Simulasi Pengaruh Desain Gating System Terhadap Hasil Casting Tulang Tibia Menggunakan Rigid Polyurethane Foam

Toding, Dimas Sebastian Bisara (2026) Simulasi Pengaruh Desain Gating System Terhadap Hasil Casting Tulang Tibia Menggunakan Rigid Polyurethane Foam. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Proses fabrikasi model tulang tibia menggunakan material Rigid Polyurethane Foam (RPUF) banyak dilakukan melalui proses casting. Namun karakter RPUF yang mengalami reaksi ekspansi dan gelling menjadi tantangan dalam menghindari kecacatan pada proses casting. Desain gating system merupakan salah satu komponen yang berfungsi untuk mengalirkan material kedalam rongga cetakan, sehingga desain gating system menjadi salah satu faktor penentu keberhasilan pengisian rongga cetakan untuk menghindari kecacatan. Penelitian ini bertujuan menganalisis pengaruh tiga desain gating system, yaitu multiple sprue pouring, two point pouring, dan slit pouring, terhadap hasil casting dapat dilihat dari adanya udara yang terperangkap, volume tidak terisi, dan persebaran densitas pada hasil pengecoran. Simulasi dilakukan menaggunakan perangkat lunak Ansys Fluent dengan menggunakan model multiphase Volume of Fluid dimana terdapat 2 fase fluida dalam cetakan yaitu poliuretan dan udara. Densitas dan viskositas dimodelkan menggunakan User Defined Funciton. Eksperimen dilakukan untuk memeriksa hasil simulasi. Hasil simulasi menunjukkan secara visual pada desain multiple sprue pouring dan slit pouring tidak terlihat adanya kecacatan, namun pada desain two point pouring terlihat kecacatan pada bagian proximal ditandai dengan adanya udara terjebak pada bagian tersebut. Kemudian persentasi unfilled volume terendah didapati pada multiple sprue pouring dengan nilai 1,9% dan pada desain slit pouring serta two point pouring didapati nilai sebesar 2,5% dan 10,8% . Dari kalkulasi densitas pada bagian proximal, tengah, dan distal tulang menunjukkan persebaran paling baik didapati pada desain slit pouring dengan persebaran densitas yang lebih merata dan memiliki rata-rata 294,24 kg/m^3, 294.84 kg/m^3, dan 295.74 kg/m^3. Hasil simulasi dibandingkan dengan hasil eksperimen didapatkan hasil yang identik yaitu cacat pada bagian proximal untuk desain two point pouring, serta tidak didapati cacat pada desain multiple sprue pouring dan slit pouring.
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The fabrication of tibia bone models made of Rigid Polyurethane Foam (RPUF) is commonly carried out through a casting process. However, the nature of RPUF, which undergoes simultaneous expansion and gelling reactions, poses a challenge in avoiding defects during casting. The gating system is one of the components responsible for delivering material into the mold cavity, so its design becomes one of the decisive factors for the successful filling of the cavity and for defect prevention. This research aims to analyze the influence of three gating system designs, namely multiple sprue pouring, two point pouring, and slit pouring, on the casting results, evaluated based on the presence of entrapped air, unfilled volume, and density distribution of the cast product. The simulation was performed using Ansys Fluent software with a multiphase Volume of Fluid model, in which two fluid phases—polyurethane and air—are present inside the mold. The density and viscosity of the polyurethane were modeled using a User-Defined Function. Experimental casting was carried out to verify the simulation results. The simulation results show that, visually, no defect is observed in the multiple sprue pouring and slit pouring designs, whereas a defect is observed in the two point pouring design at the proximal region, marked by the presence of entrapped air in that location. The lowest unfilled volume was obtained for the multiple sprue pouring design at 1.9%, while the slit pouring and two point pouring designs yielded 2.5% and 10.8%, respectively. The density calculation across the proximal, middle, and distal regions of the bone shows that the most uniform distribution was obtained for the slit pouring design, with average densities of 294.24 kg/m³, 294.84 kg/m³, and 295.74 kg/m³. When compared with the experimental results, the simulation produced identical outcomes: a defect at the proximal region for the two point pouring design, and no defect for the multiple sprue pouring and slit pouring designs.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Rigid Polyurethane Foam, Desain Gating, Fluent, Tulang Tibia, Gating Design, Tibia Bone
Subjects:	T Technology > T Technology (General) > T57.62 Simulation T Technology > TP Chemical technology > TP1140 Polymers
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis
Depositing User:	Dimas Sebastian Bisara Toding
Date Deposited:	04 Aug 2026 09:44
Last Modified:	04 Aug 2026 09:44
URI:	http://repository.its.ac.id/id/eprint/143445

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