Izzatullah, Shaffan Ahda (2020) Redesain Dari Roda Kereta Api Kecepatan Rendah Menjadi Roda Kereta Api Semi Cepat (Medium Speed Train). Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
PT. INKA sedang mengembangkan kereta api semi cepat. Salah satu komponen yang dapat dikembangkan adalah bagian roda. Dalam penelitian ini digunakan desain roda milik PT INKA yang beroperasi pada kecepatan rendah. Roda tersebut akan diredesain agar mampu digunakan pada kereta api semi cepat dengan melakukan simulasi mechanical dan thermomechanical berdasarkan standar EN-13979. Apabila desain awal roda kereta api tidak lolos dalam simulasi maka dilakukan redesain dengan modifikasi fillet antara thread dan flange, modifikasi diameter, dan modifikasi material pada roda kereta milik PT.INKA. Pada penelitian ini dilakukan simulasi menggunakan aplikasi Ansys dengan metode trancient structural, dan trancient thermal mengacu pada, jurnal Roya Sodet A. (2014), jurnal Peng (2012) dan standar EN 13979.
Tahapan pada penelitian ini terdiri dari proses pemodelan roda kereta kondisi lurus, berbelok, crossing dan drag braking, dengan memvariasikan dimensi fillet di ukuran 15mm, 16mm, dan 17mm, diameter roda pada ukuran 920mm, 940mm, 960mm, dan material roda menggunakan SSW-Q3s dan R7T, kemudian dilakukan simulasi mechanical dan thermomechanical dengan software ANSYS yang meliputi proses pendefinisian model, meshing, set up constraint, dan analisis hasil. Setelah didapatkan hasil simulasi, peneliti membandingkan hasil simulasi dengan batas hasil yang diizinkan berdasarkan standar EN-13979.
Dari simulasi mechanical didapatkan roda kereta api inka yang sudah ada tidak lolos simulasi pada kondisi berbelok, dimana nilai tegangan geser maksimum pada kondisi berbelok sebesar 303.49 Mpa (>290 Mpa). Berikutnya dilakukan modifikasi fillet antara thread dan flange dari ukuran 15 mm menjadi 16 mm dan modifikasi diameter menjadi 920 mm. Pada modifikasi fillet didapatkan penurunan tegangan yang lebih signifikan dibandingkan modifikasi diameter. Nilai tegangan geser maksimum pada kondisi berbelok tetap tidak lolos simulasi mechanical sehingga dilakukan modifikasi fillet antara thread dan flange dari ukuran 16 mm menjadi 17 mm. Nilai tegangan geser maksimum pada kondisi berbelok mengalami penurunan menjadi sebesar 277.28 Mpa (<290 Mpa) sehingga dapat dikategorikan lolos uji mechanical. Berikutnya dilakukan uji thermomechanical pada desain hasil modifikasi tersebut. Nilai tegangan residual rata-rata pada sektor 1, 2, dan 3 sebesar 49.89 Mpa, 56.13 Mpa, dan 55.03 Mpa (<250 Mpa), nilai tegangan residual rata-rata dari seluruh sektor sebesar 53.68 Mpa (<200Mpa). Lateral displacement yang terjadi sebesar 0.73 mm/-0.28 mm (<1.5 mm / > -0.5 mm). Nilai tegangan residual dan lateral displacement berada di dalam rentang batas yang diizinkan sehingga hasil modifikasi fillet antara thread dan flange dengan ukuran 17 mm dapat dianggap lolos simulasi thermomechanical.
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PT. INKA is developing medium speed train. One of the component that can be developed is the wheels. This research used PT INKA’s wheel design which operates at low speed. The wheel will be re-design as the ability increase in medium speed by do the mechanical and thermomechanical simulations based on EN-13979 Standard.. If the initial design of the train wheel does not pass the test, redesign is required by modifying the fillet between thread and flange, modifying the diameter, and the material. Simulation is done by ANSYS trancient structural and trancient thermal method based on, Roya Sodet’s journal (2014), Peng’s journal (2012), and standard EN 13979.
The research consist of some step such as modeling the rail wheel in straight, curve, crossing and drag braking conditions, then varying the dimensions of the fillet (15mm, 17mm, and 19mm), the diameter (920mm, 940mm, and 960mm), and the material (SSW-Q3s and R7T) then do the mechanical and thermomechanical simulations using ANSYS which includes the process of defining the model, meshing, setting up constrains, and analyzing the result. After obtaining the simulation results, the researcher compared it with the allowable value based on EN-13979 Standard.
From the simulation result of mechanical simulations, the existing train wheel did not pass the test under curve condition, where the maximum shear stress value at curve condition was 303.49 Mpa (>290 Mpa). Next step is to modify the fillet between thread and flange from size 15 mm to 16 mm and modify the diameter from 774 mm to 920 mm. The fillet modification obtained a more significant stress reduction than the diameter modification. The value of the maximum shear stress under curve conditions still did not pass the mechanical testing so that the fillets between the thread and flange were modified from 16 mm to 17 mm. The value of the maximum shear stress under curve conditions decreased to 277.28 Mpa (< 290 Mpa) so that it can be considered to have passed mechanical simulations. The next step is the thermomechanical simulations on the modified design. The average residual stress in sectors 1, 2 and 3 are 49.89 MPa, 56.13 MPa and 55.03 MPa (<250 MPa), the average residual stress of the entire sector is 53.68 MPa (<200 MPa). Lateral displacement that occurred was 0.73 mm / -0.28 mm (<1.5 mm / >-0.5 mm). The residual stress and lateral displacement values are within the permitted range so that the results of the modified fillet between the thread and the flange with a size of 17 mm can be considered to have passed the thermomechanical test.
| Item Type: | Thesis (Other) |
|---|---|
| Additional Information: | RSM 620.112 3 Izz r-1 |
| Uncontrolled Keywords: | Roda Kereta, Kereta Api Semi Cepat, Fillet, Diameter, SSW-Q3s, R7T, Elemen Hingga, Lurus, Berbelok, Crossing, Drag Braking, Thermomechanical, Mechanical, Standar EN-13979, Rail Wheel, Medium Speed Train, Fillet, Diameter, SSW-Q3S, R7T, Finite Element, Straight, Curve, Crossing, Drag Braking, Thermomechanical, Mechanical, EN-13979 Standard. |
| Subjects: | T Technology > TA Engineering (General). Civil engineering (General) > TA169.5 Failure analysis T Technology > TA Engineering (General). Civil engineering (General) > TA347 Finite Element Method T Technology > TJ Mechanical engineering and machinery |
| Divisions: | Faculty of Industrial Technology > Mechanical Engineering > 21201-(S1) Undergraduate Thesis |
| Depositing User: | Shaffan Ahda Izzatullah |
| Date Deposited: | 23 Aug 2020 08:37 |
| Last Modified: | 12 Jun 2023 15:10 |
| URI: | http://repository.its.ac.id/id/eprint/80519 |
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