Mukhlis, Miftahul (2026) Perancangan Struktur Mesin Pemotong Pegas Daun Dalam Rangka Pemanfaatan Kembali Pegas Daun (Studi Kasus di PT Bagong Dekaka Makmur-Malang). Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Proses pemotongan pegas daun yang dilakukan secara manual menggunakan gerinda duduk saat ini memiliki efisiensi rendah dan risiko ergonomis tinggi bagi operator. Penelitian ini bertujuan merancang struktur mesin pemotong pegas daun dengan metode pemotongan shearing guna meningkatkan produktivitas serta keamanan operasional di PT Bagong Dekaka Makmur. Metode perancangan diawali dengan tahap observasi dan studi literatur, dilanjutkan dengan pemilihan material untuk pisau potong (shear blade). Setelah itu, dilakukan pemodelan geometri 3D menggunakan perangkat lunak CAD dan analisis perhitungan gaya pemotongan yang dibutuhkan. Evaluasi kekuatan struktur kemudian dilakukan melalui perhitungan manual berbasis metode matriks serta simulasi numerik menggunakan Metode Elemen Hingga (Finite Element Analysis). Pada tahap ini, pembebanan statis diaplikasikan pada rangka untuk menganalisis respons struktur terhadap beban operasional. Hasil perhitungan menunjukkan bahwa untuk memotong plat pegas daun berdimensi tebal 10 mm dan lebar 70 mm, dibutuhkan gaya potong sebesar 31,6 ton. Pada perancangan mesin ini, material yang dipilih untuk pisau potong (shear blade) adalah AISI D2, sedangkan struktur rangkanya menggunakan material ASTM A36. Berdasarkan perbandingan antara kekuatan material dan beban kerja yang diterima, struktur rangka ini memiliki nilai faktor keamanan (safety factor) sebesar 3. Hal ini mengindikasikan bahwa struktur rancangan mampu menahan beban dengan sangat baik tanpa mengalami kegagalan. Untuk memastikan rancangan tersebut benar-benar aman, dilakukan validasi dengan membandingkan hasil perhitungan manual dan FEA. Validasi ini mengambil dua sampel ukuran elemen (mesh) dengan tingkat selisih terkecil, yaitu sampel 17 mm (menghasilkan error 1,28% pada Segmen 1 dan 0,81% pada Segmen 3) serta sampel 15 mm (menghasilkan error 3,18% pada Segmen 1 dan 1,63% pada Segmen 3). Mengingat tingkat simpangan (error) maksimum dari kedua uji tersebut hanya sebesar 3,18%, hasil perhitungan dinyatakan valid. Kesimpulannya, struktur rangka mesin pemotong ini terbukti kuat, aman, layak untuk diproduksi (difabrikasi), dan memenuhi standar teknis operasional.
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The leaf spring cutting process, currently performed manually using a bench grinder, possesses low efficiency and poses high ergonomic risks for operators. This study aims to design the structure of a leaf spring cutting machine utilizing the shearing method to increase productivity and operational safety at PT Bagong Dekaka Makmur. The design method commenced with observation and a literature study, followed by material selection for the shear blade. ubsequently, 3D geometric modeling was conducted using CAD software, along with an analytical calculation of the required cutting force. Structural strength evaluation was then carried out through manual calculations based on the matrix method and numerical simulation using Finite Element Analysis (FEA). At this stage, static loading was applied to the frame to analyze the structural response to operational loads. Calculation results indicate that cutting a leaf spring plate with a thickness of 10 mm and a width of 70 mm requires a cutting force of 31.6 tons. In this machine design, the material selected for the shear blade is AISI D2, while the frame structure utilizes ASTM A36. Based on the comparison between the material strength and the applied working load, this frame structure has a safety factor of 3. This indicates that the designed structure is highly capable of withstanding the load without experiencing failure. To ensure the design is entirely safe, validation was conducted by comparing the manual calculation results with the FEA. This validation utilized two samples of mesh element sizes with the smallest error margins, namely the 17 mm sample (yielding a 1.28% error in Segment 1 and 0.81% in Segment 3) and the 15 mm sample (yielding a 3.18% error in Segment 1 and 1.63% in Segment 3). Considering the maximum error margin from both tests is only 3.18%, the calculation results are declared valid. In conclusion, the frame structure of this cutting machine is proven to be strong, safe, feasible for fabrication, and meets operational technical standards.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Mesin Pemotong Pegas Daun, Metode Elemen Hingga, Analisa Struktur, Rangka Mesin, Perancangan Struktur.: Leaf Spring Cutting Machine, Finite Element Method, Structural Analysis, Machine Frame, Structural Design. |
| Subjects: | T Technology > TJ Mechanical engineering and machinery > TJ1185 Metal-cutting--Problems, exercises, etc. T Technology > TJ Mechanical engineering and machinery > TJ1186 Metal-cutting tools. T Technology > TJ Mechanical engineering and machinery > TJ1186.B5 Metal-cutting tools--Design and construction. T Technology > TJ Mechanical engineering and machinery > TJ1230 Cutting and sawing machinery T Technology > TJ Mechanical engineering and machinery > TJ230 Machine design |
| Divisions: | Faculty of Vocational > Mechanical Industrial Engineering (D4) |
| Depositing User: | Miftahul Mukhlis |
| Date Deposited: | 03 Aug 2026 08:49 |
| Last Modified: | 03 Aug 2026 08:49 |
| URI: | http://repository.its.ac.id/id/eprint/142389 |
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