Syarah, Roze Windu Yuni (2020) Analisa Simulasi Cold Forging Roda Kereta Berkecepatan Rendah dengan Metode Elemen Hingga. Other thesis, Institute Teknologi Sepuluh Nopember.
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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 (Other) |
|---|---|
| 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: | 23 Nov 2023 07:05 |
| URI: | http://repository.its.ac.id/id/eprint/80826 |
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