Jun 15,2023
In the world of manufacturing, the protection of mechanical systems from vibration, noise, and shock is of utmost importance.
These disruptive forces can have detrimental effects, leading to system failures and compromised performance. To combat these issues, manufacturers offer a wide range of rubber mounts specifically designed to manage and isolate vibrations, ensuring the smooth operation and longevity of machinery.
But why is rubber such an ideal material for these applications? In this article, we delve into the characteristics of natural and synthetic rubbers, explore their unique properties, and understand why manufacturers prefer natural rubber for making mounts.
We will also discuss the benefits of rubber over steel, the significance of mount shape and size, and the crucial role of vibration isolation mounts in reducing noise and vibration impacts.
Rubbers, whether natural or synthetic, are versatile substances composed of lengthy, coiled, high-molecular-weight chains interconnected by specific chemical ingredients, forming a network.
This network enables rubbers to withstand extreme deformation of at least two hundred percent. Natural rubber and various synthetic materials with rubber-like qualities fall under the term "elastomer."
Natural rubber consists of lengthy chains comprising thousands of similar chemical units. In the mid-19th century, an American chemist discovered the process of vulcanization, wherein the rubber is joined with sulfur atoms at temperatures ranging from 120 to 220 degrees Celsius.
This crosslinking creates a molecular network that imparts elasticity, strength, and other vital mechanical properties to the rubber.
Different types of vulcanizates exhibit varying properties depending on the type of crosslinking that occurs.
Vulcanizates with carbon-carbon cross-linkages generally offer higher temperature resistance, while those with higher polysulfide cross-linkages are sturdier in nature.
In engineering and industrial applications, rubbers are often compounded with fillers that influence the qualities of the vulcanizate. Common fillers include carbon black, which significantly impact properties such as creep, hysteresis, modulus, and abrasion and tear resistance.
Manufacturers may also add other chemicals to protect the rubber from oxygen, ozone, and sunlight.
The ability to tailor rubber compounds with specific qualities makes them incredibly versatile for a wide range of applications. However, it is natural rubber that shines as an ideal spring material due to its resistance to temperature variations, cost-effectiveness, resilience, durability, and compatibility with metal bonding.
These features, combined with its capacity to reduce noise and vibration transmission in harsh environments, make natural rubber a preferred choice for manufacturing various mounts.
When we think of springs, the image of coiled metal usually comes to mind. However, rubber springs offer non-linear stiffness, providing versatility in managing vibrations.
Unlike steel springs, which exhibit a linear relationship between deflection and force, rubber springs can be designed to offer different stiffness characteristics in non-linear directions.
Shear forces, such as friction, occur when opposing sides of a material experience forces in opposite directions. The substance's response to this stress is defined by its shear modulus.
Rubber mounts surpass steel mounts in this regard due to rubber's superior stretchability before permanent deformation occurs.
Rubber mounts, especially those made from natural rubber, offer numerous advantages over their steel counterparts. Let's explore some of the key reasons why manufacturers prefer using natural rubber to make mounts:
Natural rubber demonstrates exceptional resistance to a broad range of temperatures, making it suitable for applications exposed to extreme heat or cold.
It can withstand the chemicals and heat encountered in automobile engines, making it a reliable choice for automotive mounts. Additionally, natural rubber resists swelling when exposed to fluids, making it suitable for underwater conditions over extended periods.
Rubber compounds can be tailored to exhibit specific qualities based on the application requirements. Natural rubber, in particular, offers versatility and adaptability, allowing manufacturers to develop mounts suitable for a variety of environments and operating conditions.
Rubber, including natural rubber, possesses inherent damping capabilities, unlike steel. This damping ability allows rubber mounts to dampen or dissipate energy in systems subjected to vibrational forces, effectively reducing noise and vibration transmission.
Rubber mounts are generally easier to install and handle compared to their steel counterparts. Their flexibility and ease of use make them a convenient choice for various applications.
Rubber has the unique ability to convert energy to heat during deflection, which helps in dissipating excess energy. This characteristic, known as hysteresis, prevents the buildup of heat to the extent seen in metals. Natural rubber, especially when not compounded with fillers, exhibits minimal hysteresis, further enhancing its energy-dissipating capabilities.
Selecting the appropriate mount is crucial to achieving effective vibration isolation. Choosing the wrong mount can potentially worsen vibration issues. Here are some factors to consider when selecting mounts for vibration control:
It is advisable to incorporate vibration control plans early in the product design process. By considering vibration isolation from the outset, engineers can ensure that appropriate mounts and materials are chosen to minimize potential vibration problems.
Seeking the consultation of engineering professionals with expertise in vibration control can provide valuable insights and guidance in selecting the right mounts and materials for specific applications. Their knowledge and experience can help identify potential challenges and recommend effective solutions.
Collaborating with leading manufacturers equipped with extensive engineering resources and facilities is essential. These manufacturers can conduct material, product, and prototype testing under real-world conditions, ensuring the performance and reliability of the chosen mounts.
The shape and size of a vibration mount play a crucial role in its effectiveness. Consider the following aspects when evaluating the shape and size of a mount:
Rubber Volume: The amount of rubber used in the mount determines its load-bearing capacity. Larger elastomers can accommodate greater loads but may introduce more movement.
Durability and Flexibility: Proper measuring procedures must be followed to ensure that the mount's size not only fits the application but also possesses the necessary durability and flexibility to withstand the anticipated conditions without frequent replacement.
Shock Absorption: The shape of the mount should allow for the absorption and damping of shocks occurring across multiple directions and planes. In some cases, a customized design or shape might be required to optimize shock absorption.
The primary objective of isolation mounts is to mitigate the impacts of noise and vibration on machinery or structures. These mounts offer several advantages, including:
Protection of Sensitive Components: Isolation mounts safeguard sensitive parts and objects from mutual interference or damage caused by vibrations.
Noise Reduction: By effectively isolating and damping vibrations, isolation mounts help reduce or isolate potentially damaging and obnoxious noise, enhancing the overall user experience.
Extended Equipment Lifespan: Isolation mounts minimize the transmission of vibrations, thereby reducing wear and tear on machinery or structures. This extends their operational life and helps maintain optimal performance.
Versatile Applications: Isolation mounts find applications in various industries, including compressors, machinery, pumps, motors, and even precision equipment such as computers. They are suitable for both heavy and light loads, making them versatile in a wide range of settings.
Rubber mounts play a crucial role in managing vibration, noise, and shock in mechanical systems. Natural rubber, with its unique properties and versatility, emerges as an ideal material for manufacturing mounts.
Its resistance to extreme temperatures, cost-effectiveness, resilience, longevity, and compatibility with metal bonding makes it a preferred choice for many applications.
Choosing the right mount and considering factors such as vibration control plans, consultation with engineering professionals, and working with leading manufacturers are vital to ensure effective vibration isolation. The shape and size of a mount also play a significant role in determining its load-bearing capacity, shock absorption capabilities, and overall performance.
Q: Can rubber mounts be used in extreme temperatures?
A: Yes, natural rubber mounts exhibit excellent temperature resistance and can withstand a wide range of temperatures, making them suitable for applications in harsh environments.
Q: How do rubber mounts compare to steel mounts in terms of vibration control?
A: Rubber mounts offer superior vibration control compared to steel mounts. Rubber's inherent damping capabilities and ability to dissipate energy make it an effective choice for reducing noise and vibration transmission.
Q: Are rubber mounts easy to install and handle?
A: Yes, rubber mounts are generally easier to install and handle compared to steel mounts. Their flexibility and user-friendly characteristics make them convenient for various applications.
