Rheology and Processing of Paints, Plastic, and Elastomer Based Composites

By Prof. Santanu Chattopadhyay | IIT Kharagpur

Learners enrolled: 1070 | Exam registration: 111

ABOUT THE COURSE: A basic to intermediate level of learning on basic rheology and processing is embedded herein this course. Although the major focus goes with the elastomers/rubbers, the elementary rheology and processing of plastics, fibers and paints are also judiciously blended. The flavors on applied rheology and concepts of FEA based CFD for extrusion die design as a case study is also touched upon towards the end. Briefly followings contents covered through eight week lectures including numerical problem solving and practical sessions on rheometry and processing.Introduction to rheology, classification of complex fluid behavior, constitutive equations, and introduction to various fluid models. Application of shear stress-stain data to calculate volumetric flow rates and pressure drop. Flow between parallel plates and capillary with reference to wall slip, die swell and melt fracture. Basics onviscometry andrheometryare also included. Mixing in two roll, internal mixture as well as in kneaders, with machine details and standard operating procedural know- hows, extrusion, calendaring and molding will also be covered with reference to flow and deformation.

INTENDED AUDIENCE: 3rd and 4th year UG, 1st and 2nd Year PG/PhDstudents studying in Polymer Science andTechnology/ Rubber Technology/ PlasticEngineering Science and Technology/ Industrial Chemistry/ Applied Chemistry/Metallurgical and Materials Engineering/ Materials Science/ Ceramic Science andTechnology/ Nanotechnology and Personals from various R&Ds of Indian Industries havingthe prerequisites as mentioned below.

PREREQUISITES: For students: Basic backgrounds on polymers and fluids
For R&D personals: UG or PG degree(s) in any ofthe mentioned subjects as mentioned earlier

INDUSTRY SUPPORT: All rubber, plastics and paints manufacturing industries including but not limited toe.g.,Tata Steel R&D, Reliance, Haldia Petrochemicals, Tata Chemicals,IRMRA, CEAT Tyres, JK Tyres, JK Fenner, Apollo Tyres, Goodyear, Bridgestone, TATA Jamshedpur, Asian Paints, PidiliteIndustries, Berger Paints, Michelin Tyre, Phoenix Yule, ALP Overseas, BKT, AkzoNobel, Ralson,Evonik, Momentive, Sabic, Wacker, Saint Gobain, Cables and Conveyor Manufacturing Industries, MSMEs in Rubber, Paints, Fibres and Plastics Industries, Allied defense laboratories& CSIR Laboratories, CIPET, VSSC, ISRO ofGovt. of India

Summary

Course Status :	Completed
Course Type :	Core
Language for course content :	English
Duration :	8 weeks
Category :	Chemical Engineering Metallurgy and Material science & Mining Engineering
Credit Points :	2
Level :	Undergraduate/Postgraduate
Start Date :	24 Jul 2023
End Date :	13 Oct 2023
Enrollment Ends :	07 Aug 2023
Exam Registration Ends :	21 Aug 2023
Exam Date :	24 Sep 2023 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1: Basic introduction to polymer, structure process correlation, basic rheology,classification of fluids and flow through various channels

Lecture 1.1 :Basic Introduction to polymer

Lecture 1.2 :Structure process correlation

Lecture 1.3 :Basic Rheology

Lecture 1.4:Classification of fluids

Lecture 1.5:Flow of liquids through various channels 1

Lecture 1.6:Flow of liquids through various channels 2

Week 2: Introduction to various viscometers and rheometric techniques,implication of master curves and essence of time-temperature correlation

Lecture 2.1 : Introduction to viscometers and rheometers

Lecture 2.2 :Oswald viscometer, Brookfield viscometer, Falling piston viscometers, Falling ball viscometers, and MFI

Lecture 2.3 :Mooney, Plastometer, ODR, MDR

Lecture 2.4:RPA, PPR, Capillary Rheometer

Lecture 2.5:DMA- In-light of rheology

Lecture 2.6:Master Curve and its implications

Week 3: Application of rheology in paints,plastics, fibres, and rubbers

Lecture 3.1 : Introduction to paints and importance of rheology in paints

Lecture 3.2 :Rheology of paints 1

Lecture 3.3 :Rheology of paints 2

Lecture 3.4:Rheology of fibre plastics 1

Lecture 3.5:Rheology of fibre plastics 2

Lecture 3.6:Rheology of rubbers/elastomers

Week 4: Numerical problems and practical demonstration on various viscometers and rheometers

Lecture 4.1 :Some numerical problems related to basic rheology

Lecture 4.2 :Practical demonstration on Brookfield viscometer and Oswald viscometer

Lecture 4.3 :Practical demonstration on Mooney viscometer, Plastimeter, ODR and MDR

Lecture 4.4:Practical demonstration on RPA and Capillary Rheometer

Lecture 4.5:Practical demonstration on PPR

Lecture 4.6:Practical demonstration on DMA

Week 5: Importance of polymer compounding, die swell, normal force difference and significance of constitutive equationswith respect to rheological aspects

Lecture 5.1 :Importance of compoundingand introduction to compounding ingredients

Lecture 5.2 :Properties and role of various compounding ingredients

Lecture 5.3 :Surface treatment of reinforcing elements

Lecture 5.4:Rheology of filled elastomers

Lecture 5.5:Importance of die swell and surface finish (correlating with normal force differences)

Lecture 5.6:Constitutive equations and their significance

Week 6: Rubber and plastic mixing, their problems and remedies

Lecture 6.1 :Introduction to plastic and rubber mixing and blending

Lecture 6.2 :Various mixing equipments and their importance

Lecture 6.3 :Introduction to two roll and mixing on two roll 1

Lecture 6.4:Introduction to two roll and mixing on two roll 2

Lecture 6.5:Introduction to Internal mixture, kneaders and mixing using internal mixture and kneaders

Lecture 6.6:Practical demonstration of Rubber mixing on a two roll and using an internal mixer

Week 7: Processing techniques: calendaring, molding, extrusion, injection, vulcanization, and problem solving

Lecture 7.1 :Molding Techniques

Lecture 7.2 :Calendering

Lecture 7.3 :Extrusion and Injection molding

Lecture 7.4:Vulcanization

Lecture 7.5:Plastic and fibre related processing

Lecture 7.6:Problems related to various processing techniques

Week 8: Applied and advanced rheology : an overview

Lecture 8.1 :Wire coating :an examples on significance of applied rheology

Lecture 8.2 :Introduction to FEA based computational fluid mechanics on extrusion 1

Lecture 8.3 :Introduction to FEA based computational fluid mechanics on extrusion 2

Lecture 8.4:Introduction to FEA based computational fluid mechanics on extrusion 3

Lecture 8.5:Practical Demonstration on FEA

Lecture 8.6:Concluding remarks and comments on applied rheology for advance learners

Books and references

1. Applied Rheology in Polymer Processing,B.R. Gupta, 2005
2. Polymer Mixing: A Self-Study Guide, ChrisRauwendaal, Hanser Publishers, Munich,1998
3. Polymer Processing Technology, B.R.Gupta, Asian Book Private Ltd., 2008
4. Rubber Technology and Manufacturing,Blow and Hepburn, British Library, 1987
5. Rubber Processing on a Two roll, B.R.Gupta, Allied Publishers Pvt. Ltd., 1998
6. Flow properties of Polymers, Brydson, VanNostrand Reinhold Company, 1970
7. Rheology and Polymers, G.V. Vinogradovand A. Ya. Malkain, Mir Publishers,Moscow, 1980
8. Rubber processing, James L. White, HanserPublishers, Munich, 1995
9. Polymer Mixing Technology andEngineering, James L. White, A. Y. Coran,A. Moet, Hanser Publishers, Munich, 2001

Instructor bio

Prof. Santanu Chattopadhyay

IIT Kharagpur

Dr. Santanu Chattopadhyay is currently a Professor of the Rubber Technology Centre, Indian Institute of Technology Kharagpur, India. He has been serving there as a faculty member since 2004. Prof. Chattopadhyay pursued his postdoctoral research work at the Georgia Institute of Technology, from the Chemical Engineering Department. Prior to that, he did his postdoctoral studies as well at the University of Western Ontario, Canada. Prof. Chattopadhyay earned his Ph.D. from IIT Kharagpur working on Rubber Technology. Prior to these, he earned his M.Tech. (Materials Science and Engineering) and M.Sc. (Chemistry) from IIT Bombay and IIT Kharagpur, respectively. His research interests include Fracture of elastomeric composites, Life prediction of rubber products, Smart rubber composites, Biomaterials, and Polymers for health care and energy harvesting, FEA of rubbery/textile material, Rubber-based nanocomposites, Rubber compounding and modification, Viscoelastic behavior of rubbers and polymer blends, Polymer processing and rheology.

Prof. Chattopadhyay has 170+ Research articles in reputed International peer reviewed journals, 120+ International/National Conferences, 12 Book chapters, a few patents, 30+ Conference sessions chaired and invited talks. He has guided 22 PhD scholars till 2022 and currently he is supervising 18 PhD students (all figures are till 2022).

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.

The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).

Date and Time of Exams: 24 September 2023 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.

Registration url: Announcements will be made when the registration form is open for registrations.

The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.

Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 6 assignments out of the total 8 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kharagpur .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team