TI-2121: Proses Manufaktur

Departemen Teknik Industri FTI-ITB

TI-2121: Proses Manufaktur Operasi Pemesinan & Mesin Perkakas

Laboratorium Sistem Produksi www.lspitb.org ©2003


1. Hasil Pembelajaran •

Umum: Memberikan mahasiswa pengetahuan yang komprehensif tentang dasar-dasar proses pemesinan dan mesin perkakas, proses forming dan molding, metrology dan aplikasi terhadap kualitas produk dan analisis system manufaktur.

•

Khusus: Memberikan pemahaman terhadap proses pemesinan serta jenis mesin yang digunakan

TI2121 - Proses Manufaktur - 10

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1


Istilah


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Klasifikasi Komponen Pemesinan

(a) rotational (b) non-rotational (prismatic)


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2


Bentuk Permukaan Potong

(a) straight turning (b) taper turning (c) contour turning (d) plain milling (e) profile milling TI2121 - Proses Manufaktur - 10

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Forming: Bentuk Pemotongan

(a) form turning (b) drilling (c) broaching TI2121 - Proses Manufaktur - 10

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3


Kombinasi Forming dan Pergerakan Pahat

(a) thread cutting on a lathe (b) slot milling


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Turning

N=

v

D −D 0

f

π D0 f

= 2d

T

r

m

= Nf

=

L

f

N = rotational speed, rev/min v = cutting speed, m/min D0 = original diameter, mm Df = final diameter, mm d = depth of cut f = feed, mm/rev fr = feed rate, mm/min Tm = time of actual machining, min L = length, mm MRR = material removal rate mm3/min

MRR = vfd r


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4


Operasi Turning Lainnya (a) facing (b) taper turning (c) contour turning (d) form turning (e) chamfering (f) cutoff (g) threading (h) boring (i) driliing (j) knurling


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Mesin Lathe


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5


Metoda Pencekaman Benda Kerja Pada Lathe

(a) mounting the work between centers using a “dog” (b) three-jaw chuck (c) collet (d)face plate for non cylindrical workparts TI2121 - Proses Manufaktur - 10

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Contoh Urutan Operasi Turning

(1) feed stock to stop (2) turn main diameter (3) form second diameter and spotface (4) drill (5) chamfer (6) cutoff TI2121 - Proses Manufaktur - 10

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Boring Mill (1)

Types of horizontal boring mill (a) boring bar is fed into a rotating workpart (b) work is fed past a rotating boring bar


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Boring Mill (2)

Vertical boring mill TI2121 - Proses Manufaktur - 10

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Boring Mill (3)

Boring bar made of cemented carbide


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Drilling N = spindle speed, rev/min v = cutting speed, mm/min D = drill diameter, mm f = feed, mm/rev Fr = feed rate, mm/min Tm = machining time, min T = work thickness, mm A = approach allowance MRR = material rate of return

N=

f

r

v πD

= Nf

φ

A = 0.5D tan(90 − ) 2 MRR =

π

T

m

2

D f 4

r

T

m

= =

d

f

r

t+A

f

r


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8


Operasi Drillling Lainnya

(a) reaming (b) tapping (c) counter boring (d) countersinking (e) center drilling (f) spot facing TI2121 - Proses Manufaktur - 10

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Mesin Drilling

Drill press & Radial drill press TI2121 - Proses Manufaktur - 10

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Milling

Types of milling operation: (a) peripheral or plain milling (b) face milling TI2121 - Proses Manufaktur - 10

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Peripheral Milling

(a) slab milling (b) slotting (c) side milling (d) straddle milling


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Tipe Pemotongan Milling

(a) up milling (b) down milling TI2121 - Proses Manufaktur - 10

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Face Milling (a) conventional face milling (b) partial face milling (c) end milling (d) profile milling (e) pocket milling (f) surface contouring


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11


Parameter Pemesinan Milling N=

f

r

v πD

= N nt f

MRR = wd

f

r

A = d (D − d )

Tm =

L+ A

f

r

• Nt = number of teeth TI2121 - Proses Manufaktur - 10

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Mesin Milling (1)

(a) horizontal (b) vertical


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Mesin Milling (2)

(a) universal-overarm (b) ram type TI2121 - Proses Manufaktur - 10

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Machining Centers • Automated

machine tool capable of performing multiple machining operation under CNC control, having features: Automatic tool-changing Pallet shuttles Automatic workpart positioning


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Turning Centers


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Operasi pada Mill-Turn Centers

(1) turn second diameter (2) mill flat with part in programmed angular position (3) drill hole (4) cutoff TI2121 - Proses Manufaktur - 10

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Operasi Milling Lainnya

(a) shaping (b) planning TI2121 - Proses Manufaktur - 10

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Bentuk-bentuk Shaping & Planing


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Mesin Shaper


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Mesin Planer


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Operasi Milling Lainnya • Broaching

(a) external broaching (b) internal broaching TI2121 - Proses Manufaktur - 10

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Sawing

(a) power hacksaw (b) bandsaw (c) circular saw TI2121 - Proses Manufaktur - 10

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High Speed Machining

Work Material Aluminum Cast iron, soft Cast iron, ductile Steel, free machining Steel, alloy Titanium

Solid Tools (end mills, drill) Conventional High Cutting Speed (m/min) Speed (m/min) 300 3000 150 360 105 250 105 360 75 250 40 60

Indexable Tools (face mills) Conventional High Cutting Speed (m/min) Speed (m/min) 600 3600 360 1200 250 900 360 600 210 360 45 90


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Tugas 5 1. Pilih sebuah komponen nyata yang memiliki proses turning.

Sketsa kondisi material awal dan setiap tahap proses pemotongan hingga bentuk akhir produk. Tentukan parameter pemesinannya; jika v=2.5m/s, f=0.3mm/rev. Dikumpulkan di LSP Kamis, 6 November 2003 jam 12.00

2. Pilih sebuah komponen nyata lainnya yang memiliki proses milling • • •

Sketsa kondisi material awal dan setiap tahap proses pemotongan hingga bentuk akhir produk. Tentukan diameter pahat yang cocok untuk setiap proses pemesinan komponen tersebut Tentukan parameter pemesinannya Dikumpulkan di LSP Kamis, 13 November 2003 jam 12.00


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TI-2121: Proses Manufaktur

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