Farruqi, Muhammad Zulfan (2020) Studi Numerik Simulasi Proses Forging Roda Kereta Berkecepatan Sedang. Other thesis, Institut Teknologi Sepuluh Nopember.
Preview |
Text
02111640000178-Undergraduate_Thesis.pdf Download (4MB) | Preview |
Abstract
Permintaan untuk proses manufaktur yang lebih efisien telah meningkat dalam beberapa tahun terakhir. Proses penempaan dingin disajikan sebagai solusi yang memungkinkan, karena memungkinkan produksi bagian dengan permukaan akhir yang baik dan dengan sifat mekanik yang baik. Namun demikian, desain urutan penempaan dingin sangat empiris dan didasarkan pada pengalaman desainer. Pemodelan komputasi dari setiap tahap proses pembentukan dengan metode elemen hingga dapat membuat desain urutan lebih cepat dan lebih efisien, mengurangi penggunaan metode "trial and error" konvensional. Dalam penelitian ini, penerapan perangkat lunak elemen hingga komersial umum - ANSYS - telah diterapkan untuk memodelkan operasi pembentukan.
Tahapan pada penelitian ini terdiri dari proses pemodelan roda kereta yang kemudian dari situ dapat dimodelkan bagian penempanya (cetakan) menggunakan software pemodelan 3D Solidworks. Proses simulasi meliputi pendifinisian material, meshing, set up, dan analisis hasil. Setelah mendapatkan analisis hasil, dibandingkan dengan perubahan ketebalan benda kerja dan beban penekanan. Untuk ketebalan awal benda kerja divariasikan dengan nilai sebesar 76 mm, 77 mm ,78 mm, 79 mm, dan 80 mm. Sedangkan untuk beban penekanan divariasikan dengan nilai sebesar 180 MN, 190 MN, 200 MN, 210 MN, dan 200 MN. Tujuan dilakukan variasi ini adalah untuk mengetahui pengaruh perubahan ketebalan awal billet dan beban penekanan pada proses forging terhadap bentuk billet dan residual stress hasil proses forging.
Berdasarkan hasil penelitian yang telah dilakukan diketahui bahwa variasi ketebalan awal billet dan besar pembebanan berpengaruh terhadap bentuk billet dan residual stress hasil proses forging. Diperoleh bentuk billet hasil proses forging yang cukup memenuhi ruang cetakan dengan ketebalan awal billet 79 mm dan 80 mm yang diberi pembebanan terbesar dalam variasi yaitu 220 MN (22500 tonf). Namun dengan ketebalan awal billet 79 mm masih ada kekurangan pengisian pada bagian hub. Dengan ketebalan awal billet 80 mm, billet sudah mengisi bagian rim dan bagian hub, namun bagian web justru terjadi kekurangan pengisian.
Residual stress yang timbul pada roda kereta hasil forging dengan ketebalan awal billet 79 mm bersifat kompresi dan ini menguntungkan pada roda kereta. Walaupun pada bagian hub residual stress kompresifnya tergolong rendah sebesar yaitu -71,857 MPa. Hal ini juga terjadi pada roda kereta hasil forging dengan ketebalan awal billet 80 mm, namun pada bagian web residual stress kompresifnya tergolong rendah yaitu sebesar -11,52 MPa.
==============================================================================================================
The demand for more efficient manufacturing processes has increased in recent years. The cold forging process is presented as a possible solution, because it allows the production of parts with good surface finish and with good mechanical properties. Nevertheless, the design of cold forging sequences is very empirical and is based on the experience of the designer. Computational modeling of each stage of the formation process by the finite element method can make the design of sequences faster and more efficient, reducing the use of conventional "trial and error" methods. In this research, the application of general commercial finite element software - ANSYS - has been applied to model forming operations.
The stages in this study consisted of the process of modeling the train wheels, which from there could be modeled the forging parts (molds) using 3D Solidworks modeling software. The simulation process includes material definition, meshing, set up, and analysis of results. After getting an analysis of the results, it is compared with changes in workpiece thickness and stress load. For the initial thickness of the workpiece varied with values of 76 mm, 77 mm, 78 mm, 79 mm, and 80 mm. As for the stress load varied with values of 180 MN, 190 MN, 200 MN, 210 MN, and 200 MN. The purpose of this variation is to determine the effect of changes in the initial thickness of the billet and the burden of emphasis on the forging process on the shape of the billets and residual stress resulting from the forging process.
Based on the results of research that has been done, it is known that variations in the initial thickness of the billet and the size of the loading affect the shape of the billet and the residual stress resulting from the forging process. Obtained the form of a billet as a result of the forging process that is sufficient to fill the mold space with an initial billet thickness of 79 mm and 80 mm which is given the largest loading in variations, namely 220 MN (22500 tonf). However, with the initial thickness of the 79 mm billet there is still a lack of filling in the hub. With the initial thickness of 80 mm billets, billets have filled the rim and hub parts, but the web part has a lack of filling.
The residual stress that arises on the forged wheels with an initial billet thickness of 79 mm is compressive and is advantageous for the wheels of the train. Although in the hub section the compressive stress residual is low, namely -71,857 MPa. This also happened to the forged wheels with an initial billet thickness of 80 mm, but on the web the compressive stress residual was low, namely -11.52 MPa.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Finite Element, Forging, Railway Wheel, Medium Speed, Elemen Hingga, Forging, Roda Kereta, Semi Cepat |
| Subjects: | T Technology > T Technology (General) > T57.62 Simulation T Technology > TA Engineering (General). Civil engineering (General) > TA347 Finite Element Method T Technology > TS Manufactures > TS171 Product design |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis |
| Depositing User: | Zulfan Farruqi |
| Date Deposited: | 23 Aug 2020 14:12 |
| Last Modified: | 17 Jun 2023 15:52 |
| URI: | http://repository.its.ac.id/id/eprint/79317 |
Actions (login required)
 |
View Item |