Optimasi Sistem Saluran Pada Pengecoran Propeller B-Series Berbasis Mn-Al Bronze Menggunakan Simulasi Numerik

Calista, Elvira Putri Calista (2026) Optimasi Sistem Saluran Pada Pengecoran Propeller B-Series Berbasis Mn-Al Bronze Menggunakan Simulasi Numerik. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Propeller berbahan Mn-Al Bronze (MAB) banyak digunakan pada sistem propulsi kapal, namun proses pengecorannya sangatlah rentan terhadap cacat porositas dan penyusutan akibat desain geometrinya yang kompleks. Selain performa hidrodinamik, kualitas propeller juga dipengaruhi oleh desain sistem saluran dan pola solidifikasi selama proses pengecoran. Simulasi numerik dimanfaatkan untuk memvalidasi performa hidrodinamik propeller melalui CFD serta menganalisis proses pengecoran secara virtual. Penelitian ini berfokus pada optimasi sistem saluran dengan menganalisis pengaruh diameter riser, diameter pouring basin, dan bentuk sprue terhadap cacat porositas dan karakteristik pengecoran pada propeller seri-B berbahan MAB. Metode dalam penelitian ini dilakukan melalui tahapan simulasi CFD menggunakan ANSYS untuk memvalidasi performa hidrodinamik propeller, dilanjutkan dengan simulasi pengecoran menggunakan ProCAST untuk menganalisis solidifikasi dan pembentukan porositas. Hasil simulasi menunjukkan bahwa Dibandingkan dengan diameter riser sebelumnya, penambahan diameter meningkatkan waktu solidifikasi hingga 82% dan mencegah penyusutan porositas pengecoran sebesar 99.21%. Di sisi lain, diameter basin pouring hanya dapat meningkatkan waktu solidifikasi sebesar 1% hingga 3% dan mengurangi penyusutan porositas hingga 12% pada desain 6A. Bentuk sprue mengalami penurunan laju solidifikasi sebesar 1.76% dan penyusutan porositas sebesar 99.27%. Adapun desain sistem saluran yang paling optimal dalam mengurangi munculnya cacat yaitu desain 3A. Desain ini mampu mampu mengurangi munculnya penyusutan porositas hingga 99.6%.
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Propellers made of Mn–Al Bronze (MAB) are widely used in marine propulsion systems; however, their casting process is highly susceptible to porosity and shrinkage defects due to complex geometric designs. In addition to hydrodynamic performance, propeller quality is strongly influenced by gating system design and solidification behavior during casting. Numerical simulation is employed to validate the hydrodynamic performance of the propeller through CFD and to virtually analyze the casting process. This study focuses on optimizing the gating system by analyzing the effects of riser diameter, pouring basin diameter, and sprue geometry on porosity defects and casting characteristics of a B-series propeller made of MAB. The research methodology consists of CFD simulations using ANSYS to validate propeller hydrodynamic performance, followed by casting simulations using ProCAST to analyze solidification behavior and porosity formation. The simulation results show that compared to the previous riser diameter, increasing the diameter increases the solidification time by up to 82% and prevents casting porosity shrinkage by 99.21%. On the other hand, the pouring basin diameter can only increase the solidification time by 1% to 3% and reduce porosity shrinkage by up to 12% in the 6A design. The sprue shape experienced a 1.76% decrease in solidification rate and 99.27% reduction in porosity. The most optimal channel system design for reducing defects was design 3A, which reduced porosity shrinkage by up to 99.6%.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Propeller B-Series, Mn-Al Bronze, Sistem Saluran, Pengecoran, Simulasi Numerik, ProCAST B-Series Propeller, Mn-Al Bronze, Gating System, Casting, Numerical Simulation, ProCast
Subjects:	T Technology > T Technology (General) > T57.62 Simulation T Technology > TA Engineering (General). Civil engineering (General) > TA357 Computational fluid dynamics. Fluid Mechanics T Technology > TS Manufactures > TS233 Sand casting. Metal castings--Thermal properties. V Naval Science > VM Naval architecture. Shipbuilding. Marine engineering > VM753 Propellers
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 27101-(S2) Master Thesis
Depositing User:	Elvira Putri Calista
Date Deposited:	29 Jan 2026 09:29
Last Modified:	29 Jan 2026 09:29
URI:	http://repository.its.ac.id/id/eprint/130982

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