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All Journal Journal of Applied Engineering and Technological Science (JAETS) METAL : Jurnal Sistem Mekanik dan Termal
Hanif Azis Budiarto
Politeknik Manufaktur Bandung
Automotive Engineering Civil Engineering, Building, Construction & Architecture Computer Science & IT Decision Sciences, Operations Research & Management Electrical & Electronics Engineering Industrial & Manufacturing Engineering Materials Science & Nanotechnology Mechanical Engineering

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Failure Investigation of Blank Holder Force (BHF) Control in The Outside Bracket For Front Seat Rofan Yulian Romansyah; Hanif Azis Budiarto; Yuliar Yasin Erlangga; Yunita Nugrahaini Safrudin
Journal of Applied Engineering and Technological Science (JAETS) Vol. 4 No. 2 (2023): Journal of Applied Engineering and Technological Science (JAETS)
Publisher : Yayasan Riset dan Pengembangan Intelektual (YRPI)

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37385/jaets.v4i2.1779

Abstract

This study investigated the failure of the Blank Holder Force (BHF) control in the outside bracket for the front seat. The production process involved progressive dies consisting of nine stations: first pierce, first trim, second trim, idle, flange, idle, second pierce, idle, and parting. However, at the 7th-9th station, the pilot hole in the product deforms into an oval shape, which is undesirable. Gemba-Kaizen methods were used in this study, and primary data were collected by comparing the design and actual progressive dies. The results showed that product defects are primarily caused by an unbalanced BHF and inadequate piercing clearance. A uniform distribution of force during the forming process is obtained by reducing the spring number on the blank holder. This reduces the force generated during the process. Furthermore, the die clearance was increased from 0.01 mm to 0.1 mm, making press and die alignment less critical and requiring less cutting and stripping forces
Redesign of Cover Lower Dies on Compaction Tool in Sealface Manufacturing Based on Powder Metallurgy Process Riona Ihsan Media; Otto Purnawarman; Hanif Azis Budiarto; Daffa Caesario
METAL: Jurnal Sistem Mekanik dan Termal Vol 8, No 1 (2024): Jurnal Sistem Mekanik dan Termal (METAL)
Publisher : Department of Mechanical Engineering, Universitas Andalas

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.25077/metal.8.1.25-38.2024

Abstract

The cover lower dies constitute a vital component of the ejector compaction tool system employed in the powder metallurgy process for sealface production. However, a failure occurred in the compaction process, leading to the deformation of the component after the production of more than eleven sealfaces. This study investigates the ejector compaction tool system, with a specific focus on the cover lower dies, aiming to optimize the tool's construction. Employing the Pahl & Beitz design methodology, the research encompasses discussions with previous researchers, observation of existing tools, disassembly of current tools, and simulation analysis. Emphasizing static analysis to assess stress, deflection, and safety factor values, the research aims for a safety factor exceeding 2.00 in the redesigned cover lower dies. The optimal solution involves changing the material to AISI D2 with a hardness of 62 HRC, modifying the cover lower dies thickness by 13mm, and increasing springs and retained pins from 2 to 4 pieces. Consequently, the redesigned ejector compaction tool system is deemed operationally safe, signifying a successful improvement in its construction for enhanced reliability and performance.
Optimizing Low-Pressure Die Casting of A356 Aluminum Alloy Wheel Rims: A Novel Side Core With Integrated Cooling System Roni Kusnowo; Hanif Azis Budiarto; Cecep Ruskandi; Sophiadi Gunara; Ery Hidayat; Muhammad Nahrowi; Emma Dwi Ariyani
Journal of Applied Engineering and Technological Science (JAETS) Vol. 6 No. 1 (2024): Journal of Applied Engineering and Technological Science (JAETS)
Publisher : Yayasan Riset dan Pengembangan Intelektual (YRPI)

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.37385/jaets.v6i1.5122

Abstract

This study explores the development of a novel side core design with an integrated cooling system for the low-pressure die casting (LPDC) of A356 aluminum alloy wheel rims in Indonesia. The objective is to reduce cycle time and minimize casting defects. The methodology involves 3D modeling using SolidWorks and simulations performed with MAGMAsoft to evaluate filling and solidification behavior, air pressure, and air entrapment. Notably, this is the first application of a cooling system in Side cores within the Indonesian automotive industry, motivated by the need to improve production efficiency and product quality, as current manufacturing processes suffer from long cycle times and high defect rates. Simulation results show a significant reduction in cycle time by 72 seconds, improving both efficiency and product quality. This study demonstrates the effectiveness of integrating cooling systems into side cores to enhance the LPDC process.
Co-Authors Cecep Ruskandi Daffa Caesario Emma Dwi Ariyani, Emma Dwi Hidayat, Ery Muhammad Nahrowi Otto Purnawarman Riona Ihsan Media Rofan Yulian Romansyah Roni Kusnowo Sophiadi Gunara Yuliar Yasin Erlangga