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All Journal Mechanical Engineering for Society and Industry Automotive Experiences
Moch. Agus Choiron
Universitas Brawijaya, Indonesia
Aerospace Engineering Automotive Engineering Chemical Engineering, Chemistry & Bioengineering Control & Systems Engineering Electrical & Electronics Engineering Energy Engineering Industrial & Manufacturing Engineering Materials Science & Nanotechnology Mechanical Engineering Transportation

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Advanced computational techniques for predicting 3D printing distortion in selective laser melting processes of Aluminium AlSi10Mg Moch. Agus Choiron; Anindito Purnowidodo; Achfas Zacoeb; Gembong Edhi Setyawan; Willy Artha Wirawan; Yudhi Ariadi; Allan E.W. Rennie; Diva Kurnianingtyas
Mechanical Engineering for Society and Industry Vol 5 No 1 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.12581

Abstract

Distortion for 3D printing using Selective Laser Melting (SLM) on AlSi10Mg aluminium is an important issue that affects the final manufactured product. This research aims to develop a finite element method (FEM)-based computational simulation and experimental validation to predict distortion in 3D printed products using SLM. The study results found that the variation of 3D printing position affects the resulting product's distortion and mechanical properties. The 90° part print position results in smaller distortion of 0.303 and 0.335 mm than the 0° part print position of 0.329 and 0.378, respectively, making it more suitable for high-precision applications. This study confirms the importance of scan orientation in controlling distortion in the SLM process, which can be used as a guide for optimal printing parameters. With proper orientation selection, the risk of distortion or defects in SLM products can be minimised, and industrial production efficiency can be improved.
Evaluation of dimensional accuracy on SLM product using 3D laser scanner Moch. Agus Choiron; Anindito Purnowidodo; Achfas Zacoeb; Rosadila Febritasari; Willy Artha Wirawan; Imam Kusyairi; Johan Wayan Dika
Mechanical Engineering for Society and Industry Vol 5 No 2 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.13448

Abstract

Dimensional accuracy is a critical factor in additive manufacturing, especially in Selective Laser Melting (SLM). Recently, many studies had investigated the SLM process and products, but studies on the evaluation of SLM printing product to check the dimensional accuracy have not been explored. This study investigates the dimensional accuracy of SLM products by employing a 3D laser scanning technology and evaluate the compatibility between CAD designs and the final SLM printed products. The 3D laser scanning is performed using a high-precision 3D laser scanner, then continued by comparison with the CAD model through Geomagic Control X software. Dimensional accuracy was measured using visual and statistical parameters such as color graphic and deviation. Results showed that deviation of SLM printed products was within the tolerance range of ±0.1 mm. The main factors that affect accuracy are printing laser speed and print orientation. The 3D laser scanning technology proved to be effective for evaluating the dimensional accuracy of SLM printed products. This study contributes to develop the quality control methods in the field of metal-based additive manufacturing.
Effect of Tube Thickness Configuration of Two Segments Circular Crash Box on Its Crashworthiness Performance Muhammad Vendy Hermawan; Moch. Agus Choiron; Anindito Purnowidodo; Winarto Winarto
Automotive Experiences Vol. 8 No. 1 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/ae.13170

Abstract

This study aims to investigate the effect of tube configuration with different bottom fixation components on the energy absorption of a two-segment crash box. The circular tube thickness configuration has two thickness levels, half of the length of the tube has thicker walls (t2), and the other half has thinner walls (t1). The t1 values ”‹”‹are 1, 1.5, 2 and 2.5 mm while t2 is constant, 3 mm. Finite element analysis using ANSYS WORKBENCH was performed for the axial load model. The bottom fixation component uses Cutting Die Model (CDM) and Flat Model (FM). Sixteen crash box models were run to provide the effect of two tube thickness configurations and CDM-FM fixation components. The material of the circular tubes is Aluminum 6063 with a Bilinear Hardening Model assumption. Crashworthiness performance indicators were observed based on the values ”‹”‹of Energy Absorber (EA), Specific Energy Absorber (SEA), initial peak force (Fmax), and Crash Force Efficiency (CFE). The results show that the CDM model has the lowest Fmax value, due to the use of the die, which stimulates easier initial folding in the tube end area. The CDM model also has better SEA and CFE values. According to the results obtained from computer simulations, the CDM-t2t1 model with t1=1mm exhibited the highest Specific Energy Absorption (SEA) of 67.93 kJ. On the other hand, this same crash box model provided the smallest Fmax of 205.88 kN and the highest CFE value of 0.69. From these results, it can be concluded that this model provides the best crashworthiness performance.
Crashworthiness Evaluation of a Parallel 5-Tube Circular Multi-Segment Crash Box with Cutting Die Trigger for Railway Safety Muhammad Vendy Hermawan; Moch. Agus Choiron; Anindito Purnowidodo; Winarto Winarto
Automotive Experiences Vol. 8 No. 3 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/ae.14952

Abstract

This study presents a crashworthiness evaluation of a Parallel 5-Tube Circular Multi-Segment Crash Box with a cutting die trigger, designed to promote controlled progressive folding for high-speed railway applications. The crash box integrates four primary tubes and one secondary tube in a parallel configuration, featuring multi-segment wall thickness and a die-trigger mechanism designed to initiate controlled folding from the tube’s end. The die acts as a deformation initiator, guiding the folding sequence to occur progressively, thereby improving energy dissipation and reducing peak impact forces. Two impact models, namely the Cutting Die Model (CDM) and the Flat Model (FM), were employed to investigate the combined effects of trigger mechanism, multi-segment wall thickness, and impact direction using validated finite element simulations supported by quasi-static and drop-test experiments. Finite Element Analysis (FEA) simulations using ANSYS LS-DYNA were conducted to assess key crashworthiness indicators, including maximum crushing force (Fmax), energy absorption (EA), specific energy absorption (SEA), mean crushing force (Fmean), and crushing force efficiency (CFE). Experimental validation through quasi-static and drop tests confirmed the reliability of the simulation results. The findings reveal that the CDM configuration significantly outperforms the FM model, exhibiting lower Fmax and higher EA, SEA, and CFE values. Progressive folding initiated by the die mechanism enables more stable and efficient energy dissipation. Additionally, the impact direction influences deformation behavior, with the t₁”“tâ‚‚ configuration yielding superior performance. These results demonstrate the effectiveness of the proposed crash box design in meeting the stringent safety and spatial requirements of modern railway systems.
Co-Authors Achfas Zacoeb Allan E.W. Rennie Anindito Purnowidodo Diva Kurnianingtyas Gembong Edhi Setyawan Imam Kusyairi Johan Wayan Dika Muhammad Vendy Hermawan Muhammad Vendy Hermawan Rosadila Febritasari Winarto Winarto Wirawan, Willy Artha Yudhi Ariadi