., Edwin (2018) Rancang Bangun Casing Continuously Variable Transmission (CVT) Untuk Sepeda Motor Listrik. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Casing continuously variable transmission (CVT) merupakan rumah (housing) dari komponen-komponen transmisi untuk kendaraan bermotor seperti poros, pulley, bearing, helical gear, dan spur gear. Casing CVT yang terbagi menjadi tiga bagian, yaitu base case CVT, cover CVT, dan cover transmisi berfungsi sebagai pelindung dan tempat bertumpunya komponen transmisi yang berada di dalamnya. Selain itu, casing CVT juga harus mampu menahan beban kerja dari komponen-komponen transmisi tersebut. Proses pembuatan casing CVT dapat dilakukan dengan sand casting bila dibutuhkan dalam jumlah yang sedikit dan gravity die casting bila dibutuhkan untuk produksi massal. Oleh karena itu, dilakukan penelitian dengan tujuan mendapatkan redesign casing CVT yang bebas cacat dan lebih tipis melalui perangkat lunak dan ditujukan untuk proses sand casting dan gravity die casting.
Redesign yang dilakukan pada penelitian ini adalah dimensi dan material casing CVT dari motor matic yang banyak digunakan dipasaran. Casing CVT tersebut tidak diketahui jenis materialnya, maka dilakukan pengecoran secara tradisional dengan material aluminium untuk mendapatkan data awal. Dari pengecoran tersebut didapatkan variabel berupa jenis aluminium yang digunakan yaitu aluminium Al380, temperatur penuangan, dimensi sistem saluran pengecoran tradisional, lokasi cacat, dan ketebalan dinding. Dilakukan cross check antara hasil pengecoran tradisional dan hasil simulasi yang memiliki dimensi dan material yang sama dan didapatkan lokasi cacat yang sama sehingga perangkat lunak simulasi cor dapat digunakan. Dilakukan perhitungan gaya yang terjadi pada komponen casing CVT dengan input beban penumpang sebesar 150 kg, torsi maksimal motor sebesar 25 N.m, dan HP motor sebesar 3kW dan dilanjutkan dengan simulasi mekanik. Simulasi mekanik bertujuan untuk memastikan bahwa dengan menggunakan material aluminium Al380 dan ketebalan minimal, hasil redesign yang diperoleh aman untuk digunakan. Bila sudah didapatkan desain yang aman, dilakukan simulasi cor yang bertujuan untuk mendapatkan dimensi sistem saluran dan riser yang dapat menghasilkan benda cor yang bebas cacat shrinkage porosity dan gas porosity.
Dari serangkaian proses yang dilalui pada penelitian ini, didapatkan redesign casing CVT yang memiliki ketebalan 5 mm untuk sand casting dan 3 mm untuk gravity die casting dengan nilai stress hasil simulasi mekanik dibawah yield stength aluminium Al380 (159 MPa). Dimensi dari sistem saluran yang digunakan untuk proses sand casting dan gravity die casting adalah perbandingan choke : runner : ingate yaitu 1:4:4 dan nilai riser berdasarkan metode NRL. Choke untuk proses sand casting dari base case CVT, cover CVT, dan cover transmisi berturut-turut bernilai 15 mm, 17 mm, dan 18 mm. Untuk proses gravity die casting, dimensi choke dari base case CVT, cover CVT, dan cover transmisi berturut-turut bernilai 16 mm, 18 mm, dan 20 mm.
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Continuously variable transmission (CVT) case is the housing of transmission components for motor vehicles such as shafts, pulleys, bearings, helical gears, and spur gears. CVT case consist of three parts, which is CVT base case, CVT cover, and cover transmission, serves as a protector and where the transmission component mounted inside. In addition, the CVT case must also be able to withstand the workload of the transmission components. The process of making CVT case can be done with sand casting when needed in small quantities and gravity die casting when needed for mass production. Therefore, a study was conducted with the aim of obtaining a redesign of a defective and thinner CVT case through software and intended for sand casting and gravity die casting processes.
Redesign on this research focuses only on the dimensions and material of CVT case from matic motorbike which is widely used in the market. CVT case’s type of material is still unknown, hence it is casted traditionally with aluminum to get the initial data. From the foundry, the variables obtained are the type of aluminum used are aluminum Al380, casting temperature, dimensions of traditional casting system, location of defects, and wall thickness. Cross-check between traditional casting results and simulation results that have the same dimensions and materials and the result is the same defect location, therefore the casting simulation software can be used. The force for mechanical simulation that occurs on CVT case is obtained from passenger load inputs of 150 kg, maximum torque of the motor of 25 N.m, and HP motor of 3kW. Mechanical simulation aims to ensure that by using Al380 aluminum material and minimal thickness, the resulting redesign results are safe to use. When a safe design is obtained, a casting simulation is performed to obtain the dimensions of the gating system and riser which can produce cast objects that are free of shrinkage and gas porosity.
From a series of processes in this study, we found a CVT case redesign that has a thickness of 5 mm for sand casting and 3 mm for gravity die casting with stress mechanical simulation results below Al380 (159 MPa) aluminum yield strength. The dimensions of the gating system used for sand casting and gravity die casting processes are choke: runner: ingate ratio of 1: 4: 4 and riser values based on the NRL method. Choke for sand casting process from CVT base case, CVT cover, and transmission cover consecutively is 15 mm 17 mm, and 18 mm. For the gravity die casting process, the choke dimension of the CVT base case, CVT cover, and transmission cover consecutively is 16 mm, 18 mm, and 20 mm.
| Item Type: | Thesis (Undergraduate) |
|---|---|
| Uncontrolled Keywords: | aluminium, Al380, casing cvt, swingarm, pengecoran, sand casting, gravity die casting, simulasi |
| Subjects: | T Technology > TL Motor vehicles. Aeronautics. Astronautics > TL448 Electric motorcycles |
| Divisions: | Faculty of Industrial Technology > Mechanical Engineering > 21201-(S1) Undergraduate Thesis |
| Depositing User: | Edwin Edwin |
| Date Deposited: | 15 Jul 2021 08:53 |
| Last Modified: | 15 Jul 2021 08:53 |
| URI: | http://repository.its.ac.id/id/eprint/55250 |
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