Fatigue Remaining Life Assessment On Shell Rotary Dryer

Al Islami, Ichsan (2026) Fatigue Remaining Life Assessment On Shell Rotary Dryer. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Rotary dryer merupakan peralatan penting dalam industri proses yang beroperasi secara kontinu sehingga shell sebagai komponen utama mengalami pembebanan mekanik dan termal secara berulang. Kondisi tersebut dapat memengaruhi respons struktur dan umur lelah komponen. Penelitian ini bertujuan untuk menganalisis pengaruh variasi beban material terhadap respons struktur shell rotary dryer serta mengestimasi umur lelah menggunakan metode Stress–Life (S–N). Analisis dilakukan menggunakan Finite Element Method (FEM) pada perangkat lunak ANSYS Workbench dengan variasi beban material sebesar 0 ton, 4,25 ton, 8,50 ton, 12,75 ton, dan 17 ton serta temperatur operasi sebesar 45°C. Parameter yang dianalisis meliputi Equivalent Stress, Total Deformation, Maximum Principal Stress, Maximum Shear Stress, Strain Energy, Factor of Safety, Fatigue Safety Factor, dan Fatigue Life. Hasil simulasi menunjukkan bahwa peningkatan beban material menyebabkan peningkatan Equivalent Stress dari 57,612 MPa menjadi 65,444 MPa, Maximum Principal Stress dari 39,545 MPa menjadi 51,820 MPa, Total Deformation dari 2,9307 mm menjadi 2,9560 mm, serta penurunan Factor of Safety dari 3,5739 menjadi 3,5144. Seluruh nilai tegangan maksimum masih berada di bawah tegangan luluh ASTM A283 Grade C sebesar 205 MPa sehingga struktur tetap bekerja pada daerah elastis. Daerah kritis teridentifikasi berada pada transisi antara shell dan riding ring akibat perubahan kekakuan struktur. Hasil analisis fatigue menunjukkan seluruh variasi pembebanan menghasilkan fatigue life minimum sebesar 1×10⁷ siklus (Infinite Life) atau setara sekitar 39.683 jam (4,53 tahun operasi kontinu), sehingga shell rotary dryer masih layak dioperasikan pada seluruh variasi pembebanan yang dianalisis. Hasil penelitian ini dapat digunakan sebagai dasar penyusunan strategi inspeksi dan pemeliharaan berbasis kondisi (condition-based maintenance) pada rotary dryer.
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Rotary dryers are critical equipment in process industries that operate continuously, causing the shell as the main structural component to experience repeated mechanical and thermal loading. These loading conditions may affect the structural response and fatigue life of the shell. This study aims to investigate the effect of material load variations on the structural response of a rotary dryer shell and to estimate its fatigue life using the Stress–Life (S–N) approach. Structural analysis was performed using the Finite Element Method (FEM) in ANSYS Workbench with material load variations of 0, 4.25, 8.50, 12.75, and 17.00 tons under an operating temperature of 45°C. The evaluated parameters included Equivalent Stress, Total Deformation, Maximum Principal Stress, Maximum Shear Stress, Strain Energy, Factor of Safety, Fatigue Safety Factor, and Fatigue Life. The simulation results indicate that increasing the material load increases the Equivalent Stress from 57.612 MPa to 65.444 MPa, Maximum Principal Stress from 39.545 MPa to 51.820 MPa, and Total Deformation from 2.9307 mm to 2.9560 mm, while reducing the Factor of Safety from 3.5739 to 3.5144. However, all maximum stress values remain well below the ASTM A283 Grade C yield strength of 205 MPa, indicating that the shell operates entirely within the elastic region. The critical region was identified at the transition between the shell and the riding ring due to the local stiffness discontinuity. Fatigue analysis showed that all loading variations resulted in a minimum fatigue life of 1×10⁷ cycles (Infinite Life), equivalent to approximately 39,683 operating hours (4.53 years of continuous operation), indicating that the rotary dryer shell remains structurally reliable under all investigated loading conditions. The findings provide a basis for developing condition-based inspection and maintenance strategies for rotary dryer structures.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Rotary dryer, Finite Element Method, analisis struktur, fatigue life, remaining life, Stress–Life. Rotary dryer, Finite Element Method, structural analysis, fatigue life, remaining life, Stress–Life.
Subjects:	T Technology > T Technology (General) > T11 Technical writing. Scientific Writing T Technology > T Technology (General) > T55 Industrial Safety T Technology > T Technology (General) > T57.62 Simulation T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User:	Ichsan Al Islami
Date Deposited:	03 Aug 2026 23:13
Last Modified:	03 Aug 2026 23:13
URI:	http://repository.its.ac.id/id/eprint/143702

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