Studi Numerik Pengaruh Passive Damper dengan Material Brass untuk Daerah Stabil pada Proses Finishing Boring Bar

Rizqi, Muhamad Fauzan (2026) Studi Numerik Pengaruh Passive Damper dengan Material Brass untuk Daerah Stabil pada Proses Finishing Boring Bar. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Proses boring merupakan salah satu proses pemesinan yang digunakan untuk menghasilkan lubang internal dengan tingkat ketelitian tinggi. Namun, penggunaan boring bar dengan rasio overhang besar rentan mengalami getaran chatter akibat rendahnya kekakuan dinamis sistem. Getaran tersebut dapat menurunkan kualitas permukaan, mempercepat keausan pahat, mengurangi akurasi dimensi, serta membatasi produktivitas pemesinan. Penelitian ini bertujuan untuk menganalisis pengaruh variasi cutting parameter terhadap respons getaran boring bar dengan passive damper berbahan brass serta menentukan stable zone pada proses finishing boring. Penelitian dilakukan secara numerik menggunakan metode Finite Element Method (FEM) dengan bantuan perangkat lunak ANSYS Workbench. Sistem yang dianalisis berupa boring bar dengan penambahan passive damper berbahan brass sepanjang 60% dari panjang overhang. Variasi parameter pemotongan terdiri atas 27 kombinasi cutting parameter yang mencakup spindle speed, feed rate, dan depth of cut. Analisis dilakukan melalui static structural analysis untuk memperoleh kekakuan ekuivalen, modal analysis untuk mengetahui frekuensi natural sistem, serta harmonic response analysis untuk memperoleh respons deformasi pada ujung pahat arah sumbu-X, sumbu-Y, dan sumbu-Z. Hasil respons getaran kemudian diolah dalam bentuk diagram Bode, grafik surface 3D, dan stable zone berdasarkan perbandingan deformasi terhadap stability limit. Hasil simulasi menunjukkan bahwa setiap variasi cutting parameter memberikan respons getaran yang berbeda. Peningkatan feed rate dan depth of cut menyebabkan kenaikan gaya pemotongan, sehingga amplitudo deformasi boring bar cenderung meningkat. Respons getaran terbesar terjadi ketika chatter frequency berada dekat dengan daerah resonansi, terutama pada rentang sekitar 500–625 Hz, dengan puncak respons dominan berada di sekitar 553,8–587,1 Hz. Kondisi tersebut menunjukkan bahwa kestabilan proses boring tidak hanya dipengaruhi oleh besar gaya pemotongan, tetapi juga oleh kedekatan frekuensi kerja terhadap frekuensi natural sistem. Berdasarkan analisis stable zone gabungan pada sumbu-X, sumbu-Y, dan sumbu-Z, cutting parameter yang menghasilkan kondisi stabil dan bebas chatter adalah Cutting parameter 1, Cutting parameter 10, Cutting parameter 11, Cutting parameter 13, Cutting parameter 19, Cutting parameter 20, dan Cutting parameter 22. Parameter tersebut memiliki kombinasi gaya pemotongan rendah hingga sedang serta chatter frequency yang tidak berada dekat dengan daerah resonansi kritis. Dengan demikian, penggunaan passive damper berbahan brass pada boring bar mampu membantu mereduksi respons getaran dan memberikan acuan pemilihan parameter pemotongan yang lebih stabil. Hasil penelitian ini dapat digunakan sebagai referensi dalam optimasi proses finishing boring untuk mengurangi risiko chatter, menjaga kualitas hasil pemesinan, serta mendukung peningkatan produktivitas melalui pemilihan parameter pemotongan yang tepat.
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The boring process is one of the machining operations used to produce internal holes with high dimensional accuracy. However, the use of a boring bar with a large overhang ratio is prone to chatter vibration due to the low dynamic stiffness of the system. This vibration can reduce surface quality, accelerate tool wear, decrease dimensional accuracy, and limit machining productivity. This study aims to analyze the effect of cutting parameter variations on the vibration response of a boring bar equipped with a brass passive damper and to determine the stable zone in the finishing boring process. This research was conducted numerically using the Finite Element Method (FEM) with the aid of ANSYS Workbench software. The analyzed system consisted of a boring bar with the addition of a brass passive damper with a length of 60% of the overhang length. The cutting parameter variations consisted of 27 combinations, including spindle speed, feed rate, and depth of cut. The analysis was carried out through static structural analysis to obtain the equivalent stiffness, modal analysis to determine the natural frequencies of the system, and harmonic response analysis to evaluate the deformation response at the tool tip in the X-, Y-, and Z-axis directions. The vibration response results were then processed into Bode diagrams, 3D surface graphs, and stable zone maps based on the comparison between deformation and the stability limit. The simulation results show that each cutting parameter variation produces a different vibration response. An increase in feed rate and depth of cut leads to an increase in cutting force, causing the deformation amplitude of the boring bar to tend to increase. The highest vibration response occurs when the chatter frequency is close to the resonance region, particularly within the range of approximately 500–625 Hz, with dominant response peaks occurring around 553.8–587.1 Hz. This condition indicates that the stability of the boring process is not only affected by the magnitude of the cutting force, but also by the proximity of the operating frequency to the natural frequency of the system. Based on the combined stable zone analysis in the X-, Y-, and Z-axis directions, the cutting parameters that produce stable and chatter-free conditions are Cutting Parameter 1, Cutting Parameter 10, Cutting Parameter 11, Cutting Parameter 13, Cutting Parameter 19, Cutting Parameter 20, and Cutting Parameter 22. These parameters have low to moderate cutting force combinations and chatter frequencies that are not close to the critical resonance region. Therefore, the use of a brass passive damper on the boring bar can help reduce the vibration response and provide a reference for selecting more stable cutting parameters. The results of this study can be used as a reference for optimizing the finishing boring process to reduce the risk of chatter, maintain machining surface quality, and support productivity improvement through proper cutting parameter selection.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	boring bar, passive damper, brass, chatter, harmonic response, stable zone, cutting parameter.
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ1260 Drilling and boring.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis
Depositing User:	Muhamad Fauzan Rizqi
Date Deposited:	28 Jul 2026 06:58
Last Modified:	28 Jul 2026 06:58
URI:	http://repository.its.ac.id/id/eprint/138699

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