. Peter Surette joined the rubber industry in 1969 after he graduated from the University of Massachusetts, Lowell, with a B.S. Degree in Plastics Engineering. Mr. Surette has held various positions throughout his career involving laboratory management, compound design, process evaluation, process and product enhancement, laboratory design, compound specification development, procedural and MSDS writings, technical training as well as technical sales and technical service. Pete owns his own consulting business, Focused Solutions, which was established in Mel Toub has worked in the silicone elastomers division of Momentive Performance Materials (formerly GE Silicones) for more than 30 years. He has presented numerous technical papers to ACS, SAE, the International Silicones Symposium, and industry journals and holds several patents in the area of silicone rubber technology. His academic background includes BE and ME degrees in Materials Engineering from Rensselaer Polytechnic Institute as a well as an MBA also from RPI. Van Walworth is President of Research & Design Specialties, Inc., based out of the Nashville, TN area. Mr. Walworth's professional career spans over three decades as a practitioner of product R&D, tool & equipment design, process establishment and improvement, troubleshooting, project management, and spontaneous creativity. Over his career, Walworth held corporate engineering management positions with several companies including, Parker-Hannifin, Wynn's Precision, Ashtabula Rubber Company, and Thunderline Corp. Innovation. Michael R. Lovell was hired as Dean of Engineering at the University of Wisconsin-Milwaukee in August of Dean Lovell has developed unique methodologies that increase the likelihood of a team creating an innovative product from percent. Utilizing his methodology, he mentored student teams that developed 224 new products and formed eight companies over a four-year period. He has launched an Institute for Industrial Innovation at UWM. Quality. Davis R. Bothe has over 30 years of experience working, teaching and consulting in the field of process improvement. His credentials include: ASQ Fellow, IQI certified Master Black Belt, ASQ certified Quality Engineer, ASQ certified Reliability Engineer, member of the US Technical Advisory Group to the ISO Technical Committee 69 on Applications of Statistical Methods. He is author of the quality improvement books "Industrial Problem Solving," "Measuring Process Capability," and "Reducing Process Variation." 10 sce-rubber.uwm.edu

11 General Information. REGISTRATION Phone Mon.-Fri., 8am-5pm Central (toll free) (local) Online sce-registration.uwm.edu Fee The fee includes program materials, continental breakfast, lunch and breaks. Lodging and other meals are not included. Lodging You may make your own lodging arrangement at the facility of your choice. Hotel information will be mailed with your enrollment confirmation. When contacting the hotel, mention that you will be attending a University of Wisconsin Milwaukee seminar to receive a discounted rate. Cancellations Please call at least seven days before the course starts for a refund. Cancellations received less than seven days before the start of the course will be subject to a late cancellation fee. You may enroll a substitute at any time before the course starts, or you may apply the enrollment fee to a future course. In the event the School cancels a class, the University of Wisconsin Milwaukee will reschedule, refund fees or apply the fee payment to any other School of Continuing Education engineering program offered in the next 12 months. Liability of cancellation is specifically limited to the amount of the pre-paid class fee and excludes any incidental or consequential damages. Continuing Education Units (CEUs) All programs in this catalog carry Continuing Education Units (CEUs). CEUs are a means of recognizing and recording satisfactory participation in nondegree programs. One CEU is awarded for each 10 contact hours (or equivalent) in an organized continuing education experience. All CEUs earned through the University of Wisconsin Milwaukee School of Continuing Education noncredit programs become a part of your permanent record. Parking Parking is available in the Shops of Grand Avenue parking structure and other adjacent lots. The School of Continuing Education provides a parking discount for program participants. Inquire for details. Directions For the latest information on getting to and from the School of Continuing Education, visit sce-directions.uwm.edu. The webpage includes access to printable color PDFs of current maps, information about parking and public transportation, and other details relevant to our location. For Further Information Contact Murali Vedula at or mvedula@uwm.edu. RELATED PROGRAMS AND CERTIFICATES Business Process Improvement sce-businessimprovement.uwm.edu Human Resource Management sce-hr.uwm.edu Internet/Systems & Database sce-it.uwm.edu Languages sce-languages.uwm.edu Management Development sce-mgmt.uwm.edu Organizational Development sce-od.uwm.edu Project Management sce-pm.uwm.edu Sustainability sce-sustainability.uwm.edu Train the Trainer sce-ttt.uwm.edu sce-rubber.uwm.edu

12 School of Continuing Education Business, Engineering & Technology 161 W. Wisconsin Ave. Ste Milwaukee, WI Keycode: WPDF Message Code: AP W ONSITE TRAINING Capitalize on our Capabilities Any program can be designed to meet your organization's unique and specific employee development needs. Consider the advantages to partnering with UWM SCE. Contain Costs by eliminating or reducing travel, food and lodging expenses. Maximize Convenience by choosing your optimal dates, times and location. Save Time with staff spending fewer hours away from work. Build Teamwork through group brainstorming and shared learning experiences. Custom Tailor Content to your needs to accomplish specific organizational objectives. Or, use the curriculum as-is. For more information, contact Murali Vedula at or SCE-CUSTOMIZED.UWM.EDU Message Code: AP W