Subroto, Remy Maulinda Rahmawati (2019) Analisis Simulasi Numerik Pengaruh Variasi Ukuran Side Clearance Groove dan Age Hardening Terhadap Peningkatan Umur Piston Al-Si Ekskavator Hidrolik Komatsu Pc-300. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Setiap komponen mesin didesain untuk memiliki umur pemakaian tertentu, namun untuk alasan keamanan memang didesain dengan asumsi bahwa pada titik tertentu akan terjadi kondisi operasi yang diatas normal, padahal kenyataannya sangat jarang. Akhirnya banyak komponen mesin yang sudah tidak dipakai sebenarnya masih bisa digunakan ulang dengan hanya memberi sedikit perbaikan. Contohnya pada piston bekas ekskavator hidrolik KOMATSU PC-300 paduan Al-Si ADC14 (telah dipakai selama 18000 jam) dan belum mengalami kegagalan, namun terjadi aus pada bagian groove yang menyebabkan blow-by. Pada penelitian ini dilakukan simulasi menggunakan software ANSYS Workbench 19.2 untuk mencari sisa umur piston tersebut dengan metode Remaining Life Asessment (RLA) melalui simulasi fatigue life. Lalu diberikan perbaikan dari segi desain dengan memvariasikan besar clearance piston pada groove pertama dan kedua (0,03 mm; 0,04 mm; 0,05 mm; 0,06 mm; 0,07 mm) untuk mengurangi blow-by. Dan saat perlakuan panas diberi solution heat treatment 500oC dan ditahan selama 5 jam, di quenching menggunakan air hingga 20oC dan diberikan age hardening pada variasi temperatur 180oC dan 210 oC dengan variasi waktu holding 3 jam, 5 jam, 7 jam, dan 9 jam. Lalu dilakukan RLA kembali untuk mengetahui pengaruhnya terhadap sisa umur piston tersebut. Hasil simulasi fatigue life menujukkan umur sisa sebesar 2,9 tahun. Hasil simulasi fluent menujukkan dimensi side clearance pada groove piston memberi hasil laju blow-by dan tekanan blow-by yang bervariasi yaitu 64,328 L/min dan 1,801 kPa untuk side clearance 0,03 mm; 65,664 L/min dan 1,694 kPa untuk side clearance 0,04 mm; 66,852 L/min dan 1,731 kPa untuk side clearance 0,05 mm; 72,018 L/min dan 2,305 kPa untuk side clearance 0,06 mm; 72,054 L/min dan 2,247 kPa untuk side clearance 0,07 mm. Hasil perlakuan panas hardening menunjukkan pengaruh pada kekuatan fatigue piston. Temperatur 180oC pada waktu holding 3 jam; 5 jam; 7 jam; dan 9 jam menghasilkan kekuatan fatigue berturut-turut sebesar 334,5 MPa; 323,3 MPa; 268,9 MPa; dan 310,5 MPa. Sedangkan temperatur 210oC pada waktu holding 3 jam; 5 jam; 7 jam; dan 9 jam menghasilkan kekuatan fatigue berturut-turut sebesar 268,9 MPa; 211,3 MPa; 193,7 MPa; dan 166,5 MPa. Hal ini membuktikan dimensi side clearance, temperatur aging dan waktu holding berpengaruh terhadap peningkatan umur.
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Each engine component is designed to have a standard usage within a certain period of time, but for security reasons components are designed with consideration that at a certain point they can experience certain extreme conditions, while in reality it don’t really happen. Hence many of the used engine components can actually be reused with only a few improvements. For example used piston of KOMATSU PC-300 hydraulic excavator Al-Si ADC14 alloy (used for 18,000 hours) in this study that has passed the useful life but has not experience failure with some wear on the groove part which causes blow-by. In this study an experiment will be carried out using ANSYS Workbench 19.2 to calculate the remaining life of these pistons with Remaining Life Asessment (RLA) method through fatigue life simulation. Then it will be given a variation on the design of groove clearance on the first and second groove (0,15; 0,2; 0,25; dan 0,3 mm) to redce blow-by. Then it will be taken to the heat treatment simulation with a 500oC for solution heat treatment with holding time of 5 hours, then it will be quenched with sold water until 20oC. An hardening will then be given at a temperature variation 140; 180; 220; and 260 oC with variations in holding time of 6 hours, 9 hours, 12 hours, and 15 hours. After that the RLA simulation will be performed again to analyze the effect of these treatments to the remaining life of the piston. The fatigue life simulation shows the piston remaining life of 2,9 years left. The blow-by simulation shows that side clearance on piston groove does affect the blow-by rate and allowable blow-by pressure which is 64,328 L/min and 1,801 kPa for side clearance 0,03 mm; 65,664 L/min and 1,694 kPa for side clearance 0,04 mm; 66,852 L/min and 1,731 kPa for side clearance 0,05 mm; 72,018 L/min and 2,305 kPa for side clearance 0,06 mm; 72,054 L/min and 2,247 kPa for side clearance 0,07 mm. The hardening process shows that aging temperature and holding time does affect the mechanical properties of the product such as hardness and fatigue strength. Temperature 180oC with holding time of 3h; 5h; 7h; and 9h resulted in fatigue strength of 334,5 MPa; 323,3 MPa; 268,9 MPa; dan 310,5 MPa. As for temperature 210oC with holding time of 3h; 5h; 7h; and 9h resulted in fatigue strength of 268,9 MPa; 211,3 MPa; 193,7 MPa; dan 166,5 MPa. These results shows that side clearance variation, aging temperature, and holding time does affect the increase of piston’s remaining life.
| Item Type: | Thesis (Other) |
|---|---|
| Subjects: | T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ254.7 Combustion chambers T Technology > TS Manufactures > TS171 Product design T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning) |
| Divisions: | Faculty of Industrial Technology > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis |
| Depositing User: | Remy Maulinda Rahmawati Subroto |
| Date Deposited: | 22 Jul 2026 07:55 |
| Last Modified: | 22 Jul 2026 07:55 |
| URI: | http://repository.its.ac.id/id/eprint/65747 |
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