Material Selection Of Cars Tire Based On Design For Sustainability Approach.
B050710014
BACHELOR OF MANUFACTURING ENGINEERING (MANUFACTURING DESIGN)
2011
UTeM
MATERIAL SELECTION OF CAR’S TIRE BASED ON DESIGN
FOR SUSTAINABILITY APPROACH
MOHD FIRDAUS HANDY
B 050710014
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
MATERIAL SELECTION OF CAR’S TIRES BASED ON DESIGN
FOR SUSTAINABILITY APPROACH
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) with Honours.
by
MOHAMMAD FIRDAUS BIN HANDY
B 050710014
FACULTY OF MANUFACTURING ENGINEERING
2011
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
TAJUK: Material Selection of Car’s Tires Based On Design for Sustainability Approach
SESI PENGAJIAN: 2010/11 Semester 2
Saya
MOHD FIRDAUS BIN HANDY
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di
Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat
kegunaan sepert i berikut :
1.
2.
3.
4.
Tesis adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.
Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran
ant ara inst it usi pengaj ian t inggi.
)
*Sila t andakan ( √
SULIT
TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an
at au kepent ingan Malaysia yang t ermakt ub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan
oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
Disahkan oleh:
TANDATANGAN PENULIS
Alamat Tet ap:
37 JALAN KUBUR
KAMPUNG SEBERANG PINTASAN,
23050 DUNGUN,
TERENGGANU
Tarikh: _______________________
TANDATANGAN PENYELIA
Cop Rasmi:
Tarikh: _______________________
* Jika t esis ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
DECLARATION
I hereby, declared this report entitled “Material Selection of Car’s Tire Based on
Design for Sustainability Approach” is the results of my own research except as cited
in references.
Signature
:
.........................................................................................
Author’s Name
:
.........................................................................................
Date
:
.........................................................................................
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfilment of the requirement for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Design) with Honours. The member of the supervisory
committee is as follow:
.........................................................
Supervisor
ABSTRACT
Tire is one of the important parts in car which is it plays an important role in automotive
industry. In recent years, much progress has been made whether in the physical or
chemical understanding as to measure the endurance value of the tires. The objectives of
this project is to study and do a research about the tire making process and also analyze
the car’s tire by using Design for Sustainability approach and techniques. The analyzing
of the tire in this project was included the factor of weather and road surface. From the
result, it can be seen that tire’s endurance increases when the properties of tensile
strength and elongation is increase. In a short meaning of Design for Sustainability
(DFS), it is the process of designing goods and services that takes into account all the
dimensions of sustainable development and particularly environment, economic and
social factors. DFS also includes in concept of Ecodesign, Design for Environment
(DFE), and Industrial Ecosystem. For this project, the analysis or method that was used
to achieve all of the objectives are Sima-Pro software (Life-Cycle Assessment), CES
Edupack software (material selection), questionnaire and also gathering information
from many resource of literature review. In the end, the collected data from all of the
analysis will be concluded what is the better material but in many condition such as
about hot weather, cold weather, cost and also road surface.
i
ABSTRAK
Tayar adalah salah satu bahagian kereta yang sangat penting dimana ia mempunyai
fungsi yang begitu penting dalam industry kenderaan. Dalam tahun-tahun lepas, telah
banyak penyelidikan telah dilakukan samada dalam bentuk pemahaman fizikal atau pun
kimia dalam mengukur tahap keupayaan ketahanan tayar. Objektif projek ini adalah
untuk memahami dan menyelidik bagaimana proses membuat tayar dan juga melakukan
analisis pada tayar tersebut dengan menggunakan kaedah dan teknik-teknik Design for
Sustainability (DFS). Analisis tayar dalam projek ini telah merangkumi dari segi faktor
cuaca dan juga permukaan jalan. Daripada keputusan yang dikeluarkan, ia dapat dilihat
bahawa keupayaan tayar meningkat jika sifat tegangan dan pemanjangan meningkat.
Dalam maksud yang singkat, DFS adalah servis dan proses membuat barangan yang
mengambil kira semua keadaan peningkatan dalam keupayaan bertahan terutamanya
dari segi faktor persekitaran, ekonomi dan social. DFS juga terlibat dan berkait dengan
konsep Eco-design, Design for Environment, Industri Ekosistem. Dalam projek ini,
analisis yang digunakan untuk mencapai semua objektif adalah perisian Sima-Pro
(penilaian kitaran hidup), perisian CES Edupack (pemilihan bahan), bancian soalan dan
juga pengumpulan hasil-hasil bacaan dari banyak sumber. Yang terakhir, data-data yang
dikumpul dari analisis akan di konklusikan bahan manakah yang terbaik mengikut
keadaan yang tertentu seperti cuaca panas, cuaca sejuk, kos dan juga permukaan jalan.
ii
DEDICATION
To my beloved mother, father and friends, thank you for the support and encouragement.
iii
ACKNOWLEDGEMENTS
First and foremost, I thank the almighty god for being my side throughout. I wish to
extend my sincere thanks Mr. Tajul Ariffin Abdullah as my supervisor for his big help
and always guide me throughout the development of my research and analysis. I am
grateful to thank my friends, as many creative thoughts and valuable discussion about
the research have had a significant influence throughout my project development. Also
not to forget the Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia
Melaka management for allowing me to be a part of the network and thus giving me a
chance to gain useful knowledge and experiences. In addition, I am especially indebted
to my parents, Mr. Handy Aryandy and Mrs. Zainun Sulaiman for their love,
encouragement and support me throughout the development of this research.
iv
TABLE OF CONTENTS
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgements
iv
Table of Contents
v
List of Tables
ix
List of figures
x
List of Abbreviations
xii
1. INTRODUCTION
1.1
Introduction
1
1.2
Problem Statement
4
1.3
Objectives
5
1.4
Scope
5
2. LITERATURE REVIEW
2.1
2.2
Design for Sustainability
7
2.1.1
Technology Sustainability
9
2.1.2
Environmental Sustaiabilty
10
2.1.3
Architectural Sustainability
10
Sustainability Assessment
11
v
2.3
Life-Cycle Assessment
12
2.3.1
Goals and Purposes of LCA
14
2.3.2
Cradle-to-Grave
14
2.4
Sima-Pro Software
15
2.5
CES Edupack Software
16
2.6
Background of Tires
17
2.7
Load Index and Speed Index
20
2.7.1
Load Index
21
2.7.2
Speed Index
21
2.8
2.9
Air Pressure
22
2.8.1
Effects of Under-Inflation
24
2.8.2
Effects of Over-Inflation
24
2.8.3
Effects of Time and Temperature
24
Tire Making Process
25
2.9.1
Flow Manufacturing Process
26
2.9.2
Tire Main Part
28
2.9.3
Tire Main Material
29
3. METHODOLOGY
3.1
Introduction
30
3.2
Project Planning
31
3.2.1
Flow Chart
32
Method of Data Analysis
34
3.3.1
Literature Review Analysis
34
3.3.2
Questionnaire Analysis
35
3.3.2.1 Questionnaire Data Analysis
35
3.3
vi
3.4
3.3.3
Sima-Pro Analysis
39
3.3.4
CES Edupack Analysis
40
Gathering Information
41
3.4.1
Online Article, Journal and Conference Pages
41
3.4.2
Reference Books
42
3.4.3
Video Presentation
42
3.5
Best Approach Practice
42
3.6
Discussion of Questionnaire
43
3.7
Conclusion
46
4. MATERIAL ANALYSIS
4.1
Introduction
47
4.2
DFS Principles
47
4.3
Conceptual Design
49
4.4
Current Design (Polyisoprene Rubber)
49
4.4.1
Ziegler-Natta Polymerization
51
4.4.2
Properties, Advantages & Disadvantages
52
4.5
4.6
4.7
1st Propose Design (Styrene-Butadiene rubber)
53
4.5.1
55
Properties, Advantages & Disadvantages
2nd Propose Design (Ethylene Propylene Rubber)
57
4.6.1
59
Properties, Advantages & Disadvantages
3rd Propose Design (Polyurethane)
60
4.7.1
61
Properties, Advantages & Disadvantages
vii
5. RESULTS AND DISCUSSION
5.1
5.2
5.3
Sima-Pro Results
63
5.1.1
Impact Assessment Results
64
5.1.2
Total Material to Rescycle Result
69
CES Edupack Results
69
5.2.1
Detail Material’s Physical and Chemical Properties Result
70
5.2.2
Tensile Strength and Density Result
79
5.2.3
Price and Tensile Strength Result
80
5.2.4
Combustion Carbon Dioxide and Tensile Result
81
Discussion
82
5.3.1
Impact Assessment Analysis
82
5.3.2
Detail Material Properties Analysis
84
5.3.3
Graph Tensile Strength versus Density Analysis
85
5.3.4
Graph Price versus Tensile Strength Analysis
85
5.3.5
Graph Combustion CO2 versus Tensile Strength Analysis
86
5.3.6
Material Decided
87
6. DISCUSSION
6.3
Discussion
89
REFERENCES
90
viii
LIST OF TABLES
3.1
Flow chart of PSM 1 & PSM 2
32
3.2
The three levels of the materials and processes database
41
5.1
Table and graph of comparison of impact assessment every material
68
5.2
Table of detail material’s properties
78
5.3
Table point of accepted and rejected
87
ix
LIST OF FIGURES
1.1
Three circle of sustainability
2
1.2
Tire-wear-pattern and its cause
5
2.1
The stages of a process from-cradle-to-grave
13
2.2
Example of CES Edupack Analysis
16
2.3
Tire and its symbol
18
2.4
Instruction of tire symbol
19
2.5
Load Index
21
2.6
Speed Index
22
2.7
Tire’s effet from air pressure
23
2.8
Flow of tire manufacturing process
27
2.9
Parts inside tire
28
3.1
Percentage of respondent vs tire’s brand
35
3.2
Percentage of respondent vs years of tire used
36
3.3
Percentage of respondent that know how the tyre making process
37
3.4
Percentage of respondents that agreed to improve tire’s sustainability
38
4.1
Polyisoprene rubber chemical bonding
50
4.2
Hevea tree and its latex
50
4.3
Example product by isoprene rubber
51
4.4
Isoprene chemical bonding by Ziegler-Natta
51
4.5
Styrene-Butadiene rubber chemical bonding
54
4.6
Example product by styrene-butadiene rubber
55
4.7
Ethylene propylene rubber chemical bonding
58
x
4.8
Example product by ethylene propylene rubber
58
4.9
Polyurethane rubber chemical bonding
60
5.1
Polyisoprene’s graph of damage assessment
64
5.2
Styrene-butadiene’s graph of damage assessment
65
5.3
Ethylene propylene’s graph of damage assessment
66
5.4
Polyurethane’s graph of damage assessment
67
5.5
Polyisoprene properties
70
5.6
Styrene-butadiene properties
72
5.7
Ethylene propylene properties
74
5.8
Polyurethane properties
76
5.9
Graph tensile strength vs density
79
5.10
Graph price vs tensile strength
80
5.11
Graph combustion CO2 vs tensile strength
81
xi
LIST OF ABBREVIATIONS
DFE
-
Design for Environment
DFS
-
Design for Sustainability
EIA
-
Environment Impact Assessment
SEA
-
Strategic Environment Assessment
LCA
-
Life Cycle Assessment
LCC
-
Life Cycle Costing
IE
-
Industrial Engineering
VE
-
Value Engineering
MAUT
-
Multi Attribute Utility Theory
EPD
-
Environment Product Declarations
CES
-
Cambridge Educational Selecter
TBM
-
Tire Building Machine
PSM
-
Projek Sarjana Muda
IR
-
Polyisoprene Rubber
SBR
-
Styrene-Butadiene Rubber
EPR
-
Etylene Propylene Rubber
EPM
-
Etylene Propylene Monomer
EPDM
-
Etylene Propylene Diene Monomer
PUR
-
Polyurethane Rubber
xii
CHAPTER 1
INTRODUCTION
This first chapter discussed about the introduction of design for sustainability
(DFS) principles and approaches for new improvement on the car tires. In this part,
the briefing of the background, problem statement, objectives, scope, and the
expected of the study are discussed.
1.1
Introduction
Design for Sustainability (DFS) is the process of designing goods and
services that takes into account all the dimensions of sustainable development and
particularly environment, economic and social factors. Design for Sustainable is also
much related to Design for Environment (DFE) which means the systematic
consideration during design, of issues associated with environment safety and health
over the product life cycle. Both of these design takes many product development
aspects:
(a)
Material selection
(b)
Energy use
(c)
Extended component life cycle
(d)
Disassembly
(e)
Reuse
(f)
Recycling
(g)
Reprocessing/ remanufacturing
(h)
Packaging
1
Sustainability is commonly defined as capable of being maintained at a
steady level without exhausting natural resources or causing ecological damage.
When considering the sustainability of any design, it must consider all elements of
the product’s production, lifecycle and system in which it operates in order to
properly understand the entire impact upon resources of the product. It is only when
we understand the impact of the product that we can begin to even think about
tackling and reducing this impact to improve the sustainability of the product.
Sustainability is also means the capacity to endure. For humans it is the
potential for long-term maintenance of well being, which in turn depends on the well
being of the natural world and the responsible use of natural resources. Sustainability
contains three elements which are economy, society and environment. Sustainable
design also known as philosophy of designing physical objects, the built
environment, and services to comply with the principles of economic, social, and
environment sustainability.
Figure 1.1: Three circle of sustainability
(Screenshot from google.com)
2
There are four Designs for Sustainability principles, which are;
(a) Low-impact materials: choose non-toxic, sustainably produced or
recycled materials which require little energy to process.
(b) Energy efficiency: use manufacturing processes and produce products
which require less energy.
(c) Quality and durability: longer-lasting and better-functioning products will
have to be replaced less frequently, reducing the impacts of producing
replacements.
(d) Design for reuse and recycling: Products, processes, and systems should
be designed for performance in a commercial 'afterlife'.
A set of sustainability principles for engineers was then developed, based on
the long term viability of the planet, intra- and inter-generational equity, and a
holistic view for projects and engineering practice, integrating environmental, social,
and economic issues. Practical tasks and requirements for engineers, including a
checklist were then drawn up to provide further direction to practicing engineers.
(Boyle and Coates, 2005)
At a minimum, sustainable development must not endanger the natural
systems that support life on Earth: the atmosphere, the waters, the soils, and the
living beings. New and efficient technologies will be essential to increase the
capabilities to achieve sustainable development, sustain the world’s economy, protect
the environment, and alleviate poverty and human suffering. Inherent in these
activities is the need to address the improvement of technology currently used and its
replacement, when appropriate, with more accessible and more environmentally
sound technology. In short word, Sustainable development is development that meets
the needs of the present without compromising the ability of future generations to
meet their own needs. (Sotoudeh, 2005)
3
1.2
Problem Statement
Nowadays, the automotive industry has already known as a very competitive
industry. But, automotive industry has been related to environmental issues such as
air pollution, water pollution and sound pollution. Furthermore, tires and wheels are
one of the most critical parts of any road vehicle. Their quality will dictate speed,
road handling, fuel economy and road safety. Critically, their standard will have a
significant effect on stopping distance in an emergency.
The most problem that the users always had is about tread damage before its
due date. For example, tires that are under inflated or over inflated can affect tread
damage and also effect tire life, driving comfort, traction and braking. Under
inflation generates excessive flexing of the tire casing, which results in overheating,
increase of rolling resistance and premature wear. In short word, under inflation can
cause tire damage at tread. Likewise, over inflation can reduce tire life, reduce grip
and create irregular wear. As we know, road hazards like potholes, glass and rocks
are usually unavoidable. However, there are three most problem that we always had,
incorrect inflation pressure, speeding and overloading.
Driving at high speeds has a greater chance of causing tire damage than at
low speeds. If contact is made with a road hazard, it has a greater chance of causing
tire damage. Driving at speed will cause the tire a greater build up of heat, which can
cause tire damage. It can also contribute to a sudden tire destruction and rapid air
loss if the tires are not properly maintained. If a tire experiences sudden air loss, it
can lead to an accident to us.
Tire-road forces are crucial in vehicle dynamics and control because they are
the only forces that a vehicle experiences from the ground. These forces significantly
affect the lateral, longitudinal, yaw, and roll behaviour of the vehicle. Then, the noise
emissions of studded tires are an even bigger acoustic problem than tires without
spikes, and the increasing market leads to increased efforts in designing noise
optimal spike arrangements on tires. The example of tire-wear-pattern and its cause
is shown as Figure 1.2:
4
Figure 1.2: Tire-wear- pattern and its cause
(Screenshot from google.com)
1.3
Objectives
The main purpose of this project is to research and analyze the sustainability
of tires that able to give an improvement on tire’s quality and user safety. The
objectives of this study are:
(a) Identify and study what the problem that always happened.
(b) Analyze the existing car tires and its making process.
(c) Study and do a research about the detail properties of other rubber and the
existing rubber in tires.
(d) Analyze the material selection of car’s tire using Design for Sustainability
(DFS) approach and techniques.
1.4
Scope
Few necessary elements must be considered to guarantee the objectives of the
project achieved. Besides that, the data result of this project has analyzed by using
Sima-Pro software and CES edupack software. The scopes for this project are as
follows:
5
(a) The investigation base on literature study from many sources.
(b) Analyze the conceptual new designs that fulfill the engineering of Design for
Environment specification.
(c) The current tires must be analyzed to improve the sustainability based on
Design for Sustainability and Green Technology.
(d) The data analysis will cover the first principle of DFS which is about the
material.
6
BACHELOR OF MANUFACTURING ENGINEERING (MANUFACTURING DESIGN)
2011
UTeM
MATERIAL SELECTION OF CAR’S TIRE BASED ON DESIGN
FOR SUSTAINABILITY APPROACH
MOHD FIRDAUS HANDY
B 050710014
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
MATERIAL SELECTION OF CAR’S TIRES BASED ON DESIGN
FOR SUSTAINABILITY APPROACH
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) with Honours.
by
MOHAMMAD FIRDAUS BIN HANDY
B 050710014
FACULTY OF MANUFACTURING ENGINEERING
2011
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
TAJUK: Material Selection of Car’s Tires Based On Design for Sustainability Approach
SESI PENGAJIAN: 2010/11 Semester 2
Saya
MOHD FIRDAUS BIN HANDY
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di
Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat
kegunaan sepert i berikut :
1.
2.
3.
4.
Tesis adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis.
Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran
ant ara inst it usi pengaj ian t inggi.
)
*Sila t andakan ( √
SULIT
TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an
at au kepent ingan Malaysia yang t ermakt ub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan
oleh organisasi/ badan di mana penyelidikan dij alankan)
TIDAK TERHAD
Disahkan oleh:
TANDATANGAN PENULIS
Alamat Tet ap:
37 JALAN KUBUR
KAMPUNG SEBERANG PINTASAN,
23050 DUNGUN,
TERENGGANU
Tarikh: _______________________
TANDATANGAN PENYELIA
Cop Rasmi:
Tarikh: _______________________
* Jika t esis ini SULIT at au TERHAD, sila lampirkan surat daripada pihak berkuasa/ organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esis ini perlu dikelaskan sebagai SULIT at au TERHAD.
DECLARATION
I hereby, declared this report entitled “Material Selection of Car’s Tire Based on
Design for Sustainability Approach” is the results of my own research except as cited
in references.
Signature
:
.........................................................................................
Author’s Name
:
.........................................................................................
Date
:
.........................................................................................
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfilment of the requirement for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Design) with Honours. The member of the supervisory
committee is as follow:
.........................................................
Supervisor
ABSTRACT
Tire is one of the important parts in car which is it plays an important role in automotive
industry. In recent years, much progress has been made whether in the physical or
chemical understanding as to measure the endurance value of the tires. The objectives of
this project is to study and do a research about the tire making process and also analyze
the car’s tire by using Design for Sustainability approach and techniques. The analyzing
of the tire in this project was included the factor of weather and road surface. From the
result, it can be seen that tire’s endurance increases when the properties of tensile
strength and elongation is increase. In a short meaning of Design for Sustainability
(DFS), it is the process of designing goods and services that takes into account all the
dimensions of sustainable development and particularly environment, economic and
social factors. DFS also includes in concept of Ecodesign, Design for Environment
(DFE), and Industrial Ecosystem. For this project, the analysis or method that was used
to achieve all of the objectives are Sima-Pro software (Life-Cycle Assessment), CES
Edupack software (material selection), questionnaire and also gathering information
from many resource of literature review. In the end, the collected data from all of the
analysis will be concluded what is the better material but in many condition such as
about hot weather, cold weather, cost and also road surface.
i
ABSTRAK
Tayar adalah salah satu bahagian kereta yang sangat penting dimana ia mempunyai
fungsi yang begitu penting dalam industry kenderaan. Dalam tahun-tahun lepas, telah
banyak penyelidikan telah dilakukan samada dalam bentuk pemahaman fizikal atau pun
kimia dalam mengukur tahap keupayaan ketahanan tayar. Objektif projek ini adalah
untuk memahami dan menyelidik bagaimana proses membuat tayar dan juga melakukan
analisis pada tayar tersebut dengan menggunakan kaedah dan teknik-teknik Design for
Sustainability (DFS). Analisis tayar dalam projek ini telah merangkumi dari segi faktor
cuaca dan juga permukaan jalan. Daripada keputusan yang dikeluarkan, ia dapat dilihat
bahawa keupayaan tayar meningkat jika sifat tegangan dan pemanjangan meningkat.
Dalam maksud yang singkat, DFS adalah servis dan proses membuat barangan yang
mengambil kira semua keadaan peningkatan dalam keupayaan bertahan terutamanya
dari segi faktor persekitaran, ekonomi dan social. DFS juga terlibat dan berkait dengan
konsep Eco-design, Design for Environment, Industri Ekosistem. Dalam projek ini,
analisis yang digunakan untuk mencapai semua objektif adalah perisian Sima-Pro
(penilaian kitaran hidup), perisian CES Edupack (pemilihan bahan), bancian soalan dan
juga pengumpulan hasil-hasil bacaan dari banyak sumber. Yang terakhir, data-data yang
dikumpul dari analisis akan di konklusikan bahan manakah yang terbaik mengikut
keadaan yang tertentu seperti cuaca panas, cuaca sejuk, kos dan juga permukaan jalan.
ii
DEDICATION
To my beloved mother, father and friends, thank you for the support and encouragement.
iii
ACKNOWLEDGEMENTS
First and foremost, I thank the almighty god for being my side throughout. I wish to
extend my sincere thanks Mr. Tajul Ariffin Abdullah as my supervisor for his big help
and always guide me throughout the development of my research and analysis. I am
grateful to thank my friends, as many creative thoughts and valuable discussion about
the research have had a significant influence throughout my project development. Also
not to forget the Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia
Melaka management for allowing me to be a part of the network and thus giving me a
chance to gain useful knowledge and experiences. In addition, I am especially indebted
to my parents, Mr. Handy Aryandy and Mrs. Zainun Sulaiman for their love,
encouragement and support me throughout the development of this research.
iv
TABLE OF CONTENTS
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgements
iv
Table of Contents
v
List of Tables
ix
List of figures
x
List of Abbreviations
xii
1. INTRODUCTION
1.1
Introduction
1
1.2
Problem Statement
4
1.3
Objectives
5
1.4
Scope
5
2. LITERATURE REVIEW
2.1
2.2
Design for Sustainability
7
2.1.1
Technology Sustainability
9
2.1.2
Environmental Sustaiabilty
10
2.1.3
Architectural Sustainability
10
Sustainability Assessment
11
v
2.3
Life-Cycle Assessment
12
2.3.1
Goals and Purposes of LCA
14
2.3.2
Cradle-to-Grave
14
2.4
Sima-Pro Software
15
2.5
CES Edupack Software
16
2.6
Background of Tires
17
2.7
Load Index and Speed Index
20
2.7.1
Load Index
21
2.7.2
Speed Index
21
2.8
2.9
Air Pressure
22
2.8.1
Effects of Under-Inflation
24
2.8.2
Effects of Over-Inflation
24
2.8.3
Effects of Time and Temperature
24
Tire Making Process
25
2.9.1
Flow Manufacturing Process
26
2.9.2
Tire Main Part
28
2.9.3
Tire Main Material
29
3. METHODOLOGY
3.1
Introduction
30
3.2
Project Planning
31
3.2.1
Flow Chart
32
Method of Data Analysis
34
3.3.1
Literature Review Analysis
34
3.3.2
Questionnaire Analysis
35
3.3.2.1 Questionnaire Data Analysis
35
3.3
vi
3.4
3.3.3
Sima-Pro Analysis
39
3.3.4
CES Edupack Analysis
40
Gathering Information
41
3.4.1
Online Article, Journal and Conference Pages
41
3.4.2
Reference Books
42
3.4.3
Video Presentation
42
3.5
Best Approach Practice
42
3.6
Discussion of Questionnaire
43
3.7
Conclusion
46
4. MATERIAL ANALYSIS
4.1
Introduction
47
4.2
DFS Principles
47
4.3
Conceptual Design
49
4.4
Current Design (Polyisoprene Rubber)
49
4.4.1
Ziegler-Natta Polymerization
51
4.4.2
Properties, Advantages & Disadvantages
52
4.5
4.6
4.7
1st Propose Design (Styrene-Butadiene rubber)
53
4.5.1
55
Properties, Advantages & Disadvantages
2nd Propose Design (Ethylene Propylene Rubber)
57
4.6.1
59
Properties, Advantages & Disadvantages
3rd Propose Design (Polyurethane)
60
4.7.1
61
Properties, Advantages & Disadvantages
vii
5. RESULTS AND DISCUSSION
5.1
5.2
5.3
Sima-Pro Results
63
5.1.1
Impact Assessment Results
64
5.1.2
Total Material to Rescycle Result
69
CES Edupack Results
69
5.2.1
Detail Material’s Physical and Chemical Properties Result
70
5.2.2
Tensile Strength and Density Result
79
5.2.3
Price and Tensile Strength Result
80
5.2.4
Combustion Carbon Dioxide and Tensile Result
81
Discussion
82
5.3.1
Impact Assessment Analysis
82
5.3.2
Detail Material Properties Analysis
84
5.3.3
Graph Tensile Strength versus Density Analysis
85
5.3.4
Graph Price versus Tensile Strength Analysis
85
5.3.5
Graph Combustion CO2 versus Tensile Strength Analysis
86
5.3.6
Material Decided
87
6. DISCUSSION
6.3
Discussion
89
REFERENCES
90
viii
LIST OF TABLES
3.1
Flow chart of PSM 1 & PSM 2
32
3.2
The three levels of the materials and processes database
41
5.1
Table and graph of comparison of impact assessment every material
68
5.2
Table of detail material’s properties
78
5.3
Table point of accepted and rejected
87
ix
LIST OF FIGURES
1.1
Three circle of sustainability
2
1.2
Tire-wear-pattern and its cause
5
2.1
The stages of a process from-cradle-to-grave
13
2.2
Example of CES Edupack Analysis
16
2.3
Tire and its symbol
18
2.4
Instruction of tire symbol
19
2.5
Load Index
21
2.6
Speed Index
22
2.7
Tire’s effet from air pressure
23
2.8
Flow of tire manufacturing process
27
2.9
Parts inside tire
28
3.1
Percentage of respondent vs tire’s brand
35
3.2
Percentage of respondent vs years of tire used
36
3.3
Percentage of respondent that know how the tyre making process
37
3.4
Percentage of respondents that agreed to improve tire’s sustainability
38
4.1
Polyisoprene rubber chemical bonding
50
4.2
Hevea tree and its latex
50
4.3
Example product by isoprene rubber
51
4.4
Isoprene chemical bonding by Ziegler-Natta
51
4.5
Styrene-Butadiene rubber chemical bonding
54
4.6
Example product by styrene-butadiene rubber
55
4.7
Ethylene propylene rubber chemical bonding
58
x
4.8
Example product by ethylene propylene rubber
58
4.9
Polyurethane rubber chemical bonding
60
5.1
Polyisoprene’s graph of damage assessment
64
5.2
Styrene-butadiene’s graph of damage assessment
65
5.3
Ethylene propylene’s graph of damage assessment
66
5.4
Polyurethane’s graph of damage assessment
67
5.5
Polyisoprene properties
70
5.6
Styrene-butadiene properties
72
5.7
Ethylene propylene properties
74
5.8
Polyurethane properties
76
5.9
Graph tensile strength vs density
79
5.10
Graph price vs tensile strength
80
5.11
Graph combustion CO2 vs tensile strength
81
xi
LIST OF ABBREVIATIONS
DFE
-
Design for Environment
DFS
-
Design for Sustainability
EIA
-
Environment Impact Assessment
SEA
-
Strategic Environment Assessment
LCA
-
Life Cycle Assessment
LCC
-
Life Cycle Costing
IE
-
Industrial Engineering
VE
-
Value Engineering
MAUT
-
Multi Attribute Utility Theory
EPD
-
Environment Product Declarations
CES
-
Cambridge Educational Selecter
TBM
-
Tire Building Machine
PSM
-
Projek Sarjana Muda
IR
-
Polyisoprene Rubber
SBR
-
Styrene-Butadiene Rubber
EPR
-
Etylene Propylene Rubber
EPM
-
Etylene Propylene Monomer
EPDM
-
Etylene Propylene Diene Monomer
PUR
-
Polyurethane Rubber
xii
CHAPTER 1
INTRODUCTION
This first chapter discussed about the introduction of design for sustainability
(DFS) principles and approaches for new improvement on the car tires. In this part,
the briefing of the background, problem statement, objectives, scope, and the
expected of the study are discussed.
1.1
Introduction
Design for Sustainability (DFS) is the process of designing goods and
services that takes into account all the dimensions of sustainable development and
particularly environment, economic and social factors. Design for Sustainable is also
much related to Design for Environment (DFE) which means the systematic
consideration during design, of issues associated with environment safety and health
over the product life cycle. Both of these design takes many product development
aspects:
(a)
Material selection
(b)
Energy use
(c)
Extended component life cycle
(d)
Disassembly
(e)
Reuse
(f)
Recycling
(g)
Reprocessing/ remanufacturing
(h)
Packaging
1
Sustainability is commonly defined as capable of being maintained at a
steady level without exhausting natural resources or causing ecological damage.
When considering the sustainability of any design, it must consider all elements of
the product’s production, lifecycle and system in which it operates in order to
properly understand the entire impact upon resources of the product. It is only when
we understand the impact of the product that we can begin to even think about
tackling and reducing this impact to improve the sustainability of the product.
Sustainability is also means the capacity to endure. For humans it is the
potential for long-term maintenance of well being, which in turn depends on the well
being of the natural world and the responsible use of natural resources. Sustainability
contains three elements which are economy, society and environment. Sustainable
design also known as philosophy of designing physical objects, the built
environment, and services to comply with the principles of economic, social, and
environment sustainability.
Figure 1.1: Three circle of sustainability
(Screenshot from google.com)
2
There are four Designs for Sustainability principles, which are;
(a) Low-impact materials: choose non-toxic, sustainably produced or
recycled materials which require little energy to process.
(b) Energy efficiency: use manufacturing processes and produce products
which require less energy.
(c) Quality and durability: longer-lasting and better-functioning products will
have to be replaced less frequently, reducing the impacts of producing
replacements.
(d) Design for reuse and recycling: Products, processes, and systems should
be designed for performance in a commercial 'afterlife'.
A set of sustainability principles for engineers was then developed, based on
the long term viability of the planet, intra- and inter-generational equity, and a
holistic view for projects and engineering practice, integrating environmental, social,
and economic issues. Practical tasks and requirements for engineers, including a
checklist were then drawn up to provide further direction to practicing engineers.
(Boyle and Coates, 2005)
At a minimum, sustainable development must not endanger the natural
systems that support life on Earth: the atmosphere, the waters, the soils, and the
living beings. New and efficient technologies will be essential to increase the
capabilities to achieve sustainable development, sustain the world’s economy, protect
the environment, and alleviate poverty and human suffering. Inherent in these
activities is the need to address the improvement of technology currently used and its
replacement, when appropriate, with more accessible and more environmentally
sound technology. In short word, Sustainable development is development that meets
the needs of the present without compromising the ability of future generations to
meet their own needs. (Sotoudeh, 2005)
3
1.2
Problem Statement
Nowadays, the automotive industry has already known as a very competitive
industry. But, automotive industry has been related to environmental issues such as
air pollution, water pollution and sound pollution. Furthermore, tires and wheels are
one of the most critical parts of any road vehicle. Their quality will dictate speed,
road handling, fuel economy and road safety. Critically, their standard will have a
significant effect on stopping distance in an emergency.
The most problem that the users always had is about tread damage before its
due date. For example, tires that are under inflated or over inflated can affect tread
damage and also effect tire life, driving comfort, traction and braking. Under
inflation generates excessive flexing of the tire casing, which results in overheating,
increase of rolling resistance and premature wear. In short word, under inflation can
cause tire damage at tread. Likewise, over inflation can reduce tire life, reduce grip
and create irregular wear. As we know, road hazards like potholes, glass and rocks
are usually unavoidable. However, there are three most problem that we always had,
incorrect inflation pressure, speeding and overloading.
Driving at high speeds has a greater chance of causing tire damage than at
low speeds. If contact is made with a road hazard, it has a greater chance of causing
tire damage. Driving at speed will cause the tire a greater build up of heat, which can
cause tire damage. It can also contribute to a sudden tire destruction and rapid air
loss if the tires are not properly maintained. If a tire experiences sudden air loss, it
can lead to an accident to us.
Tire-road forces are crucial in vehicle dynamics and control because they are
the only forces that a vehicle experiences from the ground. These forces significantly
affect the lateral, longitudinal, yaw, and roll behaviour of the vehicle. Then, the noise
emissions of studded tires are an even bigger acoustic problem than tires without
spikes, and the increasing market leads to increased efforts in designing noise
optimal spike arrangements on tires. The example of tire-wear-pattern and its cause
is shown as Figure 1.2:
4
Figure 1.2: Tire-wear- pattern and its cause
(Screenshot from google.com)
1.3
Objectives
The main purpose of this project is to research and analyze the sustainability
of tires that able to give an improvement on tire’s quality and user safety. The
objectives of this study are:
(a) Identify and study what the problem that always happened.
(b) Analyze the existing car tires and its making process.
(c) Study and do a research about the detail properties of other rubber and the
existing rubber in tires.
(d) Analyze the material selection of car’s tire using Design for Sustainability
(DFS) approach and techniques.
1.4
Scope
Few necessary elements must be considered to guarantee the objectives of the
project achieved. Besides that, the data result of this project has analyzed by using
Sima-Pro software and CES edupack software. The scopes for this project are as
follows:
5
(a) The investigation base on literature study from many sources.
(b) Analyze the conceptual new designs that fulfill the engineering of Design for
Environment specification.
(c) The current tires must be analyzed to improve the sustainability based on
Design for Sustainability and Green Technology.
(d) The data analysis will cover the first principle of DFS which is about the
material.
6