Optimasi Desain dan Substitusi Material Untuk Automatic Coupler Head

Valentino, Jean Mario (2025) Optimasi Desain dan Substitusi Material Untuk Automatic Coupler Head. Doctoral thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Penelitian ini berfokus pada redesain dan optimasi automatic coupler head, yang berfungsi sebagai komponen penghubung kereta api dan harus mampu menahan beban dari pergerakan longitudinal kereta. Hasil penelitian sebelumnya menunjukkan bahwa automatic coupler hanya dapat menahan beban tarik hingga 100 kN pada laboratorium uji, jauh di bawah beban analitik yang seharusnya mencapai 297 kN. Oleh karena itu, redesain automatic coupler diperlukan untuk meningkatkan kekuatan tariknya. Selain itu, material yang umum digunakan untuk coupler, yaitu AAR M201, sulit ditemukan di pasaran lokal, sehingga perlu dilakukan substitusi dengan medium carbon steel seperti AISI 1045, yang sifat mekaniknya dapat ditingkatkan melalui heat treatment, yaitu quench dan temper. Tujuan penelitian ini adalah meningkatkan kekuatan automatic coupler dengan pendekatan desain dan material. Metodologi penelitian mencakup tahapan basic desain, optimasi desain menggunakan metode optimasi topologi, verifikasi desain kekuatan struktur secara numerik, pembuatan prototipe skala 1:1 dan kajian peningkatan kekuatan material AISI 1045 dengan variasi media quench dan temperatur temper. Hasil verifikasi menunjukkan bahwa desain baru hasil optimasi topologi berhasil mengurangi massa komponen hooked plate sebesar 24%, serta meningkatkan faktor keselamatan dari 1,8 menjadi 2,07. Desain baru hasil optimasi topologi juga menunjukkan penurunan tegangan tarik komponen cover hingga 473% dan tegangan tekan hingga 463% dibandingkan desain awal. Validasi melalui uji tarik prototipe menunjukkan kemampuan menahan beban hingga 314 kN. Hasil kajian peningkatan kekuatan material menunjukkan bahwa yield strength AISI 1045 meningkat hingga 116% setelah perlakuan panas quench dengan media air dengan temperatur temper 550°C. Penelitian lebih lanjut disarankan untuk melakukan validasi uji tarik prototipe menggunakan material AISI 1045 dengan parameter heat treatment yang telah didapatkan. Hasil penelitian ini diharapkan dapat menjadi referensi desain bagi industri manufaktur coupler di Indonesia, sehingga produk dalam negeri dapat bersaing di pasar komponen kereta api global.
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This study focuses on the redesign and optimization of the automatic coupler head, which serves as a connecting component in railway systems and must be capable of withstanding loads from longitudinal movements of the train. Previous research has indicated that the automatic coupler can only withstand a tensile load of up to 100 kN, significantly below the analytical load that should reach 297 kN. Therefore, a redesign of the automatic coupler is necessary to enhance its tensile strength. Additionally, the commonly used material for couplers, AAR M201, is difficult to source in the local market, necessitating substitution with medium carbon steel such as AISI 1045, whose mechanical properties can be improved through heat treatment processes, specifically quenching and tempering. The objective of this research is to enhance the strength of the automatic coupler through design and material approaches. The research methodology includes stages of basic design, design optimization using topology optimization methods, numerical verification of structural strength, the fabrication of a 1:1 scale prototype, and an investigation into the enhancement of the strength of AISI 1045 material with variations in quenching media and tempering temperatures. Verification results indicate that the new design resulting from topology optimization successfully reduced the mass of the hooked plate component by 24% and increased the safety factor from 1.8 to 2.07. The new design also demonstrated a reduction in tensile stress of the cover component by up to 473% and compressive stress by up to 463% compared to the initial design. Validation through tensile testing of the prototype showed the ability to withstand loads of up to 314 kN. The study on material strength enhancement revealed that the yield strength of AISI 1045 increased by up to 116% following heat treatment through water quenching at a tempering temperature of 550°C. Further research is recommended to validate the tensile testing of the prototype using AISI 1045 material with the established heat treatment parameters. The findings of this research are expected to serve as a design reference for the coupler manufacturing industry in Indonesia, enabling domestic products to compete in the global railway component market.

Item Type:	Thesis (Doctoral)
Uncontrolled Keywords:	Automatic Coupler, Optimasi Topologi, Heat Treatment, Baja AISI 1045, Topology Optimization, AISI 1045 Steel
Subjects:	T Technology > TF Railroad engineering and operation T Technology > TF Railroad engineering and operation > TF1327.O58 High speed ground transportation (train) T Technology > TF Railroad engineering and operation > TF240 Railway construction T Technology > TJ Mechanical engineering and machinery > TJ230 Machine design
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21001-(S3) PhD Thesis
Depositing User:	Jean Mario Valentino
Date Deposited:	01 Feb 2025 04:16
Last Modified:	01 Feb 2025 04:16
URI:	http://repository.its.ac.id/id/eprint/117612

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