Analisa Simulasi Cold Forging Roda Kereta Berkecepatan Rendah dengan Metode Elemen Hingga

Syarah, Roze Windu Yuni (2020) Analisa Simulasi Cold Forging Roda Kereta Berkecepatan Rendah dengan Metode Elemen Hingga. Undergraduate thesis, Institute Teknologi Sepuluh Nopember.

[img] Text
02111640000039_Undergraduate_Thesis.pdf - Accepted Version
Restricted to Repository staff only

Download (6MB) | Request a copy

Abstract

Pembuatan roda kereta api menurut standar Association of American Railroads (AAR) melalui proses forging atau casting. Forging merupakan proses pembentukan logam untuk menghasilkan produk dengan memberikan gaya tekan dan laju pembebanan tertentu. Proses forging yang dilakukan adalah cold forging. Penelitian ini bertujuan untuk mengatahui pengaruh ketebalan billet dan besarnya beban. Penelitian dilakukan dengan material AISI 4340 melalui simulasi pada software ANSYS Explicit Dynamic hal ini karena pemodelan komputasi dari setiap tahap proses pembentukan dengan metode elemen hingga dapat membantu desain lebih cepat dan efisien. Untuk verifikasi material menggunakan persamaan Johnson – Cook Strength, parameter yang digunakan berdasarkan data roda kereta api di Negara Iran dengan tipe S1002. Kemudian untuk ketebalan dan besar pembebanan mengacu pada penelitian terdahulu. Tahapan pada penelitian ini terdiri dari proses pemodelan roda kereta dimana outputannya dies atau cetakan menggunakan software pemodelan 3D Solidworks. Kemudian proses simulasi menggunakan software Ansys. Dimana tahapan simulali meliputi mendefinisikan engineering data, impor geometri, mendesain billet, set up, meshing, uji konvergensi, dan analisis hasil. Dari proses penelitian ini akan didapatkan nilai dan arah residual stress akibat deformasi. Sehingga peneliti dapat mengetahui pengaruh variasi parameter yang dilakukan. Perbandingan ini dilakukan untuk menentukan manakah ukuran billet dan besar ii pembebanan yang tepat dalam membentuk roda kereta berkecepatan kecil dengan residual stress sesuai dengan yang diizinkan. Dari serangkaian metodologi yang telah dilakukan, pada penelitian tugas akhir ini didapatkan bahwa pengaruh ketebalan billet awal terhadap proses forging yaitu semakin tebal billet forging, maka geometri semakin sesuai dengan cetakan. Begitupula dengan besar gaya. Kemudian didapatkan konfigurasi variasi yang menghasilkan bentuk roda paling baik dibandingkan konfigurasi lainnya, yaitu forging dengan ketebalan awal billet 75mm dengan gaya forging 140MN dengan residual stress yang dihasilkan bersifat kompresi atau menguntungkan pada saat operational baik pada bagian roda yaitu hub, web dan rim baik pada arah radial, axial dan circumferential. Kata Kunci: Cold Forging, Residual stress, Finit Element Method, Low Speed ======================================================== Manufacture of a railway wheel according to the Association Of American Railroads (AAR) is through forging or casting process. Forging is a steel forming process to produce a product by applying a specific pressure load and velocity load. The forging process that is used for this research is cold forging. This research aims to find out the effect of billet thickness and load magnitude. This research was done by using AISI 4340 as the material and using ANSYS explicit dynamic as the software for simulation because the modelling computation of each forming phase using finite element method could help to produce more faster and efficient design. To verify the material using johnsoncook strength, the parameter that is used is according to railway wheel data on I ranian railway type s1002. Then for the thickness and load magnitude are according to previous research. The phase of this research consist of railway wheel modelling process with the output of dies using 3d modelling software that is solidworks. The simulation process software is using Ansys, where the simulation process encompass engineering data, import geometry, designing billet, set up, meshing, convergence test and analyizing result. From this research process, will be obtained the value and direction of residual stress produced from deformation. So that the researcher could know the effect of parameter variation that is applied. This comparison is done for determining which billet thickness and load magnitude iv that is correct in forming the low speed railway wheel with allowable residual stress. From the series of methodologi that has been done, on this research known that starting billet thickness effect toward forging process that is the more forging billet thickness applied, the more wheel geometry can be fit into the mold. Same with the load magnitude. Then we obtained the variation configuration that produce the best wheem shape compares to other configuration, which is forging with starting billet thickness of 75 mm with the load magnitude of 140 MN with the residual stress produced had compressive behaviour or benefitting the train when it in operational condition whether the wheel part of hub, web and rim or the direction of radial, axial and circumferential. Key Word: Cold Forging, Residual stress, Finit Element Method,Low Speed

Item Type: Thesis (Undergraduate)
Uncontrolled Keywords: Cold Forging, Residual stress, Finite Element Method, Low Speed, Cold Forging, Residual stress, Finite Element Method, Low Speed
Subjects: T Technology > TF Railroad engineering and operation > TF240 Railway construction
T Technology > TF Railroad engineering and operation > TF270 Railway structures and buildings
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis
Depositing User: Roze Windu Yuni Syarah
Date Deposited: 24 Aug 2020 04:56
Last Modified: 24 Aug 2020 04:56
URI: http://repository.its.ac.id/id/eprint/80826

Actions (login required)

View Item View Item