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Jig and fixture Redesign for Main Bearing Housing Component Komara, Asep Indra
Jurnal Teknologi Terapan Vol 5, No 2 (2019): Jurnal Teknologi Terapan
Publisher : P3M Politeknik Negeri Indramayu

Main bearing housing is one of the gear transmission product components. The production process of this component needs to be repaired. The repair process is carried out on the fixture construction used today. Redesign is done as one of the solution to improve of the existing fixture design. The measurement results of the products that are machined with the existing fixture are still not in accordance with the requirements of the released product drawing. This is thought to occur because of an error in determining the operating procedur of the machining process that has an impact on the design of the fixture, especially in determining the reference to each machining processes carried out. Therefore, the new fixture needs to be designed so that the resulting product can fit the drawing demands. The repair process is carried out through a gradual study that refers to the methodology of the SME in order to be systematic and structured. Each stage of the design is carried out in detail starting from the study of product analysis, machining analysis, machine analysis, operator analysis and economic analysis. Based on the results of a product analysis study, a new machining process sequence has been produced. The new fixture design has been produced based on this sequence of machining processes. Based on the results of the study, it shows that the results of the redesign of the fixture repair show the conditions that are in accordance with the demands of the product images of the main bearing housing

PERANCANGAN DAN VALIDASI FIXTURE PEMESINAN KOMPONEN UTAMA PRODUK RAGUM MEJA Komara, Asep Indra; Afif, Muhammad Fadhlan; Ariefijanto, Dedy
JTERA (Jurnal Teknologi Rekayasa) Vol 5, No 1: June 2020
Publisher : Politeknik Sukabumi

Ragum meja adalah salah satu produk Politeknik Manufaktur Bandung yang terdiri atas dua komponen utama yaitu rahang gerak dan rahang tetap. Pemesinan kedua komponen ini sebelumnya dilakukan menggunakan mesin konvensional dengan menggunakan beberapa fixture. Permasalahannya adalah kuantitas dan kualitas produk masih belum memenuhi harapan. Proses pemesinan diputuskan diganti menggunakan mesin Computer Numerical Control (CNC) sehingga memerlukan fixture baru. Penelitian ini bertujuan untuk merancang fixture pemesinan komponen utama produk ragum meja. Perancangan dilakukan menggunakan metode yang dikembangkan oleh Verein Deutscher Ingenieure (VDI) dimana langkah-langkah yang dilakukan adalah identifikasi produk, analisis pemesinan dan perencanaan alat potong, analisis mesin, analisis operator dan layout produk, dan analisis ekonomis. Selanjutnya dilakukan kajian perhitungan dan validasi terhadap rancangan fixture. Berdasarkan hasil studi yang dilakukan, perbaikan proses pemesinan dapat dilakukan dengan usulan skema yang baru. Rancangan fixture baru memungkinkan proses pemesinan empat produk yang terdiri dari masing-masing dua rahang gerak dan dua rahang tetap. Fixture telah mengakomodir penggunaan automatic pallet and tool changer pada mesin sehingga pemasangan produk dan pergantian alat potong dilakukan dengan cepat. Waktu pemesinan untuk kedua komponen diestimasi berubah dari 11,5 jam menjadi 1,4 jam.

Desain dan Pengembangan Transfer Case untuk Kendaraan Multi Guna Kapasitas Angkut 750 Kilogram Asep Indra Komara; Panji Mufti Ali; Antonius Adi Soetopo
Manutech : Jurnal Teknologi Manufaktur Vol. 12 No. 02 (2020): Manutech: Jurnal Teknologi Manufaktur
Publisher : Politeknik Manufaktur Negeri Bangka Belitung

The Automotive Power Train Development Center (P3TO) POLMAN Bandung aims to develop utility vehicles for agricultural and plantation areas with a loading capacity of 750 kg. One of the studies focuses on the design and development of the transfer case transmission system, an additional unit in the transmission system for distributing power from the engine to the wheels and production machines through Power Take-Off (PTO). The purpose of this research is to produce a transfer case design that provides large power output, reliable, safe, and cheap. The engineering process is preceded by studying on existing construction then modifying and designing it to meet demands by applying the Pahl & Beitz methodology consisting of planning and clarifying tasks, making a list of demands, making basic concepts, designing transfer cases, and validating designs. The main evaluation criteria such as vehicle operations in all-terain, engine, gearbox, and vehicle speed were observed. The results were also validated using three methods, namely theoretical, KISSsoft software, and finite element simulation in solids work. This research produced a transfer case design of 1.8 rations with a size of 461 mm x 433 mm x 223 mm and a weight of 25 kg. All gear and shaft components are able to withstand the load that occurs in the transfer case due to operational, engine, and production machine tools.

Jig and fixture Redesign for Main Bearing Housing Component Asep Indra Komara
Jurnal Teknologi Terapan Vol 5, No 2 (2019): Jurnal Teknologi Terapan
Publisher : P3M Politeknik Negeri Indramayu

Main bearing housing is one of the gear transmission product components. The production process of this component needs to be repaired. The repair process is carried out on the fixture construction used today. Redesign is done as one of the solution to improve of the existing fixture design. The measurement results of the products that are machined with the existing fixture are still not in accordance with the requirements of the released product drawing. This is thought to occur because of an error in determining the operating procedur of the machining process that has an impact on the design of the fixture, especially in determining the reference to each machining processes carried out. Therefore, the new fixture needs to be designed so that the resulting product can fit the drawing demands. The repair process is carried out through a gradual study that refers to the methodology of the SME in order to be systematic and structured. Each stage of the design is carried out in detail starting from the study of product analysis, machining analysis, machine analysis, operator analysis and economic analysis. Based on the results of a product analysis study, a new machining process sequence has been produced. The new fixture design has been produced based on this sequence of machining processes. Based on the results of the study, it shows that the results of the redesign of the fixture repair show the conditions that are in accordance with the demands of the product images of the main bearing housing

Perancangan dan Validasi Fixture Pemesinan Komponen Utama Produk Ragum Meja Asep Indra Komara; Muhammad Fadhlan Afif; Dedy Ariefijanto
JTERA (Jurnal Teknologi Rekayasa) Vol 5, No 1: June 2020
Publisher : Politeknik Sukabumi

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31544/jtera.v5.i1.2019.11-24

Ragum meja adalah salah satu produk Politeknik Manufaktur Bandung yang terdiri atas dua komponen utama yaitu rahang gerak dan rahang tetap. Pemesinan kedua komponen ini sebelumnya dilakukan menggunakan mesin konvensional dengan menggunakan beberapa fixture. Permasalahannya adalah kuantitas dan kualitas produk masih belum memenuhi harapan. Proses pemesinan diputuskan diganti menggunakan mesin Computer Numerical Control (CNC) sehingga memerlukan fixture baru. Penelitian ini bertujuan untuk merancang fixture pemesinan komponen utama produk ragum meja. Perancangan dilakukan menggunakan metode yang dikembangkan oleh Verein Deutscher Ingenieure (VDI) dimana langkah-langkah yang dilakukan adalah identifikasi produk, analisis pemesinan dan perencanaan alat potong, analisis mesin, analisis operator dan layout produk, dan analisis ekonomis. Selanjutnya dilakukan kajian perhitungan dan validasi terhadap rancangan fixture. Berdasarkan hasil studi yang dilakukan, perbaikan proses pemesinan dapat dilakukan dengan usulan skema yang baru. Rancangan fixture baru memungkinkan proses pemesinan empat produk yang terdiri dari masing-masing dua rahang gerak dan dua rahang tetap. Fixture telah mengakomodir penggunaan automatic pallet and tool changer pada mesin sehingga pemasangan produk dan pergantian alat potong dilakukan dengan cepat. Waktu pemesinan untuk kedua komponen diestimasi berubah dari 11,5 jam menjadi 1,4 jam.

PERANCANGAN ULANG MACHINING FIXTURE UNTUK PRODUK CYLINDER HEAD DAN COVER CRANKCASE TIPE 168 Asep Indra Komara
Machine : Jurnal Teknik Mesin Vol 6 No 1 (2020): Machine : Jurnal Teknik Mesin
Publisher : Jurusan Teknik Mesin Fakultas Teknik Universitas Bangka Belitung

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33019/jm.v6i1.1367

The cylinder head and crankcase cover are components of an engine produced by a manufacturing company in Tangerang. Companies need to make improvements to the production process of these components in order to compete with their competitors. The improvement of the production process is done by improving the machining process stages and re-designing the engine product fixture. Actually the company already has a fixture for the engine machining process, but the fixture cannot be used to produce engine components because it still does not function properly. The problem that occurs is the deviation of the dimensions of machining results and the ineffectiveness of the machining process thereby reducing work productivity. Therefore, it is necessary to design a new fixture that is able to answer both of these problems. Fixture design through the application of the VDI 2222 method combined with the design method according to the Handbook of Jig Fixture has resulted in a fixture design and estimated new machining process time for engine components. The fixture design is then analyzed and validated using engineering software to ensure the fixture's rigidity of the clamping force, machining force, and deflection that occur during the machining process which can have an impact on dimensional deviations. Based on the results of the study conducted, a fixture design for machining cylinder head and crankcase cover products has been produced with fixture dimensions of 450 x 459 x 1125 with a weight of 190 kg. The time needed to complete the cylinder head product is 308.67 seconds and the crankcase cover is 224.19 seconds. The maximum clamping force required is 0.36 kN. Deflection that occurs in the clamping rod is 0.0048 mm, the fixture frame is 0.029 mm and the product deformation is 0.06 mm. The fixture design is expected to be able to solve the problems that exist in the company today.

Perancangan Alat Pengangkut Sampah Pada Saluran Air Secara Kontinyu Asep Indra Komara; Luthfi Fattah Buchari
Jurnal Teknologi dan Rekayasa Manufaktur Vol 1 No 2 (2019): Vol 1 No 2 (2019): Volume: 1 | Nomor: 2 | Oktober 2019
Publisher : Pusat Pengembangan, Penelitian dan Pengabdian kepada Masyarat (P4M) Politeknik Manufaktur Bandung (Polman Bandung)

This article discusses the design process of a chocolate crusher machine based on VDI 2222. The design activities begin with identifying the needs and demands of the customer until finishing the solution for the customer in the form of a design work drawing in technical documentation. The proposed method is validated in a case study of making a chocolate chopper machine design. The machine generally functions as a separator between the cocoa beans and the shell of the seeds which have been chopped in such a way as to produce the required dimensions. At the planning stage, identifying the machine's need is to be able to chop the cocoa beans until the smallest grain has a maximum dimension of 4 mm. Three alternative functions are given and assessed as a result of the conceptualization stage. Evaluation is given to the draft design by considering the material, manufacturing and maintenance aspects. At the completion stage, technical documentation in the form of detailed work drawings is produced. By setting the rotating speed, a chocolate crusher can make beans with dimensions of 2-4 mm and production capacity is about 600 kg/hour.

STUDI RANCANG BANGUN MESIN PLASTIC WASTE SHREDDER DENGAN KAPASITAS 15 KG/HARI DENGAN APLIKASI METODE VDI 2222 Riky Adhiharto; Asep Indra Komara; Annisa .
Jurnal TEDC Vol 13 No 3 (2019): JURNAL TEDC
Publisher : UPPM Politeknik TEDC Bandung

Show Abstract | Download Original | Original Source | Check in Google Scholar | Full PDF (1453.247 KB)

Persoalan sampah plastik di kampus Polman Bandung masih menjadi tugas bersama seluruh sivitas kampus. Dengan menghasilkan sampah plastik rata-rata 10 kg/hari, teknik perancangan mengambil langkah untuk membuat serangkaian mesin pendaur ulang sampah plastik yang akan diolah kembali menjadi bijih plastik atau produk cetakan plastik. Rangkaian mesin ini dimulai dari mesin pencacah plastik. Tujuan dari penelitian ini adalah untuk menghasilkan mesin pencacah plastik yang mampu mencacah sampah plastik 15kg/hari dengan sistem rancangan mesin penghancur waste shredder. Proses penghancuran mengadaptasi proses shearing dimana pisau penghancur akan merobek sampah plastik sehinggga sampah plastik akan terdeformasi, shear angle yang dipakai pada pisau sebesar 5˚. Material pisau ST60/S45C dirasa cukup mampu untuh mencacah sampah plastik, hal ini dilihat dari nilai kekerasan, tensile strength dan tegangan geser dari material pisau yang melebihi material plastik PE, PP, ABS dan PP. Dari hasil rancangan dan perhitungan, ukuran mesin yaitu 490 x 590 x 792, daya motor penggerak 1HP/0.75kW 1 phase 220V dengan putaran 1415rpm yang dibantu oleh elemen transmisi pulley SPZ1060 dan SPZ800. Komponen pencacah yang dipakai terdiri dari 8 buah rotary cutter berdimensi Ø13 x 12 dan 16 buah fix cutter. Terdapat sistem penyaring mesh yang memiliki lubang mesh 12mm, sehingga cacahan yang keluar berukuran <12mm, hanya saja bentuk dan ukuran yang keluar dari sistem penyaring tidak seragam. Kata kunci: waste shreeder, sampah plastik, rotary cutter, shear angle

DESAIN DAN PENGEMBANGAN MESIN MICRO-PRESS PEMBENTUK KOMPONEN MIKRO Asep Indra Komara; Aida Mahmudah; Adinda Sri Lestari; Johanes C. J. Hasibuan
Jurnal Rekayasa Mesin Vol. 13 No. 3 (2022)
Publisher : Jurusan Teknik Mesin, Fakultas Teknik, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/jrm.v13i3.1140

The increasing application of micro electro mechanical systems technology on daily life devices increases the need for micro components. Furthermore, it must be supported by reliable fabrication technology to produce micro-sized products. One of these technologies is micro-sheet metal forming, which is a forming technology from sheet metal with 10-300µm thickness. The development of this technology requires a special press machine that is used in the scope of micro-scale work, named micro-press. Micro-press is still rare due to it was used for individual experiment purposes. Thus, it is necessary to develop the micro-press to support research and manufacturing of micro-part. In this study, the design of a micro-press is intended to accommodate the miniaturization problems and to be easy in fabrication and re-fabrication. Then, the micro-press will contribute to fulfill the micro-parts need. By using the VDI 2222 design method, the design of a 5kN micro-press machine with a servo motor drive is obtained, and validation of construction strength was carried out with the help of the appropriate CAE software. The results of the design validation show that the construction of the micro-press machine is quite strong. The selected component has a strength specification that is greater than required, and the maximum stress that occurs in the frame, which is 80.096 N/mm2, is still very lower than the allowable stress on the SPHC material. The magnitude of the resultant displacement shows a fairly small value, i.e. 0.178 mm.

PERANCANGAN PLASTIC WASTE SHREDDER MACHINE PORTABLE DI KAMPUS POLMAN BANDUNG Dedy Ariefijanto; Nadhifah Rysca Novianty; Asep Indra Komara
Machine : Jurnal Teknik Mesin Vol 9 No 1 (2023): Machine : Jurnal Teknik Mesin
Publisher : Jurusan Teknik Mesin Fakultas Sains dan Teknik Universitas Bangka Belitung

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33019/jm.v9i1.4029

Plastic Waste Shredder Machine is a machine that is used to reduce the size of waste into small pieces for recycling process. This machine is a development from previous machines. The design methodology in this study is VDI 2222. Determination of component dimensions is based on analysis of critical components with the help of Computer Aided Engineering software. This machine works by inserting plastic bottle waste to the hopper, the size will be reduced in shredding area with two-blade system that moves oppositely with a fixed knife on each side, and the result is the plastic chips with a maximum size of 5x5 mm. After the design process, the machine is operated with an electric motor with a power of 0,75 kW and output rotation of 50 rpm. This machine can process 10 kg/day plastic waste with machine dimensions of 400 x 600 x 900 mm and total machine weight of 124 kg.

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