Perancangan Sistem Hidrolik Sebagai Penggerak Cutting Machine Untuk Memotong Pegas Daun (Studi Kasus Di PT. Bagong Dekaka Makmur – Malang)

Lesmana, Trio Aji (2026) Perancangan Sistem Hidrolik Sebagai Penggerak Cutting Machine Untuk Memotong Pegas Daun (Studi Kasus Di PT. Bagong Dekaka Makmur – Malang). Other thesis, Institut Teknologi Sepuluh Nopember.

Text 2039221094-Undergraduate_Thesis.pdf - Accepted Version Restricted to Repository staff only Download (5MB) | Request a copy

Abstract

Proses pemotongan pegas daun (leaf spring) bekas dalam program pemanfaatan kembali (reuse) di PT. Bagong Dekaka Makmur saat ini masih menggunakan mesin gerinda konvensional. Metode tersebut memiliki kelemahan krusial, antara lain waktu proses yang relatif lama serta tingginya risiko keselamatan kerja, seperti paparan percikan api, potensi pecahan batu gerinda, kebisingan, dan posisi kerja yang tidak ergonomis. Kondisi ini berdampak pada rendahnya produktivitas serta ketidakseragaman dimensi hasil potongan. Penelitian ini bertujuan untuk merancang sistem hidrolik sebagai penggerak utama mesin pemotong (cutting press) pegas daun guna meningkatkan efisiensi waktu, menjamin keselamatan kerja, dan menghasilkan kualitas potongan yang presisi. Metodologi penelitian meliputi studi literatur, observasi lapangan, dan pengujian tarik material pegas daun baja SUP 9 (ketebalan 10 mm) untuk menentukan gaya potong geser (shearing force). Perhitungan kapasitas hidrolik mengacu pada teori Esposito dan analisis ketahanan tekuk batang silinder berdasarkan hukum Euler. Sirkuit hidrolik dimodelkan menggunakan perangkat lunak FluidSIM, sedangkan desain mekanik disusun menggunakan CAD. Berdasarkan analisis gaya pemotongan sebesar 316.006 N (32,2 ton), diperoleh spesifikasi optimal komponen hidrolik meliputi silinder aktuator ganda merek Jufan (diameter bore 160 mm, rod 90 mm, langkah 130 mm) dengan tekanan kerja 185 bar. Sistem ditenagai motor listrik TECO 22 kW (18,5 HP) yang menggerakkan pompa roda gigi Bucher CB2D-F23 dengan laju aliran 34,905 liter/menit. Aliran fluida dikendalikan oleh OP. 4.1 R RR VM S PTS DA MA 1 3R3 (50 liter/menit) menggunakan oli Pertamina Turalik HE 32 dalam tangki reservoir 69,81 liter. Implementasi rancangan ini diproyeksikan mampu meningkatkan kapasitas produksi hingga 60 produk per jam dengan siklus aktuasi 10 detik per unit. Secara keseluruhan, perancangan ini memberikan solusi teknis yang tepat guna untuk memitigasi bahaya kerja dan mendukung kemandirian teknologi pemeliharaan armada bus.
======================================================================================================================================
The cutting process of used leaf springs in the reuse program at PT. Bagong Dekaka Makmur currently relies on conventional grinding machines. This method presents critical operational drawbacks, including relatively long processing times and severe occupational safety hazards, such as exposure to sparks, grinding wheel fragmentation, high noise levels, and non-ergonomic operator postures. These conditions directly result in low productivity and dimensional inconsistencies. This study aims to design a hydraulic system as the primary actuator for a leaf spring cutting press machine to enhance cutting time efficiency, guarantee operator safety, and produce precise cutting quality. The methodology comprises a literature review, field observations, and laboratory tensile testing on SUP 9 steel leaf spring specimens (10 mm thickness) to establish the required shearing force. Hydraulic capacity calculations were conducted based on Esposito's principles and Euler's buckling resistance theory. The hydraulic circuit was simulated using FluidSIM software, while the mechanical assemblies were modeled using CAD software. Based on the calculated cutting force requirement of 316,006 N (32.2 tons), optimal specifications for the hydraulic components were determined, comprising a Jufan double-acting cylinder (160 mm bore, 90 mm rod, 130 mm stroke) operating at a working pressure of 185 bar. The system is driven by a 22 kW (18.5 HP) TECO electric motor powering a Bucher CB2D-F23 gear pump with a flow rate of 31.35 liters/minute. Fluid flow is regulated by a P120 Directional Control Valve (120 liters/minute) using Pertamina Turalik HE 32 oil within a 108.15-liter reservoir tank. This cutting press machine is projected to increase production capacity up to 60 units per hour with a 10-second actuation cycle per unit. In conclusion, this design provides an effective engineering solution to eliminate workplace hazards and support fleet maintenance technological autonomy.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	sistem hidrolik, cutting press, mesin pemotong pegas daun, leaf spring, hydraulic system, cutting press, leaf spring cutting machine, leaf spring.
Subjects:	T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ1186 Metal-cutting tools. T Technology > TJ Mechanical engineering and machinery > TJ840.A2+ hydraulic machinery
Divisions:	Faculty of Vocational > Mechanical Industrial Engineering (D4)
Depositing User:	Trio Aji Lesmana
Date Deposited:	04 Aug 2026 06:23
Last Modified:	04 Aug 2026 06:23
URI:	http://repository.its.ac.id/id/eprint/140709

Actions (login required)

View Item