Pengaruh Rasio Pengurangan Ketebalan, Sudut Die, Dan Koefisien Gesek Terhadap Tegangan Maksimum Dan Tegangan Sisa Pada Proses Ironing Cup Aluminium

Faizin, Akhmad (2022) Pengaruh Rasio Pengurangan Ketebalan, Sudut Die, Dan Koefisien Gesek Terhadap Tegangan Maksimum Dan Tegangan Sisa Pada Proses Ironing Cup Aluminium. Doctoral thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Deep drawingmerupakan proses pengerjaan logam guna membentuk lembaran/plat menjadi bentuk cupsebagai produk pada pembuatan selongsong peluru, panci, tabung, kaleng minuman, dan lain-lain. Hasil proses deep drawingumumnya memiliki diameter luar dan ketebalan dinding yang tidak seragam, sehingga diperlukan proses lanjut. Ironingmerupakan proses lanjut yang cocok untuk membuat produk cupmemiliki diameter luar dan ketebalan dinding seragam. Ironingtermasuk proses pembentukan logam, yaitu proses pengurangan ketebalan dinding sebuah produk berbentuk cup, yang umumnya dilakukan secaracold forming.Beban luar yang dibutuhkan untuk prosesini, dapat menimbulkantegangan maksimum dan tegangan sisa(residual stress).Tegangan maksimum dugunakan untuk pembentukan. Tegangan sisadapat menguntungkan atau merugikan tergantung pada fungsi produk, besar, dan arahtegangan sisa. Tegangan sisa dapat bertindak sebagai beban tambahan pada beban yang diberikandan berpengaruh pada kualitas produk, yaitu: ketepatan dimensi, kekasaran permukaan, dan sifat mekanik. Kecepatan proses ironingsangat dipengaruhi oleh sifat mekanik material cup, thickness reduction ratio(TRR), dan desain presstool.Nilai TRRterbatas dan jika dilampaui beresiko rusaknya produk. Berbagai penelitian tentang dilakukan guna mendapatkan proses yang optimal.
Pada penelitian ini dilakukan stress analysismenggunakan simulasi pemodelan softwareANSYS guna mendapatkan tegangan maksimum dan tegangan sisa yang terjadi.Analisis dilakukan dengan memvariasikan TRR20% hingga 30%, sudut die25ohingga 30o, dan koefisien gesek 0.05, hingga 0.15. Selanjutnya dilakukan pengolahan dan analisis untuk mendapatkan parameter prosespaling signifikanberpengaruh terhadap tegangan maksimum dan tegangan sisa, sertanilai parameteryang menghasilkan respon paling optimal. Analysisdilakukan pada cupaluminium AA1100 dengan diameter luar 37 mm, tinggi 20 mm, dan tebal dinding 2 mm.
Hasil menunjukkan bahwanilai TRR, sudut die, dan koefisien gesek secara berurutan20%, 25o, dan 0.05 mampu menghasilkan respontegangan maksimumdan tegangan sisapaling optimalsebesar 352.074 N/mm2dan 130.6958 N/mm2.Selain itu, hasil eksperimen menunjukkan perbaikan kualitas permukaan dari N7menjadi N5dan peningkatan angka kekerasan dari 44 BHN menjadi 52 BHN.
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Deep drawing is a metalforming process to form a sheet/blank into a cup shapedas a product in the manufacture of bullet casings, pans, tubes, drink cans, and others. The results of the deep drawing process generally have a non-uniform outer diameter and wall thickness, so further processing is required. Ironing is an advanced process suitable for making cup products have a uniform outer diameter and wall thickness. Ironing is a metal forming process, namely the process of reducing the wall thickness of a cup-shaped product, which is generally done by cold forming. The load required for this process can cause maximum stress and residual stress. The maximum stress is used for forming. Residual stresses can be beneficial or detrimental depending on product function, its magnitude, and its direction. Residual stress can act as an additional load on the applied load and affect the quality of the product, namely: dimensional accuracy, surface roughness, and mechanical properties. The speed of the ironing process is strongly influenced by the mechanical properties of the cup material, thickness reduction ratio (TRR), and press tool design. The TRR value is limited and if it is exceeded there is a risk of product damage. Various studies have been carried out toobtain the optimal process.
In this study, stress analysis was carried out using the ANSYS software modeling simulation in order to obtain the maximum stress and residual stress that occurred.The analysis was carried out by varying the TRR from 20% to 30%, the die angle from 25 to 30, and the coefficient of friction from 0.05 to 0.15.Furthermore, processing and analysis are carried out to obtain the process parameters that have the most significant effect on the maximum stress and residual stress, as well as the parameter values that produce the most optimal response.The analysis was carried out on AA1100 aluminum cups with an outer diameter of 37 mm, a height of 20 mm, and a wall thickness of 2 mm.
The results showed that the TRR, die angle, and coefficient of friction respectively20%, 25o, and 0.05 were able to produce the most optimal maximum stress and residual stress response of 352,074 N/mm2and 130.6958 N/mm2.In addition, the experimental results showed an improvement in surface quality from N7 to N5 and an increase in the hardness number from 44 BHN to 52 BHN.

Item Type:	Thesis (Doctoral)
Additional Information:	RDM 620.112 3 Fai p-1
Uncontrolled Keywords:	ironing, ratio, sudut die, koefisien gesek, residual stress
Subjects:	H Social Sciences > HD Industries. Land use. Labor > HD61 Risk Management
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21001-(S3) PhD Thesis
Depositing User:	- Davi Wah
Date Deposited:	17 Apr 2023 06:32
Last Modified:	17 Apr 2023 06:32
URI:	http://repository.its.ac.id/id/eprint/97875

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