Romadhon, Yardan Parama (2026) Perancangan Ulang Knuckle Kendaraan Urban Etanol Nogogeni X Dengan Analisis Kekuatan Struktur Berbasis Finite Element Analysis Dan Design For Assembly. Other thesis, Institut Teknologi Sepuluh Nopember.
![[thumbnail of 2038221016-Undergraduate_Thesis.pdf]](http://repository.its.ac.id/style/images/fileicons/text.png) |
Text
2038221016-Undergraduate_Thesis.pdf Restricted to Repository staff only Download (9MB) | Request a copy |
Abstract
Knuckle merupakan komponen penting pada sistem kemudi kendaraan yang berfungsi meneruskan beban vertikal, longitudinal, dan lateral dari roda menuju rangka kendaraan. Pada kendaraan Urban Etanol Nogogeni VIII, desain knuckle eksisting masih menggunakan konstruksi plat dengan sambungan rivet dan baut yang menyebabkan proses perakitan bergantung pada jig eksternal, menyulitkan proses maintenance, serta membutuhkan waktu yang lama saat perakitan. Selain itu, pemilihan material yang belum mempertimbangkan optimasi massa menyebabkan komponen memiliki bobot yang lebih besar dari kebutuhan aktual kendaraan. Oleh karena itu, penelitian ini bertujuan merancang ulang knuckle kendaraan Urban Etanol Nogogeni X yang lebih mudah dirakit, mudah dibongkar saat perawatan, ringan, serta tetap aman secara struktural. dan massa komponen. Kata kunci: Knuckle, Design for Assembly, Finite Element Analysis, Aluminium 6061-T6, Aluminium 7075-T6, KMHE Hasil penelitian menunjukkan bahwa desain knuckle usulan (Variasi 1) dengan material Aluminium 6061-T6 terpilih sebagai rancangan paling optimal. Penerapan metode DFA berhasil meningkatkan efisiensi perakitan dari 22,51% menjadi 32,88%, mereduksi waktu perakitan dari 266,55 detik menjadi 127,75 detik, serta mengurangi jumlah komponen dari 41 menjadi 18 part. Hasil simulasi FEA membuktikan bahwa struktur aman pada seluruh kondisi pembebanan (akselerasi, deselerasi, dan berbelok), dengan tegangan maksimum sebesar 68,957 MPa, faktor keamanan minimum 4,0025, dan umur lelah mencapai 1,1395 × 10⁶ siklus. Rancangan akhir ini berhasil menurunkan massa komponen menjadi 43,23% yang sebelumnya sebesar 1.133,45 g menjadi 643,44 g sehingga secara efektif meningkatkan kemudahan maintenance dan mendukung efisiensi performa kendaraan Nogogeni X pada ajang Kontes Mobil Hemat Energi (KMHE).
=================================================================================================================================
The knuckle is a critical component in a vehicle steering system that functions to transfer vertical, longitudinal, and lateral loads from the wheels to the vehicle frame. In the Urban Ethanol Nogogeni VIII vehicle, the existing knuckle design still utilizes a plate-based construction with rivet and bolt connections, causing the assembly process to rely on external jigs, complicating maintenance activities, and requiring a relatively long assembly time. In addition, the material selection has not yet considered mass optimization, resulting in a component weight that exceeds the actual operational requirements of the vehicle. Therefore, this study aims to redesign the knuckle of the Nogogeni X Urban Ethanol vehicle to achieve easier assembly and disassembly during maintenance, reduced weight, and adequate structural safety. The research methodology begins with the development of a knuckle geometry model using SolidWorks CAD software based on the self-locating feature concept to improve assembly convenience. Assembly efficiency is then evaluated using the Boothroyd-Dewhurst Design for Assembly (DFA) method through analyses of handling time, insertion time, component count, and assembly efficiency. Structural strength analysis is conducted using Finite Element Analysis (FEA) in ANSYS Workbench 2021 R2 under acceleration, deceleration, and cornering loading conditions. Two material alternatives, Aluminum 6061-T6 and Aluminum 7075-T6, are evaluated to determine the most optimal material based on stress distribution, deformation, safety factor, fatigue life, and component mass. The results indicate that the proposed knuckle design (Variation 1) made of Aluminum 6061-T6 is the most optimal configuration. The implementation of the DFA method improved assembly efficiency from 22.51% to 32.88%, reduced assembly time from 266.55 s to 127.75 s, and decreased the number of components from 41 to 18 parts. The FEA results demonstrate that the redesigned structure is safe under all loading conditions, including acceleration, deceleration, and cornering, with a maximum von Mises stress of 68.957 MPa, a minimum factor of safety of 4.0025, and a fatigue life of 1.1395 × 10⁶ cycles. In addition, the final design reduced the component mass by 43.23%, from 1,133.45 g to 643.44 g, thereby improving maintenance accessibility and enhancing the overall performance efficiency of the Nogogeni X vehicle for the Indonesia Energy-Efficient Car Contest (Kontes Mobil Hemat Energi, KMHE).
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Knuckle, Design for Assembly, Finite Element Analysis, Aluminium 6061-T6, Aluminium 7075-T6, KMHE ===================================================================== Knuckle, Design for Assembly, Finite Element Analysis, Aluminium 6061-T6, Aluminium 7075-T6, KMHE. |
| Subjects: | T Technology > TS Manufactures > TS171 Product design |
| Divisions: | Faculty of Vocational > Mechanical Industrial Engineering (D4) |
| Depositing User: | Yardan Parama Romadhon |
| Date Deposited: | 01 Aug 2026 06:22 |
| Last Modified: | 01 Aug 2026 06:22 |
| URI: | http://repository.its.ac.id/id/eprint/141688 |
Actions (login required)
 |
View Item |