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OPTIMIZATION OF VARIABEL HELIX ANGLE PARAMETERS IN CNC MILLING OF CHATTER AND SURFACE ROUGHNES USING TAGUCHI METHOD Hardinsi, Festo Andre; Novareza, Oyong; Sonief, Achmad As’ad
JEMIS (Journal of Engineering & Management in Industrial System) Vol 9, No 1 (2021)
Publisher : Industrial Engineering Department, Faculty of Engineering, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/ub.jemis/2021.09.01.3

In the manufacturing industries, the main problem in process of operating CNC milling machine was chatter effect (self-excited vibration) which increases the quality of the surface roughness. In this study is to determine optimal value of parameters for chatter and surface roughness. The chatter measured using accelerometer MPU-6050 with Arduino by software LabVIEW-2019 based on peaks-FFT value and the surface roughness measured by SJ-301 tester. The research parameters like variable helix angle, spindle speed, feed rate, and depth of cut using stainless steel 304 by Taguchi method. The optimum parameters value obtained are variable helix 35/38 degrees, spindle speed 3000 RPM, feed rate 150 mm/min and depth of cut 0.4 mm. Based on ANOVA value, the variable helix angle and depth of cut are found to be significant for chatter and surface roughness. The depth of cut was high contribution by ANOVA chatter by 93.84% and surface roughness by 91.93%.

ANALYZING THE PROPERTIES OF A COMPOSITE OF PCL-GRAPHITE BY THE INJECTION MOLDING Setyarini, Putu Hadi; Fariqi, Ikhwan Hafiz; Sonief, Achmad As’ad
International Journal of Mechanical Engineering Technologies and Applications Vol. 5 No. 2 (2024)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2024.005.02.1

Coral reefs are vulnerable to several natural phenomena such as ocean warming, acidification, coral diseases, and plastic pollution. In order to tackle these problems, scientists are now working on the development of biocomposites utilizing biodegradable polymers such as polycaprolactone (PCL). Graphite can be used in conjunction with PCL to enhance its characteristics. The work is centered around conducting water absorption experiments on a composite material consisting of PCL and graphite. The investigation employs PCL granular and graphite powdered materials. The materials undergo heating, crushing, and weighing processes to ascertain weight ratios. Next, the mixture is shaped into specimens. The product's shape and distribution of chemical constituents are analyzed using water absorption, hydrophobicity, FTIR, and SEM testing. The findings indicate that the water absorption diminishes as the concentration of graphite powder increases. An alloy containing 10% graphite had the highest water absorption rate. The hydrophobicity test assesses the ability of a specimen's surface to repel water by introducing NaCl droplets and observing droplet production. The contact angle value exhibits a direct correlation with the increase in graphite content. The FTIR study indicates that there are no changes in the functional groups, resulting in a limited connection between the PCL matrix and the graphite filler. The temperature during the injection molding process affects the microstructure of the polymer. Lower temperatures lead to reduced crystallization, whereas higher temperatures result in denser molecular groupings. Graphite is a highly suitable choice for use as a filler in a PCL matrix because of its layered structure, large surface area, and excellent capacity to effectively fill voids within the matrix.

COMPARISON OF CHATTER CONTROL OF VARIABLE AND REGULAR HELIX TOOLS IN THE ALUMINUM END-MILLING PROCESS Sonief, Achmad As’ad; Ma'arif, Moch. Syamsul; Pratikto, Pratikto; Juliano, Hans
International Journal of Mechanical Engineering Technologies and Applications Vol. 4 No. 1 (2023)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2023.004.01.6

In the chatter, machining operations are undesirable because of the phenomena that affect product results, machining accuracy, tool life, and high operating value. Chatter is a vibration phenomenon that occurs in cutting tools due to the self-excitation of the influence of cutting parameters during the operation process of the machine. Types of chatter in machinery are regenerative and resonant. Because the pitch angles of variable helix tools vary, the helix angles of variable tools produce different tooth passing frequencies on each tool eye next to each other and can be used to prevent and control resonance. This study aimed to compare chatter control from the variable helix and regular-angle tools in the aluminum end milling process. The method is carried out through the end milling process experiment to determine the chatter control of the variable helix and regular-angle tools through the stability loop diagram. The results from this study were obtained by comparing control chatters in the milling process through controlling variable and standard helix angles as a guideline to produce the best surface roughness in the end milling process made from aluminum. The comparison of estimated control charts from variable helix tools is more comprehensive than regular helix tools.

STRESS DISTRIBUTION ANALYSIS ON LIGAMENT AUGMENTATION AND RECONSTRUCTION SYSTEM (LARS) USING FINITE ELEMENT METHOD (FEM) Aulia , Fauzan; Sonief, Achmad As’ad; Hidayati , Nafisah Arina
International Journal of Mechanical Engineering Technologies and Applications Vol. 4 No. 1 (2023)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2023.004.01.7

The Ligament Augmentation and Reconstruction System (LARS) is a prosthetic device used to support knee ligaments severed due to injury. The role of LARS in supporting the knee ligaments is to take over the position of the natural ligaments that have been severed, binding the thigh bone and shin bone. LARS is made from polyethylene terephthalate (PET) material, commonly used in industry. LARS is a prosthetic product widely used to heal ligament injuries. However, despite its everyday use, no one has confirmed whether LARS can support a severed ligament. There has never been a study analyzing this tool, even from the company that makes LARS. They only state that LARS is safe and suitable for healing ligament injuries. Therefore, a LARS analysis is needed to convince the public that the tool is safe. This study analyzed the stress distribution in LARS during the standing-to-squatting condition. The results show an uneven stress distribution between the LARS inside the femur and other parts of the LARS. However, the stress distribution is still in a safe condition that does not directly reduce the strength of the LARS.

FINITE ELEMENT ANALYSIS ON DUAL SMALL PLATE AND SINGLE FIXATION PLATE FOR DISTAL COLLARBONE FRACTURE TREATMENT Prabaswara, Ilham; Sonief, Achmad As’ad; Hidayati, Nafisah Arina; Anam, Khairul
International Journal of Mechanical Engineering Technologies and Applications Vol. 4 No. 1 (2023)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2023.004.01.9

Distal fractures on the collarbone are one of the most common fractures. Using internal fixation is one of the most widely used methods for treating fractures in the collarbone. A dual fixation plate for a collarbone fracture is reported to reduce reoperation due to fixation devices. In this study, the element analysis results will be presented using finite element analysis software (FEA software) for the fixation of collarbone fractures using dual plate fixation, superior plate, and anteroinferior plate. A three-dimensional model of a collarbone fracture with a fracture distance of 3 mm is used to obtain the equivalent von Mises stress value. There was no significant difference in the bending and compressive loadings on the double small plate fixation, superior plate fixation, and anteroinferior plate fixation. The von Mises stress equivalent for double small plate fixation has the most significant value compared to superior and anteroinferior plate fixation. This demonstrates that dual small plate fixation has better biomechanical properties than single plate fixation because it has better stress shielding ability and will accelerate bone healing due to the low load on the collarbone if used by an active patient.

EFFECT OF VARIABLE HELIX ANGLE OF END MILLING TOOL ON VIBRATION AND SURFACE ROUGHNESS OF SS-AISI 304 Sonief, Achmad As’ad; Sasongko, Mega Nur; Widhiyanuriyawan, Denny Widhiyanuriyawan; Pratikto, Pratikto
International Journal of Mechanical Engineering Technologies and Applications Vol. 6 No. 1 (2025)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2025.006.01.12

Vibration in milling processes adversely affects product quality, machining precision, tool lifespan, and operating costs. A common vibration type, chatter, arises from self-excitation influenced by cutting parameters. Chatter can be classified into regenerative and resonant types. To mitigate resonance, cutting tools with variable helix angles are employed, as their varying pitch angles generate distinct tooth-passing frequencies for each blade. This study investigates the impact of helix angles on cutting parameters during end milling and their effects on vibration amplitude and surface roughness of AISI 304 stainless steel. Experimental end milling trials were conducted with different helix angle tools and cutting parameter variations. The findings reveal that optimizing the helix angle significantly reduces vibration amplitude and enhances surface finish. Controlling helix angle proves crucial for achieving superior surface quality and stable operation in end milling processes of stainless steel materials.

EFFECT OF VARIABLE HELIX ANGLE OF END MILLING TOOL ON VIBRATION AND SURFACE ROUGHNESS OF SS-AISI 304 Sonief, Achmad As’ad; Sasongko, Mega Nur; Widhiyanuriyawan, Denny Widhiyanuriyawan; Pratikto, Pratikto
International Journal of Mechanical Engineering Technologies and Applications Vol. 6 No. 1 (2025)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2025.006.01.12

Vibration in milling processes adversely affects product quality, machining precision, tool lifespan, and operating costs. A common vibration type, chatter, arises from self-excitation influenced by cutting parameters. Chatter can be classified into regenerative and resonant types. To mitigate resonance, cutting tools with variable helix angles are employed, as their varying pitch angles generate distinct tooth-passing frequencies for each blade. This study investigates the impact of helix angles on cutting parameters during end milling and their effects on vibration amplitude and surface roughness of AISI 304 stainless steel. Experimental end milling trials were conducted with different helix angle tools and cutting parameter variations. The findings reveal that optimizing the helix angle significantly reduces vibration amplitude and enhances surface finish. Controlling helix angle proves crucial for achieving superior surface quality and stable operation in end milling processes of stainless steel materials.

COMPARISON OF CHATTER CONTROL OF VARIABLE AND REGULAR HELIX TOOLS IN THE ALUMINUM END-MILLING PROCESS Sonief, Achmad As’ad; Ma'arif, Moch. Syamsul; Pratikto, Pratikto; Juliano, Hans
International Journal of Mechanical Engineering Technologies and Applications Vol. 4 No. 1 (2023)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2023.004.01.6

In the chatter, machining operations are undesirable because of the phenomena that affect product results, machining accuracy, tool life, and high operating value. Chatter is a vibration phenomenon that occurs in cutting tools due to the self-excitation of the influence of cutting parameters during the operation process of the machine. Types of chatter in machinery are regenerative and resonant. Because the pitch angles of variable helix tools vary, the helix angles of variable tools produce different tooth passing frequencies on each tool eye next to each other and can be used to prevent and control resonance. This study aimed to compare chatter control from the variable helix and regular-angle tools in the aluminum end milling process. The method is carried out through the end milling process experiment to determine the chatter control of the variable helix and regular-angle tools through the stability loop diagram. The results from this study were obtained by comparing control chatters in the milling process through controlling variable and standard helix angles as a guideline to produce the best surface roughness in the end milling process made from aluminum. The comparison of estimated control charts from variable helix tools is more comprehensive than regular helix tools.

STRESS DISTRIBUTION ANALYSIS ON LIGAMENT AUGMENTATION AND RECONSTRUCTION SYSTEM (LARS) USING FINITE ELEMENT METHOD (FEM) Aulia , Fauzan; Sonief, Achmad As’ad; Hidayati , Nafisah Arina
International Journal of Mechanical Engineering Technologies and Applications Vol. 4 No. 1 (2023)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2023.004.01.7

The Ligament Augmentation and Reconstruction System (LARS) is a prosthetic device used to support knee ligaments severed due to injury. The role of LARS in supporting the knee ligaments is to take over the position of the natural ligaments that have been severed, binding the thigh bone and shin bone. LARS is made from polyethylene terephthalate (PET) material, commonly used in industry. LARS is a prosthetic product widely used to heal ligament injuries. However, despite its everyday use, no one has confirmed whether LARS can support a severed ligament. There has never been a study analyzing this tool, even from the company that makes LARS. They only state that LARS is safe and suitable for healing ligament injuries. Therefore, a LARS analysis is needed to convince the public that the tool is safe. This study analyzed the stress distribution in LARS during the standing-to-squatting condition. The results show an uneven stress distribution between the LARS inside the femur and other parts of the LARS. However, the stress distribution is still in a safe condition that does not directly reduce the strength of the LARS.

FINITE ELEMENT ANALYSIS ON DUAL SMALL PLATE AND SINGLE FIXATION PLATE FOR DISTAL COLLARBONE FRACTURE TREATMENT Prabaswara, Ilham; Sonief, Achmad As’ad; Hidayati, Nafisah Arina; Anam, Khairul
International Journal of Mechanical Engineering Technologies and Applications Vol. 4 No. 1 (2023)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2023.004.01.9

Distal fractures on the collarbone are one of the most common fractures. Using internal fixation is one of the most widely used methods for treating fractures in the collarbone. A dual fixation plate for a collarbone fracture is reported to reduce reoperation due to fixation devices. In this study, the element analysis results will be presented using finite element analysis software (FEA software) for the fixation of collarbone fractures using dual plate fixation, superior plate, and anteroinferior plate. A three-dimensional model of a collarbone fracture with a fracture distance of 3 mm is used to obtain the equivalent von Mises stress value. There was no significant difference in the bending and compressive loadings on the double small plate fixation, superior plate fixation, and anteroinferior plate fixation. The von Mises stress equivalent for double small plate fixation has the most significant value compared to superior and anteroinferior plate fixation. This demonstrates that dual small plate fixation has better biomechanical properties than single plate fixation because it has better stress shielding ability and will accelerate bone healing due to the low load on the collarbone if used by an active patient.

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