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All Journal Rekayasa Mesin Turbo : Jurnal Program Studi Teknik Mesin Jurnal Teknologi dan Rekayasa Alat Berat (JTRAB)
Nugroho Santoso
Program Studi Diploma Teknik Mesin Sekolah Vokasi Universitas Gadjah Mada Yogyakarta
Automotive Engineering Control & Systems Engineering Engineering Industrial & Manufacturing Engineering Mechanical Engineering

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Analisa Crack Coil Spring Track Adjuster pada Undercarriage Excavator CAT 320GC Aldi Lavandida Utama; Santoso, Nugroho; Setyana, Lilik Dwi; Hendaryanto, Ignatius Aris
Jurnal Teknologi dan Rekayasa Alat Berat Vol 2 No 1 (2025): JTRAB Volume 2, No 1, 2025
Publisher : Department of Mechanical Engineering, Vocational College, Gadjah Mada University.

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22146/jtrab.v2i1.15209

Abstract

Heavy equipment, such as excavators, plays a crucial role in infrastructure and mining projects. The demanding worksite conditions and production targets require excavators to maintain high productivity, which can lead to material failures. A critical failure observed in the CAT 320GC excavator was the fracture of the coil spring in the undercarriage system. Several factors can contribute to coil spring failure, including worksite conditions, material defects, inadequate maintenance, and operational errors. This study aims to identify the root causes of coil spring fracture by analyzing its mechanical properties. The research methodology includes chemical composition analysis, visual and microstructural examination, hardness testing, and impact testing. The findings indicate that material failure was primarily caused by corrosion on the surface, which accelerated the fracture process. Additionally, repeated excessive loads from track shoe movements contributed to fatigue failure. The coil spring material was identified as high-carbon steel, closely resembling the 51xx (Chromium Steels) type. The fracture exhibited brittle characteristics with a granular or crystalline pattern, and the average impact energy was measured at 0.1541 J/mm². The coil spring material demonstrated an average hardness of 522.83 VHN, confirming its high hardness but brittle nature. The microstructural analysis revealed a predominance of fine lamellar pearlite in the dark regions of the fractured area.
Analisis Kegagalan Material Patahnya Coil Spring pada Track Adjuster Excavator PC 78 Leo Adi Saputra; Santoso, Nugroho; Setyana, Lilik Dwi; Basuki, Budi
Jurnal Teknologi dan Rekayasa Alat Berat Vol 2 No 1 (2025): JTRAB Volume 2, No 1, 2025
Publisher : Department of Mechanical Engineering, Vocational College, Gadjah Mada University.

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.22146/jtrab.v2i1.15707

Abstract

One of the critical components of an excavator's undercarriage is the coil spring, which frequently breaks due to extreme working conditions, lack of routine maintenance, and material defects. This coil spring failure often occurs in the PC 78 excavator unit. The resolution of this issue requires an undetermined period of time. This problem can lead to decreased and suboptimal excavator productivity. The objective of this study is to identify the causes of coil spring fractures, evaluate its mechanical strength, and determine the type of material used. The methods applied include chemical composition analysis, microstructure examination, hardness testing, and impact testing. Visual observations indicate that the coil spring failure is caused by material fatigue, crack initiation, propagation, and final fracture characterized by beach marks and striations. Chemical composition analysis reveals the dominance of iron (Fe), carbon (C), chromium (Cr), and manganese (Mn), classifying the material as AISI 51xx steel. Microstructural examination shows a dominance of bainite, which contributes to the material's hardness. Vickers hardness testing indicates high hardness values consistent with the observed microstructure. Impact testing results suggest that the fractured specimen exhibits ductile behavior.
Increased the Surface Hardness of Recycled Piston Waste by Variation of Shot Pressure in Shot-Peening Method Priyambodo, Bambang Hari; Setiawan, Widia; Santoso, Nugroho; Athaillah , Fakhri; Palmiyanto, Martinus Heru; Priyanto, Kaleb
Jurnal Rekayasa Mesin Vol. 17 No. 2 (2026)
Publisher : Jurusan Teknik Mesin, Fakultas Teknik, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/ub.jrm.v17i2.2133

Abstract

The increasing demand for aluminium in the motorcycle industry has led to significant concerns regarding sustainability and resource utilization. Recycling aluminium waste, particularly from discarded motorcycle pistons, presents a viable solution to address material shortages and reduce environmental impact. This study explores the effects of shot-peening treatment on recycled aluminium derived from motorcycle piston waste, aiming to enhance its mechanical properties and microstructural characteristics. Recycled aluminium specimens were produced through sand casting and subsequently subjected to shot-peening at varying pressures of 5, 6, 7, and 8 bar for 20 minutes. The hardness measurements revealed a substantial improvement, with values recorded as 107, 144, 171, and 209 HV, respectively, demonstrating a 170% increase at the highest pressure compared to untreated specimens. Microstructural analysis indicated notable changes, including increased density, grain refinement, and the formation of a hardened surface layer. The depth of the modified layer ranged from 50 to 200 μm, depending on the applied pressure. Furthermore, shot-peening induced compressive residual stress, which is beneficial for improving fatigue resistance and overall durability. These findings suggest that optimizing shot-peening parameters can significantly enhance the performance of recycled aluminium, making it a promising material for various industrial applications. This study contributes to sustainable manufacturing practices by promoting the reuse of aluminium waste, reducing reliance on virgin materials, and supporting circular economy principles. The implementation of shot-peening in aluminium recycling has the potential to improve material properties, expand its industrial applicability, and minimize environmental impact in the transportation and manufacturing sectors.
Design and Analysis of a 5 m3 Excavator Bucket for Coal Handling Using Topology Optimization and Finite Elemen Analysis Hidayat, Farhan; Basuki, Budi; Santoso, Nugroho; Bekti Wibowo, Setyawan; Harjono
TURBO [Tulisan Riset Berbasis Online] Vol 15 No 2 (2026): TURBO: Jurnal Program Studi Teknik Mesin (in Progress)
Publisher : Universitas Muhammadiyah Metro

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24127/trb.v15i2.5420

Abstract

Conventional excavator bucket designs frequently exhibit over-engineering, which reduces operational efficiency due to excessive structural mass. This study aims to optimize the PC500 bucket with a capacity of 5 m³ to reduce mass and evaluate fatigue. 3D modeling was performed using SolidWorks, while Finite Element Analysis (FEA) testing was simulated through Ansys Workbench. The load simulations applied the parameters of HARDOX 400 steel material. The topology optimization results successfully reduced the bucket mass by 10.65%, from 2,702.04 kg to 2,414.31 kg. The payload capacity also increased from 5 m³ to 5.2 m³. The FEA recorded a maximum von Mises stress of 256.71 MPa with a minimum safety factor of 3.895, ensuring structural safety. The fatigue evaluation proved that the design is safe from fatigue failure. The optimized bucket is proven to be lighter, more efficient, and has a larger capacity.
Co-Authors Aji, Muhammad Sulistiyo Alamin, Rachmat Aldi Lavandida Utama Athaillah , Fakhri Bambang Hari Priyambodo Bekti Wibowo, Setyawan Budi Basuki Harjono Hidayat, Farhan Ignatius Aris Hendaryanto Jibril Maulana Leo Adi Saputra Lilik Dwi Setyana Mandala, Wirawan Widya Martinus Heru Palmiyanto Priyanto, Kaleb Radhian Krisnaputra Setiawan, Widia Setiawan, Widia Suharnadi, Bambang Surojo, Surojo Tarmudi, Achsan Winarto, Felixianus Eko Wismo Wiyadi Wiyadi