Mesin Drilling & Broaching Proses Manufaktur
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Drilling (Gurdi) Penggurdian (drilling process) adalah proses membuat lubang dalam sebuah benda kerja dengan cara menekan sebuah gurdi (pahat drill) yang berputar. Proses bisa juga sebaliknya, di mana gurdi/pahat drill nya yang diam (fixed/stationer), sementara benda kerja yang akan dilubangi yang berputar.
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Drilling & Broaching
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Proses Drilling & Boring Proses pembuatan lubang, pembesaran lubang (boring). Proses umumnya menggunakan pahat bermata potong ganda (twist rill).
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Mesin Drilling Speed adjustment
Head Forward/Reverse lever
Spindle
Column
Chuck
Table
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Proses Drilling Proses pembuatan lubang dalam sebuah benda kerja dilakukan dengan cara menekan pahat drill yang berputar, atau sebaliknya pahat drill nya yang diam (fixed/stasioner), sementara benda kerja yang akan dilubangi yang berputar. Meskipun mesin drill pada dasar nya sebuah mesin untuk kegunaan tunggal, tetapi sejumlah operasi yang mirip, dapat juga dilakukan dengan menambah alat potong yang sesuai. Meluaskan & menghaluskan lubang – tahap finishing (Reaming), adalah memperbesar lubang yang telah ada sebelum nya, dimana luas lubangnya sudah sampai pada ukuran yang sesuai untuk penyelesaian halus. Reaming ini dirancang bukan untuk memotong geram yang tebal, tetapi untuk penyelesaian halus saja. 6
Beberapa contoh mesin drilling
Manual Drill Press
Radial Drilling Machine 7
Multi Spindles Drilling Machine
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Mesin Drilling
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Mesin Drilling
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Horizontal Drilling Machine
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Large Drilling Machine (1)
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Large Drilling Machine (2)
GANTRY TYPE TEN SPINDLES CNC DRILLING MACHINE
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Large Drilling Machine (3)
TABLE TYPE SIX SPINDLES CNC DRILLING MACHINE
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Large Drilling Machine (4)
TABLE TYPE 41 SPINDLES CNC DRILLING MACHINE
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Berbagai Operasi Proses Drilling Berikut adalah beberapa jenis operasi yang dilakukan pada mesin drilling.
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Proses Drilling Khusus (1) Pahat potong jenis gergaji: jenis ini di rancang untuk membuat lubang dengan diameter besar pada benda kerja. 17
Proses Drilling Khusus (2) Pahat potong jenis fly cutter: jenis ini di rancang untuk membuat lubang dengan diameter sangat besar pada benda kerja berupa plat. 18
Proses Drilling Khusus (3) Pahat potong jenis sekop: jenis ini di rancang untuk membuat lubang dengan diameter antara 35 mm s/d 380 mm, dimana bahan pahatnya terbuat dari baja kecepatan tinggi, kalau pun dari jenis baja lain , maka ujung nya harus diberi karbida.
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Pahat u/ proses drilling. Berikut adalah detil pahat untuk proses drilling (pembuatan lubang).
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Boring and Boring Mill Figure 23.17 (a) Schematic illustration of a steel boring bar with a carbide insert. Note the passageway in the bar for cutting fluid application. (b) Schematic illustration of a boring bar with tungsten-alloy “inertia disks” sealed in the bar to counteract vibration and chatter during boring. This system is effective for boring bar length-to-diameter ratios of up to 6.
Figure 23.18 Schematic illustration of a vertical boring mill. Such a machine can accommodate workpiece sizes as large as 2.5m (98 in.) in diameter. 21
ChiselPoint Drill and Crankshaft Drill
Figure 23.19 Two common types of drills: (a) Chisel-point drill. The function of the pair of margins is to provide a bearing surface for the drill against walls of the hole as it penetrates into the workpiece. Drills with four margins (double-margin) are available for improved drill guidance and accuracy. Drills with chip-breaker features also are available. (b) Crankshaft drills. These drills have good centering ability, and because chips tend to break up easily, these drills are suitable for producing deep holes. 22
General Capabilities of Drilling
Figure 23.20 Various types of drills and drilling and reaming operations.
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Types of Drills
Figure 23.21 Various types of drills. 24
Gun Drill
Figure 23.22 (a) A gun drill showing various features. (b) Schematic illustration of the gun-drilling operation.
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Trepanning
Figure 23.23 (a) Trepanning tool. (b) Trepanning with a drill-mounted single cutter.
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General Recommendations for Speeds and Feeds in Drilling
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Troubleshooting Guide for Drilling
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Vertical Drill Press and Radial Drilling Machine
Figure 23.24 (a) Schematic illustration of the components of a vertical drill press. (b) A radial drilling machine. Source: (b) Courtesy of Willis Machinery and Tools. 29
Three-Axis Computer Numerical-Control Drilling Machine
Figure 23.25 A three-axis computer numerical-control drilling machine. The turret holds as many as eight different tools, such as drills, taps, and reamers.
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Helical Reamer and Inserted-Blade Adjustable Reamer
Figure 23.26 (a) Terminology for a helical reamer. (b) Inserted-blade adjustable reamer. 31
Tapping Tapping adalah proses pembuatan ulir pada lubang yg sebelumnya sudah di drill.
Figure 23.27 (a) Terminology for a tap. (b) Tapping of steel nuts in production. 32
Cervical Spine Implant
Figure 23.28 A cervical spine implant.
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Pahat Drill - Multi-point tool
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Pahat u/ proses drilling. 23/64” Drill
Counterbore tool
0.375” Reamer
Countersink tool
Center Drill 7/32” Drill 35
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Parameter dan Perhitungan Dasar Proses Drilling Waktu permesinan
t
m
l f n
w
t
Laju pembuangan geram (bila sebelumnya tidak ada lubang pd benda kerja)
Daya pemotongan Daya motor
Zw
f
2
d n m
4
P pZ m
P
e
t
s
w
P
m
m 36
Friction drilling Friction/flow/thermal drilling merupakan proses drilling dengan memanfaatkan putaran dan tekanan pahat ke arah aksial sehingga terjadi gesekan antara pahat dan benda kerja. Panas yg timbul karena gesekan menyebabkan kenaikkan temperatur shg b-kerja menjadi plastis/lunak sehingga bisa ditekan, dilubangi dan membentuk selubung (bushing) sesuai arah tekanan pahat.
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Friction drilling process: Step 1: The Flow-drill comes into contact with the material using relatively high axial pressure and rotational speed. The generated heat makes the material soft and malleable enough to be formed and perforated. Step 2: As the Flow-drill pushes into the material, some of the displaced material forms a collar around the upper surface of the work-piece. The rest of the material forms a bushing in the lower surface of the work-piece.
Step 3: All this happens in a matter of seconds. The resulting collar and bushing can be up to 3 times the original material thickness. The diameter of the bush is accurately determined by the cylindrical part of the Flow-drill tool.
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Friction drilling machine
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Flow-drill is: a chip less process, capable of strong threaded connections for metric, imperial and gas threads, capable of drilling steel, stainless steel, copper, aluminum and brass,
environmentally friendly, no waste, no single fasteners, and recyclable. 40
Flow-drill (+) Very quick process, The process reshapes all material so that no material is lost, The sleeve that is longer than the original diameter of the target material makes it possible to make very strong bolt joints in thin material, Moreover, it is a clean process, because no litter (particles) is produced. 41
Flow-drill (-) The friction drilling process is not possible in massive material: The melting metal must be able to flow somewhere. Yet it is possible to friction drilling holes in subjects up to 12 mm thick. The target material must be able to withstand the added heat. Materials that have been painted, plastic coated, galvanized, or heat treated are often unsuitable for this process. 42
Flow/friction-drill application Hand rails Doors Stairs Acoustic walls Bridge Parapets
Car cross beam Steering column Exhaust pipe sensor Chasis frame Bumpers
Manifolds Radiators Under Floor Heating Heat Exchangers Solar Panels
Desks Chairs Computer Racks Wheel Chairs Hospital beds
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Mesin Broaching Merupakan proses perautan untuk menghasilkan profil khusus, misalnya internal keyways, Pahat yg digunakan merupakan pahat bergerigi yang disebut broach,
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Mesin Broaching o Chip removal is done with progressively larger cutting teeth, o Keyways in sprockets and gears,
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Mesin Broaching
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Broach geometry
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Pull type internal broach
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