Perancangan Ulang Dimensi Chassis Nogogeni VIII Pada Variasi Ketebalan Material Aluminium 6063 Hollow 2x1 IN

Pamuji, Mahendra Stia (2026) Perancangan Ulang Dimensi Chassis Nogogeni VIII Pada Variasi Ketebalan Material Aluminium 6063 Hollow 2x1 IN. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Tim Nogogeni ITS mengikuti Kontes Mobil Hemat Energi (KMHE) kategori urban etanol. Pengembangan sebelumnya, chassis Nogogeni VII memiliki massa cukup besar sehingga mempengaruhi performa kendaraan, terutama ketika deselerasi dan gliding. Penelitian ini dilakukan untuk merancang ulang dimensi chassis Nogogeni VIII agar diperoleh desain yang lebih ringan, namun memenuhi kriteria kekuatan dan kekakuan. Perancangan dilakukan dengan mengubah profil aluminium hollow dari 3×1 Inch menjadi 2×1 Inch menggunakan material Aluminium Alloy 6063 dengan variasi ketebalan 0,9 mm, 1 mm, dan 1,4 mm. Metode penelitian ini meliputi studi literatur, pemodelan CAD, perhitungan pembebanan, penentuan boundary condition, meshing, uji konvergensi, simulasi struktur menggunakan metode Finite Element Analysis (FEA) pada ANSYS Workbench. Parameter yang dianalisis meliputi torsional stiffness, longitudinal stiffness, lateral stiffness, equivalent von-Misses stress, total deformation, massa chassis, serta pengujian eksperimen torsional stiffness dan simulasi fatigue life pada desain terpilih. Hasil menunjukkan bahwa chassis existing memiliki torsional stiffness sebesar 4,5 kNm/deg, chassis baru tebal 0,9 mm, 1 mm, dan 1,4 mm masing-masing sebesar 2,3 kNm/deg, 2,76 kNm/deg, dan 3,14 kNm/deg. Ditinjau dari rasio kekakuan torsional terhadap berat, chassis 2×1 inch tebal 1 mm memiliki nilai terbaik sebesar 362,66 sehingga dipilih sebagai desain optimal. Hasil simulasi statis menunjukkan kondisi belok menjadi pembebanan paling kritis dengan nilai tegangan dan deformasi total terbesar. Pada simulasi fatigue, chassis terpilih memiliki fatigue life sebesar 1,1822×106 siklus dengan damage 0,84591, termasuk kategori high cycle fatigue. Pengujian eksperimen menunjukkan perbedaan 23,6% dibanding simulasi dikarenakan menggunakan kondisi ideal pada geometri, sedangkan pengujian aktual dipengaruhi kualitas sambungan las, kondisi tumpuan, dan distribusi beban. Berdasarkan hasil tersebut, chassis 2×1 tebal 1 mm dinilai desain paling optimal karena mampu memberikan keseimbangan antara kekakuan, kekuatan, umur fatigue, dan efisiensi massa. Pengembangan selanjutnya disarankan meningkatkan kualitas pengujian eksperimen pada sambungan las, menambahkan validasi pembebanan lateral dan longitudinal, serta memperluas analisis fatigue sesuai kondisi lintasan aktual.
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The ITS Nogogeni Team participates in the Energy-Efficient Car Contest (KMHE) in the urban ethanol category. In the previous development, the Nogogeni VII chassis had a relatively high mass, which affected vehicle performance, especially during deceleration and gliding. This research was conducted to redesign the dimensions of the Nogogeni VIII chassis to obtain a lighter design while still meeting the requirements of strength and stiffness. The redesign was carried out by changing the aluminium hollow profile from 3×1 inch to 2×1 inch using Aluminium Alloy 6063 with thickness variations of 0.9 mm, 1 mm, and 1.4 mm. The research method includes literature study, CAD modelling, load calculation, boundary condition determination, meshing, convergence testing, and structural simulation using the Finite Element Analysis (FEA) method in ANSYS Workbench. The analysed parameters include torsional stiffness, longitudinal stiffness, lateral stiffness, equivalent von Mises stress, total deformation, chassis mass, experimental torsional stiffness testing, and fatigue life simulation on the selected design. The results show that the existing chassis has a torsional stiffness of 4.5 kNm/deg, while the new chassis with thicknesses of 0.9 mm, 1 mm, and 1.4 mm have torsional stiffness values of 2.3 kNm/deg, 2.76 kNm/deg, and 3.14 kNm/deg, respectively.Based on the torsional stiffness-to-weight ratio, the 2×1 inch chassis with a thickness of 1 mm has the best value, which is 362.66, and is therefore selected as the optimal design. The static simulation results show that the turning condition is the most critical loading condition, as it produces the highest stress and total deformation. In the fatigue simulation, the selected chassis has a fatigue life of 1.1822×10⁶ cycles with a damage value of 0.84591, so it is classified as high cycle fatigue.The experimental test shows a difference of 23.6% compared to the simulation. This occurs because the simulation uses ideal geometry conditions, while the actual test is affected by weld joint quality, support conditions, and load distribution. Based on these results, the 2×1 inch chassis with a thickness of 1 mm is considered the most optimal design because it provides a balance between stiffness, strength, fatigue life, and mass efficiency. For future research, it is recommended to improve the experimental testing quality, especially on welded joints, add validation for lateral and longitudinal loading, and expand the fatigue analysis based on actual track conditions.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Chassis , Aluminium 6063, Stiffness, Finite Element Analysis, Fatigue Life, Mobil Hemat Energi Chassis, Aluminium 6063, Stiffness, Finite Element Analysis, Fatigue Life, Energy-Efficient Car
Subjects:	T Technology > T Technology (General) > T57.62 Simulation T Technology > TA Engineering (General). Civil engineering (General) > TA347 Finite Element Method T Technology > TA Engineering (General). Civil engineering (General) > TA480.A6 Aluminum alloys. T Technology > TS Manufactures
Divisions:	Faculty of Vocational > Mechanical Industrial Engineering (D4)
Depositing User:	Mahendra Stia Pamuji
Date Deposited:	30 Jul 2026 01:52
Last Modified:	30 Jul 2026 01:52
URI:	http://repository.its.ac.id/id/eprint/139661

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