PENERAPAN CAD/CAM DALAM PEMBUATAN DETAIL

PART BRACKET TOP PLATE MENGGUNAKAN

Pro/ENGINEER 5.0
Di
BALAI MESIN PERKAKAS, TEKNIK PRODUKSI DAN
OTOMASI
Gedung Teknologi 2 Balai MEPPO Kawasan PUSPITEK Serpong
Tangerang Selatan
(Laporan Kerja Praktik)

Disusun Oleh:
DWI NOVRIADI
1015021028

JURUSAN TEKNIK MESIN

FAKULTAS TEKNIK
UNIVERSITAS LAMPUNG
BANDAR LAMPUNG
2013

LEMBAR PENGESAHAN

Nama Mahasiswa

: Dwi Novriadi

No. Pokok Mahasiswa : 1015021028

Jurusan

: Teknik Mesin

Fakultas

: Teknik

Judul Laporan

: PENERAPAN CAD/CAM DALAM PEMBUATAN

DETAIL PART BRACKET TOP PLATE
MENGGUNAKAN Pro/ENGINEER 5.0

Waktu pelaksanaan

: 1 Juli s.d. 31 Juli 2013

Tempat Pelaksanaan

: Divisi Produksi Balai Mesin Perkakas, Teknik Produksi,

Dan Otomasi Badan Pengkajian dan Pengembangan
Dan Teknologi (Balai MEPPO-BPPT), Kawasan
Puspitek Serpong Tangerang Selatan, 15134.

Bandar Lampung, 05 April 2014

Menyetujui,
Pembimbing Kerja Praktik

Dosen Pembahas

Dr.Eng. Suryadiwansa Harun, S.T, M.T.

NIP.19700501 200003 1 001

Achmad Yahya Teguh P, S.T.,M.T

NIP. 19800205 200501 1 002

Mengesahkan,
Ketua Jurusan Teknik Mesin

Harmen, S.T., M.T.

NIP. 19690620 200003 1 001

SANWACANA

Puji syukur penulis panjatkan kepada Allah SWT karena berkat rahmat,
hidayah dan pertolongan-Nya penulis dapat menyelesaikan laporan kerja praktik
ini. Kerja praktik ini merupakan salah satu syarat menyelesaikan studi S1 pada
jurusan Teknik Mesin Universitas Lampung. Kerja praktik ini mempunyai tujuan
utama yaitu memberikan kesempatan untuk mahasiswa belajar di lingkungan
industri dan menerapkan ilmu yang diperoleh pada bangku kuliah.
Dalam kerja praktik ini penulis mendapat kesempatan untuk melakukan
kerja praktik di PT. Dirgantara Indonesia yang dilaksanakan pada 1 Juli sampai
dengan 31 Juli 2013.
Penulis sangat berterima kasih dan memberikan penghargaan sedalamdalamnya kepada seluruh pihak yang membantu penulis menyelesaikan kerja
praktik dan laporan kerja praktik ini. Penulis terutama ingin mengucapkan terima
kasih dengan setulus hati kepada:
1. Bapak Harmen, S.T., M.T. sebagai ketua jurusan Teknik Mesin Unila.
2. Bapak Dr.Eng.Suryadiwansa Harun sebagai dosen pembimbing yang telah
memberikan segala bantuan, pengetahuan, saran, dan motivasi kepada
penulis.
3. Bapak Ahmad Yahya. TP, S.T., M.T. sebagai dosen pembahas kerja
praktik penulis, yang telah memberikan saran dan komentar agar penulis
dapat menyelesaikan laporan dengan sebaik mungkin.
4. Bapak Dr. Gusri Akhyar Ibrahim, M.T. selaku dosen koordinator kerja
praktik, yang telah membantu penulis agar dapat kerja praktik di Balai
MEPPO-BPPT Serpong
5. Bapak Harnowo, M.T. selaku dosen koordinator kerja praktik yang baru,
yang

telah

memberikan

penulis

saran

dan

kesempatan

untuk

melaksanakan seminar kerja praktik.

6. Kedua orang tuaku, adik-adikku dan semua keluarga penulis yang
senantiasa mendukung, mendoakan, dan membantu penulis agar dapat
menyelesaikan kerja praktik dengan sebaik mungkin.

ii

7. Bapak Edi dan bapak Nasril selaku pembimbing kerja praktik penulis di
Balai MEPPO-BPPT yang telah bertindak sebagai orang tua bagi penulis,
yang mengajarkan, memberikan motivasi, dan menyemangati penulis agar
terus belajar dan tidak pernah putus asa selama kerja praktik. Penulis tidak
akan pernah lupa semua budi Bapak selama ini.
8. Mas Yanyan dan Mas Ali selaku programmer di Balai MEPPO-BPPT
yang telah penulis anggap sebagai saudara bagi penulis yang sabar
mendidik penulis untuk belajar pemrograman mesin CNC.
9. Devi Susila Wati yang selalu memarahi dan memberi semangat saat kerja
Praktik
10. Rahmat Dani, Dwi Andri Wibowo, dan Baron Hariyanto yang selalu
menemani dalam kerja praktik selama 30 hari.
11. Sakty Vanesa yang selalu menemani dan memberi semangat kepada
penulis.
12. Teman-teman Teknik Mesin 2010 yang telah membantu dan memotivasi
penulis untuk memberikan yang terbaik bagi teknik mesin kita.
13. Dan untuk seluruh pihak yang telah mendoakan, membantu, dan
memotivasi

penulis sehingga laporan kerja praktik ini tersusun dengan

baik.
Penulis menyadari bahwa laporan ini masih memiliki kekurangan dalam penulisan
dan penyusunannya, sehingga penulis sangat mengharapkan saran dan kritik yang
bersifat membangun dari para pembaca. Penulis sangat berharap agar laporan
kerja praktik ini dapat memberi inspirasi dan bermanfaat bagi penulis, kalangan
civitas akademik Unila, dan masyarakat.

Bandar Lampung, 05 April 2014

Penulis,

Dwi Novriadi

iii

DAFTAR ISI

Halaman
LEMBAR PENGESAHAN ................................................................................ i
SANWACANA ..................................................................................................

ii

DAFTAR ISI ......................................................................................................

iv

DAFTAR TABEL ..............................................................................................

DAFTAR GAMBAR .......................................................................................... vi

BAB I PENDAHULUAN .................................................................................

1.1. Latar Belakang ....................................................................................

1.2. Tujuan ................................................................................................... 2

1.3. Batasan Masalah ................................................................................... 2
1.4. Sistematiaka Penulisan .........................................................................

BAB II TINJAUAN PUSTAKA ......................................................................

2.1. Pengenalan CAD/CAM .......................................................................

2.2. Mesin CNC (Computer Numerical Control) ........................................

2.3. Pro/E (Pro Engineer) 5.0 ......................................................................

13

BAB III METODOLOGI ................................................................................. 18

3.1. Tempat dan Waktu Pelaksanaan ........................................................... 18
3.2. Metode Pelaksanaan .............................................................................

18

3.3. Diagram Alur Kerja Praktik .................................................................

19

BAB IV DATA DAN PEMBAHASAN ...........................................................

21

4.1. Data pengamatan ..................................................................................

21

4.2. Pembahasan ..........................................................................................

131

BAB V PENUTUP ............................................................................................

135

5.1. Simpulan ............................................................................................... 135

5.2. Saran .....................................................................................................

136

DAFTAR PUSTAKA .......................................................................................

137

LAMPIRAN

iv

DAFTAR TABEL

Tabel 2.1. Rekomendasi untuk kecepatan potong (HSS-Co)

Halaman
12

DAFTAR GAMBAR

Halaman
Gambar 2.1. Pemrograman Absolut ..................................................................
Gambar 2.2. Pemrograman relatif ......................................................................
Gambar 2.3. Dialog Box untuk membuat file manufaktur .................................
Gambar 2.4. Mfg Setup ......................................................................................
Gambar 2.5. Operation Setup..............................................................................
Gambar 2.6. Parameter cutter .............................................................................
Gambar 2.7. Parameter pemotongan ..................................................................
Gambar 3.1 Diagram alir kerja praktik ...............................................................
Gambar 4.1. Gambar teknik detail Bracket Top Plate........................................
Gambar 4.2 Penggambaran sketsa ......................................................................
Gambar 4.3 Pemberian ketebalan part sebesar 100 mm ....................................
Gambar 4.4 Pemberian tap hole .........................................................................
Gambar 4.5 Pembuatan lubang baut sedalam 22.25 mm ...................................
Gambar 4.6 Pembuatan tap hole pada bagian bawah part .................................
Gambar 4.7 Pemberian pad untuk sketsa pada Gambar 4.7 ...............................
Gambar 4.8 Penggambaran sketsa ......................................................................
Gambar 4.9. Raw material yang siap digunakan ................................................
Gambar 4.10. Endmill Cutter..............................................................................
Gambar 4.11. Pembuatan dan assembly workpiece............................................
Gambar 4.12. Insert coordinate system...............................................................
Gambar 4.13. setting operasi dan parameter mesin NC .....................................
Gambar 4.14. memasukkan parameter cutter untuk membuat lubang ..............
Gambar 4.15. memasukkan parameter pembuatan lubang .................................
Gambar 4.16. Paramter cutter untuk rought cutting ...........................................
Gambar 4.17. Parameter rought cutting..............................................................
Gambar 4.18. NC Check .....................................................................................
Gambar 4.19. zero point untuk side hole dan membuat parameter operasi ......
Gambar 4.20 Parameter cutter ............................................................................
Gambar 4.21. memasukkan parameter pemotongan ...........................................
Gambar 4.22. parameter cutter untuk rought cutting..........................................
Gambar 4.23. Parameter rought cutting..............................................................
Gambar 4.24. NC Check pada side hole .............................................................
Gambar 4.25. membuat titik nol dan parameter pemesinan ...............................
Gambar 4.26. parameter cutter............................................................................
Gambar 4.27. parameter pemotongan .................................................................
Gambar 4.28. Parameter ball cutter.....................................................................
Gambar 4.29. NC Check pada pemotongan akhir ..............................................
Gambar 4.30. Pembuatan lubang baut pada sisi miring .....................................
Gambar 4.31. Pembuatan lubang baut pada bagian bawah Bracket...................
Gambar 4.32. Proses cutting pada bagian atas ...................................................
Gambar 4.33. Sisa material pada saat simulasi pemotongan sisi miring ..........

7
8
15
15
16
17
17
20
22
23
23
23
24
24
24
25
25
26
28
28
29
29
30
30
31
31
32
32
32
33
33
34
34
35
35
36
36
37
61
64
134

vi

BAB I. PENDAHULUAN

1.1. Latar Belakang

CAD/CAM telah menjadi bagian penting dalam dunia industri. sejak tahun 1950an hingga sekarang CAD/CAM dan sistem komputerisasi bagi dunia industri telah
berkembang pesat. Hal ini ditunjukkan dengan munculnya berbagai software
CAD/CAM yang telah beredar. CAD/CAM merupakan sebuah sistem yang
berfungsi untuk mengembangan dan mengedit desain lebih cepat dan akurat.
Ketika model geometris tiga dimensi yang dihasilkan dalam proses desain,
kemudian menjadi elemen untuk rekayasa analisis, perencanaan proses
pemesinan, dokumentasi, kontrol kualitas, dan sebagainya.

CAD (Computer Aided Design) adalah program komputer yang memungkinkan

seorang perancang (designer) untuk mendesain gambar rekayasa (design
engineering) dengan mentransformasikan gambar geometris secara cepat.
Software CAD sekarang sudah dapat digunakan untuk menganalisis dan menguji
suatu komponen sebelum di produksi, sehingga produktifitas meningkat dan biaya
produksi dapat menurun. Sedangkan CAM (Computer Aided Manufacturing)
adalah sistem manufaktur yang mengoptimalkan kemampuan program untuk
menerjemahkan desain yang dibuat oleh CAD sehingga dapat digunakan untuk
mengontrol mesin NC (Numerical Controlled Machines). Sistem CAD/CAM
sendiri terjadi apabila

spesifikasi disain, jadi CAD/CAM merupakan

penggabungan desain dan instruksi manufaktur.

Salah satu perangkat lunak CAD/CAM yang digunakan di Balai MEPPO-BPPT

adalah Pro Engineer WildFire 5.0 (Pro/E WildFire 5.0). Vendor software ini
mengkategorikan perangkat lunak ini sebagai Computer Aided Design (CAD),
Computer Aided Engineering (CAE), dan Computer Aided Manufacturing (CAM)
yang berbasis pada pemodelan tiga dimensi. Verifikasi menggunakan Pro/E
dimulai dengan melihat tool path yang dibuat berdasarkan gambar tiga dimensi,
kemudian gambar tersebut diberikan beberapa perintah mengenai proses
pemesinan untuk melihat simulasi proses pemesinan. Selain bentuk geometri,
output yang dihasilkan dari CAD/CAM dapat berupa bahasa NC (Numerical
Control) yaitu G-Codes dan M-Codes. Bahasa inilah yang umum digunakan untuk
menjalankan mesin CNC. Output dari pemrograman NC dengan Pro/E langsung
dapat dipakai untuk menjalankan proses produksi karena sudah dilengkapi postprocessor. Dimana model CAM dibuat menjadi bahasa NC (numerical control)
berupa G-Codes dan M-Codes, dengan bahasa tersebut mesin CNC dapat bekerja
sesuai yang terprogram dari proses CAD/CAM-nya.

Sehubungan dengan uraian di atas penulis tertarik untuk mempelajari perangkat

lunak CAD/CAM dalam proses manufaktur, dengan studi kasus pembuatan part
braket top plate. Hal ini dikarenakan Pro/E lebih mudah untuk dipelajari,
aktraktif, efisien, dan memiliki simulasi stock removal, sehingga menjadi tren di
industri dan masyarakat luas.

1.2. Tujuan

Tujuan dari pelaksanaan kerja praktik ini adalah untuk mengaplikasikan perangkat
lunak CAD/CAM untuk menghasilkan G-Code (Kode NC) untuk keperluan
pemesinan dengan menggunakan Software Pro/Engineering 5.0.

1.3. Batasan Masalah

Masalah yang diteliti dalam kerja praktik ini dibatasi pada:

1. Pemodelan geometri komponen dengan menggunakan Pro/ENGINEER

V5.
2. Proses pemesinan yang disimulasikan menggunakan Pro/ENGINEER V5
adalah milling.
3. Penentuan cutting condition hanya untuk pemotongan material mild steel.

1.4. Sistematika Penulisan

Sistematika penulisan yang terdapat pada laporan kerja praktik ini terdiri dari:

Bab I. Pendahuluan
Bab ini berisi latar belakang, tujuan, dan batasan masalah sebagai pembahasan
utama dalam laporan kerja praktik dan sistematika penulisan.

Bab II. Tinjauan Pustaka

Memberikan gambaran tentang teori-teori dan uraian yang berkaitan CAD/CAM,
pemrograman NC, proses pemesinan milling, dan simulasi proses pemesinan
menggunakan Pro/ENGINEER V5.

Bab III. Metodologi

Menjelaskan tentang teknik pengambilan data serta urutan pengerjaan dalam
membuat simulasi proses pemesinan menggunakan Pro/ENGINEER V5.

Bab IV. Data Dan Pembahasan

Membahas data-data yang diperoleh selama kerja praktik, perhitungan yang
dipakai, serta analisa dari data-data tersebut.

Bab V. Penutup
Memberikan kesimpulan dan saran

yang diperoleh setelah melakukan

pembahasan.

DAFTAR PUSTAKA
Lampiran

BAB II. TINJAUAN PUSTAKA

2.1. Pengenalan CAD/CAM

CAD (Computer Aided Design)

adalah suatu program komputer untuk

menggambar suatu produk atau bagian dari suatu produk. Produk yang ingin
digambarkan bisa diwakili oleh garis-garis maupun simbol-simbol yang memiliki
makna tertentu. CAD bisa berupa gambar 2 dimensi dan 3 dimensi.
CAD merupakan teknologi untuk membuat rencana gambar (rancangan) dengan
bantuan komputer. Sistem CAD membantu

insinyur pada waktu merancang,

melakukan perhitungan matematika dan membuat gambar rakitan maupun

elemennya. Selain itu, seorag insinyur bisa mendapatkan ukuran komponen,
menganalisa tegangan dan faktor-faktor lainnya. Sistem CAD pada komputer
menggantikan banyak istrumen gambar, meja gambar, dan arsip-arsip gambar.
Tidak seperti alat gambar sebelumnya, sistem CAD meningkatkan produktifitas
rekayasa tanpa menggantikan fungsi-fungsi dasar pembuat rencana, insinyur dan
teknisi gambar.
Berawal dari menggantikan fungsi meja gambar kini perangkat lunak CAD telah
berevolusi dan terintegrasi dengan perangkat lunak computer aided engineering
dengan perangkat lunak CAE dan CAM. Integrasi ini dimungkinkan karena
perangkat lunak CAD saat ini kebanyakan merupakan aplikasi gambar 3 dimensi
atau biasa disebut solid modelling. Solid model memungkinkan kita untuk
memvisualisasikan komponen dan rakitan yang kita buat secara realistik. Selain
itu model mempunyai properties seperti massa, volume, pusat gravitasi, luas
permukaan dan lain-lain.

CAM (Computer Aided Manufacturing) merupakan teknologi perencanaan,

pengaturan dan pengontrolan pembuatan produk dengan bantuan komputer.
Sistem CAM mencakup bidang-bidang keahlian seperti CAPP (Computer Aided
Process

Planing/Persiapan

pekerjaan

yang

dibatu

dengan

komputer).

Pemrograman NC (Numerical Control) dan pemrograman robot, pembuatan

instruksi pekerjaan (peraturan kerja), perencanaan dan penyediaan perkakas
potong dan alat-alat penjepit. Serta mencakup juga FMS (sistem komputer untuk
pengontrolan sistem produksi yang fleksibel). Tujuan dari pengembangan sistem
CAM ini dipusatkan untuk mengurangi interaksi dengan operator.
Dengan kata lain CAD/CAM merupakan perangkat lunak yang saling
berhubungan secara langsung antara desain, produk dan manufaktur. sistem CAD
digunakan untuk mengembangkan model geometris dari sebuah part, kemudian
model ini digunakan oleh sistem CAM untuk menghasilkan program atau bahasa
pemrograman untuk peralatan mesin CNC.
CAD/CAM memungkinkan untuk pengembangan cepat dan pengeditan desain
dan dokumentasi. Ketika model geometris tiga dimensi yang dihasilkan dalam
proses desain, kemudian menjadi elemen umum untuk analisis, proses
perencanaan pemesinan (termasuk CNC bagian pemrograman), dokumentasi
(termasuk gambar teknik), kontrol kualitas, dan sebagainya.

2.2. Mesin CNC (Computer Numerical Control)

CNC merupakan singkatan dari Computer Numerically Controlled, yaitu mesin
perkakas yang dilengkapi dengan sistem mekanik dan kontrol berbasis komputer
yang mampu membaca instruksi kode N, G, F, T, dan lain-lain, dimana kode-kode
tersebut akan menginstruksikan ke mesin CNC agar bekerja sesuai dengan
program benda kerja yang dibuat.
Secara umum cara kerja mesin perkakas CNC tidak berbeda dengan mesin
perkakas konvensional yang dalam pengerjaannya masih menggunakan cara-cara
manual. Fungsi CNC dalam hal ini lebih banyak menggantikan pekerjaan operator

dalam mesin perkakas konvensional tersebut. Misalnya pekerjaan setting tool atau
mengatur gerakan pahat sampai pada posisi siap memotong, gerakan pemotongan
dan gerakan kembali keposisi awal, dan lain-lain. Demikian pula dengan
pengaturan kondisi pemotongan (kecepatan potong, kecepatan makan dan
kedalaman pemotongan) serta fungsi pengaturan yang lain seperti penggantian
pahat, pengubahan transmisi daya (jumlah putaran poros utama), dan arah putaran
poros utama, pengekleman, pengaturan cairan pendingin dan sebagainya. Mesin
perkakas CNC dilengkapi dengan berbagai alat potong yang dapat membuat
benda kerja secara presisi dan dapat melakukan interpolasi yang diarahkan secara
numerik (berdasarkan angka).
Parameter sistem operasi CNC dapat diubah melalui program perangkat
lunak (software load program) yang sesuai. Tingkat ketelitian mesin CNC lebih
akurat

hingga

ketelitian

seperseribu

millimeter,

karena

penggunaan

ballscrew pada setiap poros transportiernya. Ballscrew bekerja seperti lager yang
tidak memiliki kelonggaran/spelling namun dapat bergerak dengan lancar.
Mesin CNC dapat bekerja secara otomatis atau semi otomatis setelah
diprogram terlebih dahulu melalui komputer yang ada. Program yang dimaksud
merupakan program untuk membuat benda kerja yang telah direncanakan atau
dirancang sebelumnya. Sebelum benda kerja tersebut dieksekusi atau dikerjakan
oleh mesin CNC, program tersebut di cek berulang-ulang agar program benarbenar telah sesuai dengan bentuk benda kerja yang diinginkan serta benar-benar
dapat dikerjakan oleh mesin CNC. Pengecekan tersebut dapat melalui layar
monitor yang terdapat pada mesin atau dapat di cek menggunakan bantuan
softwere. Setelah program benar-benar telah berjalan seperti rencana, baru
kemudian dilaksanakan/dieksekusi oleh mesin CNC (Pusztai, 1983).

2.2.1. Dasar-dasar Pemrograman

Ada beberapa langkah yang harus dilakukan seorang programmer sebelum
menggunakan mesin CNC, pertama mengenal sistem koordinat yang ada pada
mesin CNC, yaitu sistem koodinat cartesius, yang terdiri dari koordinat mutlak

(absolut) dan koordinat relatif (inkremental). Selanjutnya menentukan system

koordinat yang akan digunakan dalam pemrograman, apakah program akan
menggunakan sistem pemograman metode absolut atau inkremental. Pada
umumnya sistem koordinat yang sering digunakan adalah sistem koordinat
kartesius ini, yaitu koordinat mutlak (absolut) dan koordinat relatif/berantai
(incremental). Langkah kedua adalah memahami prinsip gerakan sumbu utama
dalam mesin CNC.

2.2.1.a. Pemrograman Absolut

Pada sistem ini titik awal penempatan alat potong yang digunakan sebagai acuan
adalah menetapkan titik referensi yang berlaku tetap selama proses operasi mesin
berlangsung. Untuk mesin bubut, titik referensinya

diletakkan

pada sumbu

(pusat) benda kerja yang akan dikerjakan pada bagian ujung. Sedangkan pada
mesin frais, titik referensinya diletakkan pada pertemuan antara dua sisi pada
benda kerja yang akan dikerjakan.

Sumber: Fanuc Operators Manual

Gambar 2.1. Pemrograman Absolut

2.2.1.b. Pemrograman Relatif (Inkremental)

Pada system ini titik awal penempatan yang digunakan sebagai acuan adalah
selalu berpindah sesuai dengan titik actual yang dinyatakan terakhir. Untuk mesin
bubut maupun mesin frais diberlakukan cara yang sama. Setiap kali suatu gerakan
pada proses pengerjaan benda kerja berakhir, maka titik akhir dari gerakan alat
potong itu dianggap sebagai titik awal gerakan alat potong pada tahap berikutnya.

Sumber: Fanuc Operators Manual

Gambar 2.2. Pemrograman relatif

2.2.2. CNC Codes

Ada dua jenis yang utama dari CNC codes atau pada program lainnya dinamakan
letter addresses. Sebagian besar CNC codes disebut dengan G-Codes dan MCodes. Kode-kode inilah yang digunakan untuk menjalankan mesin CNC dalam
memproduksi komponen (Zeid, 1991).
G-Codes adalah fungsi persiapan (preparatory function), termasuk
didalamnya pergerakan aktual dari tools. hal tersebut meliputi pergerakan
bebas, pergerakan pemakanan, pergerakan pemakanan secara radial,
pengasaran (roughing) dan pembuatan profil.

M-codes adalah fungsi lainnya (miscelaneaous function), yang meliputi

tindakan yang penting selama proses pemesinan, tapi bukan pergerakan
aktual tools. Sebagai contoh spindel on dan off, pergantian tools, pendingin on dan off, program stop, dan fungsi yang serupa lainnya.
Terdapat letter addresses yang digunakan pada G-Codes dan M-Codes untuk
membuat suatu kata. Sebagian besar huruf yang biasa digunakan untuk pemrograman antara lain (Nanfara, 1995).
N

Block number menyatakan awal dari sebuah blok

fungsi persiapan (preparatory function), seperti yang telah

dijelaskan sebelumnya

koordinat sumbu X

koordinat sumbu Y

koordinat sumbu Z

lokasi pusat busur pada sumbu X

lokasi pusat busur pada sumbu Y

lokasi pusat busur pada sumbu Z

mengatur kecepatan spindel

mengatur besarnya pemakanan

penjelasan tools yang dipakai

fungsi lainnya (miscelaneaous function)

2.2.2.a. G-Codes
Sebagian besar G-Codes adalah modal, yang berarti mereka tetap aktif sampai
dibatalkan dengan G-Codes lainya. Berikut adalah G- Codes untuk CNC milling
yang telah dideskripsikan (Groover, 1999).
G00

Gerakan cepat

Modal

G01

Gerakan linear

Modal

G02

Gerakan melingkar (CW)

Modal

G03

Gerakan Melingkar (CCW)

Modal

G04

Dwell/pause

G17

Pemilihan bidang XY

Modal

G18

Pemilihan bidang XZ

Modal

G19

Pemilihan bidang YZ

Modal

G20/G70

satuan inci

Modal

G21/G71

Satuan metrik

Modal

G28

Kembali ke titik acuan

G29

Kembali dari titik acuan

G40

Pembatalan kompensasi Pahat

Modal

G41

Kompensasi pahat ke kanan

Modal

G42

Kompensasi pahat ke kiri

Modal

G43

Kompensasi panjang pahat (+)

Modal

G44

Kompensasi panjang pahat (-)

Modal

G49

Pembatalan Kompensasi panjang

Modal

G80

Pembatalan siklus canned

Modal

G81

Pembuatan lubang

Modal

G82

Pembuatan counter bore

Modal

G83

Pembuatan lubang dalam

Modal

G90

Posisi absolut

Modal

G91

Posisi incremental

Modal

G92

Penentuan ulang origin

G98

Set bidang menjadi default

G99

Gerak menjauh dari bidang

10

2.2.2.b. M-Codes
berikut adalah M-Codes untuk CNC milling yang telah didefinisikan.
M00

Pemberhentian program

M01

Pemberhentian program opsional

M02

Program berakhir (tidak dapat dilanjutkan lagi)

M03

Putaran spindel searah jarum jam

M04

Putaran spindel berlawanan jarum jam

M05

Spindel stop

M06

Pergantian tools

M08

Pendingin on

M09

Pendingin off

M10

Pencekam on

M11

Pencekam off

M30

Program berakhir, reset untuk kembali

2.2.3. Milling
Milling (freis) adalah operasi pemesinan dimana benda kerja dipotong oleh pahat
yang berputar dengan mata potong jamak. sumbu putar dari pahat yang berputar
adalah tegak lurus dari arah pemakanan. Pahat dari operasi milling dinamakan
milling cutter dan ujung potong dari pahat dinamakan teeth (gigi). Geometri yang
dihasilkan dari operasi milling dinamakan plane surface (bidang permukaan).
Berbagaigeometri pengerjaan dapat dibuat bergantung pada jalur cutter-Nya, juga
bentuk cutter-Nya. Dikarenakan banyak bentuk yang dapat dibuat dan tingkat
produktifitas tinggi menjadikan milling sebagai operasi pemesinan yang sangat
banyak digunakan (Groover, 1999).

11

2.2.4. Cutting Condition in Milling

Kecepatan potong ditentukan berdasarkan diameter luar dari milling cutter. hal ini
juga dapat diubah untuk mencari kecepatan putaran spindel menggunakan persamaan yang sudah cukup dikenal yaitu (Groover, 1999).
N

1000V
D

untuk melakukan milling dengan kedalaman potong yang besar, direkomendasikan menggunakan kecepatan potong yang rendah, agar tidak terjadi defleksi dan getaran (Pinem, 2009).
Tabel 2.1. Rekomendasi untuk kecepatan potong (HSS-Co) (Pinem, 2009).
material

Mild
steel,
Brass,
Bronze

Medium
tensile
steel, Mild
steel
forging,
Cast iron,
Hard
brass,
bronze
copper

High tensile
steel,
unalloyed
titanium,
ferritic low
alloy

high tensile
steel
(1002
180 kgf/mm )
Tool steel,
medium
strength
stainless steel

heat
resistance
high alloy,
high
strength
titanium
alloy, high
strength
stainless
steel

Alumunium,
Alloyed
Alumunium,
Plastics,
woods

Type
Short

35-45

28-33

15-20

10-15

5-10

80-120

Long

20-30

15-25

10-15

8-12

3-8

50-80

Pemakanan merupakan faktor utama untuk sebuah produktifitas proses pemesinan. Rekomendasi dari pemakanan dipengaruhi oleh material yang akan di
potong, material pahat, dan kedalaman potong dimana umur pahat sangat
diperhatikan. Pemakanan pada milling biasanya dinamakan pemakanan per gigi
cutter atau chip load, yang menyatakan ukuran dari geram yang terpotong oleh
setiap mata potong. Hal ini dapat diubah menjadi feedrate dengan menggunakan
nilai kecepatan spindel dan jumlah gigi (mata potong) pada cutter seperti
feedrate = T x Z x N

12

Dimana T = Feed per tooth (mm/gigi); N = Kecepatan putaran spindel (rpm); Z =

jumlah mata potong. Feed per tooth akan berubah bila kedalaman potong berubah
juga. Pada operasi slot direkomendasikan kedalaman potong yaitu diameter
cutter. Jika kedalaman potong dinaikan sampai samapai sebesar diameter cutter,
pemakanan harus diturunkan 50%.
Tetapi jika kedalaman potong diturunkan menjadi Diameter cutter, pemakanan
tidak dapat dilipatgandakan, hanya diizinkan pemakanan dinaikan sampai 30%.
Hal ini dikarenakan terbatasnya kekuatan pada mata potong cutter dan dapat
menyebabkan chipping. Untuk produktifitas yang tinggi pemakaian cutter dengan
mata potong yang jamak direkomendasikan, hanya saja dengan kedalaman potong
yang kecil.
Pada side cutting direkomendasi 1,5D x 0,1D (kedalaman aksial, dan kedalaman
radial) sebagai kedalaman potong. Jika kedalaman arah radial digantikan 0,3D,
pemakanan akan diturunkan 50%. Pada kasus kedalaman potong arah radial
kurang dari 0,05D seperti operasi finishing, sebagai contoh untuk menghasilkan
kualitas pengerjaan permukaan yang baik cukup dengan meningkatkan putaran
spindel 20-30% daripada meningkatkan pemakanan pada persentasi pemakaian
yang sama. Jadi kualitas pengerjaan permukaan yang sukses dihasilkan dengan
menurunkan pemakanan (Pinem, 2009).

2.3. Pro/E (Pro Engineering) 5.0

Pro/Engineering merupakan pelopor perangkat lunak desain 3 dimensi yang
memakai sistem parametrik. Artinya desain komponen terbentuk dari berbagai
fitur dan referensi dan bentuk hubungan antar fitur tersebut. Untuk komponen
akhir yang sama jika cara pemberian dimensi dan hubungan antar fitur berbeda
makan akan menghasilkan bentuk komponen yang berbeda ketika suatu dimensi
diubah (Ahmad, 2009).
Sistem pemodelan parametrik (parametric modeling system) adalah sistem
pemodelan berbasis fitur (feature-based modeler). Dalam lingkungan parametric

13

modeling, komponen tersusun dari gabungan fitur-fitur. Fitur dengan ruang positif
memiliki massa misalnya ekstrusi boss. Sedangkan fitur dengan ruang negatif
adalah fitur yang memotong atau mengurangi massa dari suatu komponen,
misalnya hole (lubang). Jika kita perhatikan fitur-fitur dalam pemodelan
parametrik mirip dengan operasi permesinan, misalnya extrude dengan proses
ekstrusi, revolve dengan proses pembubutan/turning, sweep dengan frais/slot
milling (Suhairi, 2009).

2.3.1. Manufaktur Model Pro/Engineer

Mempersiapkan model referensi merupakan hal pertama yang perlu dipersiapkan
dalam pemodel manufaktur. Persiapan ini mencakup semua fitur yang diperlukan
untuk pemodelan. Pengguna akan memiliki pilihan untuk menciptakan benda
kerja secara otomatis atau manual. Pembuatan benda kerja otomatis menggunakan
siluet model untuk membuat baik blok atau bar. Demikian pula, jika model selesai
berasal dari casting, maka benda kerja untuk jenis model harus dibuat secara
manual dan merakit ke model referensi. Pengguna harus secara berkala
menyimpan model selama proses pembuatan. Hal ini bertujuan untuk menghindari
kehilangan data akibat program crash karena memori habis dalam perhitungan
path alat NC kompleks.

2.3.2. Pembuatan Model Manufaktur

Pengguna perlu untuk memulai Pro / ENGINEER Wildfire 5.0 dan membuat
sebuah file manufaktur baru. Tempatkan nama yang sesuai untuk file mfg. Dan
pastikan bahwa tipe diatur ke Manufaktur dan sub tipe diatur NC Assembly. Jika
sebelumnya telah menetapkan metrik (milimeter) sebagai template default, lalu
pilih OK. Dan jika tidak, hapus centang pada Use default template di kotak dialog.
Kemudian memastikan bahwa template mmns_mfg_nc dipilih dan pilih OK di
kotak pilihan file dialog (Ahmad, 2009).

14

Gambar 2.3. Dialog Box untuk membuat file manufaktur

2.3.3. Setting Manufaktur

Pengguna perlu memilih Mfg Setup dari menu manager untuk mengatur lingkup
manufaktur yang diperlukan untuk model. Akan muncul sebuah dialog box yang
menunjukkan sebuah operasi mesin NC, koordinat nol sistem akan diminta untuk
diidentifikasi.

Pengguna juga dapat mengatur referensi yang berbeda untuk

urutan NC yang berbeda.

Gambar 2.4. Mfg Setup

15

Gambar 2.5. Operation Setup

Pengguna dapat memilih setup alat mesin dengan memilih ikon yang terdapat
pada operation setup. Sebuah kotak dialog akan muncul dan pengguna akan
diminta untuk memasukkan konfigurasi mesin seperti jumlah sumbu dan tipe
mesin yang digunakan.

2.3.4. Parameter Pemotongan

Pada tahap ini pengguna dapat memasukkan parameter cutter dan pemotongan.
Parameter cutter berisi tentang jenis dan dimensi cutter yang akan digunakan.
Sedangkan parameter pemotongan berisi tentang kecepatan pemakanan (cutting
feed), toleransi, sudut pahat, kecepatan spindle, dan lainnya.

16

Gambar 2.6. Parameter cutter

Gambar 2.7. Parameter pemotongan

Setelah parameter cutter dan pemotongan dimasukkan file cutter location (NCL)
akan terbentuk, file ini berisi koordinat lokasi tool dalam Pro/Engineer. Namun
file tersebut belum berbentuk G-code yang merupakan bahasa pemrograman
mesin NC. G-Code akan terbentuk setelah memproses file NCL yang telah
terbentuk sebelumnya. NCL diproses dengan menu Post Proccess yang terdapat di
dalam software Pro/Engineer.

17

BAB III. METODOLOGI

3.1. Tempat Dan Waktu Pelaksanaan

Tempat

Divisi Produksi Balai Mesin Perkakas, Teknik Produksi, dan

Otomasi Badan Pengkajian dan Pengembangan Teknologi (Balai
MEPPO-BPPT), Kawasan Puspitek Serpong Tangerang Selatan,
15134.

Waktu

Hari Kerja :

01 Juli s.d. 31 Juli 2013

Senin s/d Jumat pukul 08.00 16.00 WIB (Istirahat pukul 12.00
13.00 WIB, khusus hari Jumat istirahat pukul 11.30 13.00 WIB).

3.2. Metode Pelaksanaan

Metode yang penulis lakukan selama kerja praktik di Balai MEPPO-BPPT dalam
pengambilan dan analisis data sebagai berikut:
3.2.1. Observasi
Observasi yang penulis lakukan selama melaksanakan kerja praktik di Balai
MEPPO-BPPT antara lain: pengamatan lokasi workshop, pengamatan alur
produksi pada alur produksi, dan pengamatan secara umum mengenai mesin NC
yang ada pada workshop.
3.2.2. Wawancara dan Diskusi
Wawancara penulis lakukan terhadap pihak-pihak terkait seperti wawancara
kepada pembimbing kerja praktik di lapangan, staf-staf bidang produksi, serta

18

para teknisi dari mesin produksi pada bagian machining. Adapun wawancara dan
diskusi ini penulis lakukan untuk memproleh informasi dan pengetahuan yang
tidak penulis dapatkan saat observasi.

3.2.3. Studi Literatur

Studi dilakukan untuk mendapatkan spesifikasi mesin NC, cutter, holder, yang
akan dipakai dalam pemodelan dan penganalisaan data. Studi literatur dilakukan
untuk mendapatkan teori penunjang tentang CAD/CAM, dan proses pemesinan
milling.
3.2.4. Pembuatan Model CAD, Setting Manufaktur, dan Generate G-Code.
Membuat model geometri dari part Bracket Top Plate dengan menggunakan
CAD. Pemodelan berdasarkan blueprint yang telah di cek dan dianalisis oleh
bagian desain. Kemudian model CAD tersebut diberikan data berupa parameter
yang terdapat pada mesin NC, yaitu kecepatan potong, kecepatan pemakanan,
kecepatan spindle dan dalam pemotongan. Model yang telah dibuat CAM akan
dibuatkan G-code menggunakan post process pada CL Menu yang sesuai dengan
mesin NC yang dipakai. Setelah G-code di-dapatkan, data tersebut ditransfer ke
mesin NC untuk diproses.

3.3. Diagram Alir Kerja Praktik

Mulai

1. Pengenalan lingkungan perusahaan

2. Menentukan studi kasus

Pemodelan CAD dengan Pro/E

1. Part Bracket Top Plate
2. Raw material (Stock)

19

Pemodelan NC-Machining dengan Pro/E

Penentuan cutting condition

pada milling dengan input
1. Diameter cutter
2. Putaran spindel
3. Jenis material

Penentuan parameter pemesinan ke

dalam simulasi
1. Kedalaman potong optimal setiap jenis
pengerjaan
2. Kecepatan potong optimal
3. feedrate optimal

Verifikasi program

Modifikasi
program?

Ya

Tidak
Generate NC-Code dan
submit program

Pengolahan data, analisa , dan pembahasan

1. Memproleh hasil
2. Memproleh kesimpulan dan
saran

Selesai

Gambar 3.1 Diagram alir kerja praktik

20

BAB IV. DATA DAN PEMBAHASAN

4.1. Data Pengamatan

4.1.1. Aliran Proses Pembuatan Bracket Top Plate
Bracket top plate merupakan sebuah komponen (part) dari sebuah mesin press
hidrolik yang berfungsi sebagai penyanggah plat yang terletak pada guide way.
Guide way mempunyai fungsi sebagai jalur gerak plat penahan sehingga dapat
mengoptimalkan penekanan pada mesin press.

Proses pembuatan detail Bracket Top Plate dengan CAD/CAM pertama-tama

harus membuat suatu model geometrik, berupa gambar 3 dimensi hal ini
berdasarkan dari studi dan simulasi yang dilakukan staff dalam merancang mesin
pembuat selongsong peluru. Kemudian model tersebut dibuat sebuah release part
berupa gambar teknik. Model geometrik dan gambar teknik tersebut dibuat
dengan menggunakan software Pro/E dan dijadikan acuan pengerjaan CAM-nya.

4.1.2. Proses Produksi Detail Bracket Top Plate Dengan CAD/CAM

Proses produksi menggunakan CAD/CAM pada Balai MEPPO-BPPT dilakukan
pada bagian Produksi. Dalam pembuatan komponen mesin pembuat selongsong
peluru menggunakan sistem CAD/CAM, yang bertugas mengerjakannya adalah
seorang teknisi. Teknisi akan mengerjakan komponen setelah menerima
Blueprint. Blueprint yang diterima oleh teknisi berupa gambar teknik yang
memiliki spesifikasi .

21

4.1.3. Gambar Teknik Detail Bracket Top Plate

Seperti yang kita ketahui bahwa gambar adalah sebagai media atau alat untuk
menyatakan maksud atau pemikiran seseorang. Oleh karena itu, gambar sering
digunakan sebagai alat komunikasi yang pokok di kalangan orang-orang teknik.
Gambar mempunyai tugas meneruskan maksud dari perancang dengan tepat
kepada orang-orang yang bersangkutan, kepada perencana proses, programmer,
bagian inspeksi, perakitan dan sebagainya. Pada gambar teknik ini dapat diketahui
geometri dan dimensi dari komponen tersebut. Sehingga seorang teknisi dapat
membuat konsep pengerjaan machining-nya. Gambar 4.1 adalah gambar teknik
dari detail Bracket Top Plate dengan dimensi dalam satuan milimeter.

Gambar 4.1. Gambar teknik detail Bracket Top Plate

4.1.4. Pembuatan Model 3 Dimensi Menggunakan Pro/E

Meskipun teknisi telah mendapatkan blueprint komponen dari perancang, teknisi
harus mempunyai keahlian mendesain model dalam dua atau tiga dimensi. Hal ini
dikarenakan terkadang terjadi kesalahan geometri atau dimensi pada blueprint,
kesalahan desain fixture dan lainnya, oleh sebab itu seorang teknisi harus mampu
mengatasi hal tersebut.

22

Berikut langkah-langkah umum pembuatan model tiga dimensi mengunakan

Pro/E

4.1.4.a. Penggambaran sketsa dengan bentuk dan dimensi seperti gambar 4.2

Gambar 4.2 Penggambaran sketsa

4.1.4.b. Pemberian ketebalan mengunakan Extrude sebesar 100 mm.

Gambar 4.3 Pemberian ketebalan part sebesar 100 mm

4.1.4.c. Pemberian tap hole

Gambar 4.4 Pemberian tap hole

23

4.1.4.d. Pemberian lubang baut

Gambar 4.5 Pembuatan lubang baut sedalam 22.25 mm

4.1.4.e. Pembuatan tap hole pada bagian bawah part

Gambar 4.6 Pembuatan tap hole pada bagian bawah part

4.1.4.f. Pembuatan sketch untuk memotong part

Gambar 4.7 Pemberian pad untuk sketsa pada Gambar 4.7

24

4.1.4.g. Penggambaran pemotongan bagian bawah part

Gambar 4.8 Penggambaran sketsa

4.1.5. Pemodelan Komponen Dan Peralatan Yang Dipakai

Sebelum pembuatan program NC dilakukan, terlebih dahulu harus dipersiapkan
model part dari benda kerja yang akan di-machining, dan alat bantu lainnya
seperti clamp, fixture, bolt, nut, dan raw material. Model part dan alat bantu
lainnya dapat ditampilkan bersama menurut beberapa cara, tetapi sebaiknya
menggunakan fasilitas assembly design yang memungkinkan untuk menampilkan
gabungan dari beberapa model part tanpa mengganggu part original-nya.
4.1.5.a. Material Yang Digunakan
Jenis raw material yang digunakan adalah mild steel ST50, yang tergolong dalam
high carbon steel. Raw material ini telah menjalani proses facing terlebih dahulu
dengan menggunakan mesin milling sehingga menjadi bahan yang siap pakai.

Gambar 4.9. Raw material yang siap digunakan

25

4.1.5.b. Penjelasan Mesin CNC Yang Dipakai

Mesin CNC yang digunakan adalah mesin Leadwell V30, yang mempunyai 3 axis
pengerjaan dengan spesifikasi terlampir pada lampiran. Mesin Leadwell V30 melakukan pengerjaan milling dengan posisi cutter vertikal.

4.1.5.c. Cutter
Pada perencanaan pembuatan Part Bracket Top Plate menggunakan endmill
berukuran diameter 20 mm dengan panjang mata pahat sebesar 40 mm dan
panjang pahat sebesar 100 mm. Untuk spesifikasi dapat dilihat pada lampiran.

Gambar 4.10. Endmill Cutter

4.1.6. Perhitungan
Berdasarkan tabel 2.1. di dalam tinjauan pustaka kecepatan potong untuk
pemotongan material mild steel, dengan cutter short type adalah sebesar 35
m/menit s.d. 45 m/menit.

4.1.6.a. Perhitungan untuk rough cutting

Asumsi kecepatan potong
Diameter cutter

Dimana

: 45 m/menit
: 20 mm

N = Revolusi
D = Diameter cutter

26

V = Kecepatan potong

Dimana

T = Feed per tooth

Z = Jumlah mata potong
N = Revolusi

Dengan asumsi kedalaman potong diameter cutter

4.1.6.b. Perhitungan untuk pengeboran

Asumsi kecepatan potong
Diameter cutter

Dimana

: 45 m/menit
: 6 mm

N = Revolusi
D = Diameter cutter
V = Kecepatan potong

Dimana

T = Feed per tooth

Z = Jumlah mata potong
N = Revolusi

27

4.1.7. Pembuatan Simulasi Machining dengan Pro/E

Pembuatan simulasi ini dimulai dengan membuat workpiece atau model raw
material yang di-assembly secara langsung ke model geometri Part Top Bracket.
Kemudian menentukan zero point dengan menggunakan perintah insert coordinat
system untuk menentukan awal mula pahat akan bergerak.

Gambar 4.11. Pembuatan dan assembly workpiece

Gambar 4.12. Insert coordinate system

28

setelah menentukan koordinat sistem, selanjutnya memasukkan parameter tool

dan operasi pemesinan ke dalam simulasi. Berikut adalah langkah-langkah
memasukkan parameter kedalam simulasi:
4.1.7.a. Memasukkan parameter operasi
pada tahap ini parameter yang dimasukkan berupa titik nol pemesinan, jenis dan
tipe mesin NC, serta control pada mesin CNC.

Gambar 4.13. setting operasi dan parameter mesin NC

4.1.7.b. Memasukkan parameter pemesinan untuk pemotongan

Pada tahap ini parameter drill cutter dimasukkan untuk membuat top hole pada
bracket.

Gambar 4.14. memasukkan parameter cutter untuk membuat lubang

29

Gambar 4.15. memasukkan parameter pembuatan lubang

setelah dilakukan pengeboran, kemudian rought cutting untuk membuat lubang
tap dari kedua lubang tersebut dengan cutter berdiameter 8 mm. Pemasukkan
paramter ini dilakukan terpisah dari drilling kecuali operasi pemesinannya.

Gambar 4.16. Paramter cutter untuk rought cutting

30

Gambar 4.17. Parameter rought cutting

Melakukan checking parameter dengan menggunakan NC Check untuk
mengetahui kesalahan yang terjadi pada parameter

Gambar 4.18. NC Check

4.1.7.c. Membuat side hole

Pada tahap ini dibuat dibuat titik nol baru dan memasukkannya ke dalam
parameter operasi.

31

Gambar 4.19. zero point untuk side hole dan membuat parameter operasi

Gambar 4.20 Parameter cutter

Gambar 4.21. memasukkan parameter pemotongan

32

Setelah memasukkan parameter pengeboran, selanjutnya memasukkan parameter

rought cutting untuk membuat tap pada salah satu lubang.

Gambar 4.22. parameter cutter untuk rought cutting

Gambar 4.23. Parameter rought cutting

Melakukan NC Check untuk melihat hasil parameter side bore pada part.

33

Gambar 4.24. NC Check pada side hole

4.1.7.d. melakukan pemotongan part
Menentukan titik nol pemotongan dan memasukkan parameter pemesinan

Gambar 4.25. membuat titik nol dan parameter pemesinan

memasukkan parameter cutter dan parameter pemotongan. Cutter yang digunakan

berdiameter 20 mm dengan panjang mata cutter sepanjang 40 mm.

34

Gambar 4.26. parameter cutter

Gambar 4.27. parameter pemotongan

Untuk finishing, digunakan ball mill untuk memperhalus permukaan diagonal dari
part. Masukkan parameter ball mill cutter dan parameter pemotongan

35

Gambar 4.28. Parameter ball cutter

Melakukan NC Check terhadap parameter pemotongan dan pada finishing. Untuk
memastikan parameter yang sudah dimasukkan adalah benar.

Gambar 4.29. NC Check pada pemotongan akhir.

36

4.1.8. Generate G-Code untuk seluruh hasil pemotongan.

Setelah semua parameter dan NC Check dilakukan untuk semua parameter, maka
dapat segera ditampilakn data berupa G-Code, yaitu bahasa program yang
digunakan oleh semua mesin CNC. Untuk mentransfer data menjadi NC-Data
diperlukan translator yang disebut post-processor yang berfungsi menerjemahkan
point to point cutter location file menjadi G-Code dan M-Code.

G-Code dapat langsung ditransfer dengan

menggunakan Pro/E, hal ini

dikarenakan Pro/E mempunyai post processor untuk melakukannya. Hasil

generate code terdapat di lampiran.

4.1.8.a. G-Code untuk pembuatan lubang baut pada bagian sisi miring

Gambar 4.30. Pembuatan lubang baut pada sisi miring

%

N0040X-25.

N0005(FADAL VMC 6030 - VH65)

N0045G80

N0010G90G40G80

N0050G0Z100.

N0015T1M6

N0055X-75.

N0020S3000M3

N0060G83X-75.Y20.Z-

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N7290X-75.506Y16.28

N7485G3X-72.003Y21.257I-2.997J-1.257

56

N7490G1Z-16.8

N7685G1X-77.997Y21.257Z-18.

N7495X-77.997

N7690X-77.997Y21.257Z-18.

N7500X-77.997Y21.257Z-16.8

N7695X-72.003

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N7655G1Z-18.

N7850G2X-73.279Y17.243I-3.162J.75

N7660X-73.279

N7855G1X-73.279Y17.243Z-19.2

N7665X-73.279Y17.243Z-18.

N7860X-76.721

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N7675G1X-78.162

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N7680G2X-77.997Y21.257I3.162J.75

N7875G1Z-19.6

57

N7880X-73.279

N8075G1X-73.279Y17.243Z-20.8

N7885X-73.279Y17.243Z-19.6

N8080X-76.721

N7890G3X-71.838Y19.25I-1.721

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N8065X-71.838

N8260G1Z-22.4

N8070G2X-73.279Y17.243I-3.162J.75

N8265X-77.997

58

N8270X-77.997Y21.257Z-22.4

N8465X-72.003

N8275G3X-78.162Y19.25I2.997

N8470X-72.003Y21.257Z-23.6

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59

N8660G3X-71.838Y19.25I-1.721

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N8930X-77.997Y21.257Z-27.2

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60

N9050G1X-78.162Y19.25Z-28.

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N9090M5

N9065G1X-73.279Y17.243Z-28.

N9095M2

N9070X-76.721

N9075X-76.721Y17.243Z-28.

4.1.8.b. G-Code untuk membuat lubang tap baut pada bagian bawah cracket

Gambar 4.31. Pembuatan lubang baut pada bagian bawah Bracket

%

N0080M5

N0005(FADAL VMC 6030 - VH65)

N0085T2M6

N0010G90G40G80

N0090S1000M3

N0015T1M6

N0095G0X67.268Y47.25

N0020S2000M3

N0100G43Z50.H2M7

N0025G0X19.984Y21.5

N0105Z10.

N0030G43Z50.H1M7

N0110G1Z-.4F300.

N0035G83X19.984Y21.5Z-

N0115X70.732

24.293Q10R10.F300.

N0120X70.732Y47.25Z-.4

N0040G80

N0125G3X72.162Y49.25I-1.732J2.75

N0045G83X64.984Y21.5Z-

N0130G1X65.838

61.953Q10R10.F300.

N0135G2X66.Y51.25I3.162J.75

N0050X69.Y50.

N0140G1X66.Y51.25Z-.4

N0055X64.984Y78.5

N0145X72.

N0060G80

N0150X72.Y51.25Z-.4

N0065G83X19.984Y78.5Z-

N0155G3X72.Y51.25I-3.J-1.25

24.293Q10R10.F300.

N0160G1Z-.8

N0070G80

N0165X66.

N0075G0Z50.

N0170X66.Y51.25Z-.8

61

N0175G3X65.838Y49.25I3.

N0370X66.Y51.25Z-2.4

N0180G1X72.162

N0375G3X65.838Y49.25I3.

N0185G2X70.732Y47.25I-3.162J.75

N0380G1X72.162

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N0195X67.268

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N0200X67.268Y47.25Z-.8

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N0250X72.Y51.25Z-1.2

N0445X72.

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N0450X72.Y51.25Z-2.8

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N0465X66.

N0275G3X65.838Y49.25I3.

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Gambar 4.32. Proses cutting pada bagian atas

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4.2. Pembahasan

Pada kerja praktik ini penulis mengambil tema Penerapan CAD/CAM dalam
pembuatan komponen bracket top plate yang merupakan bagian dari mesin press
hirolik. Pada proses pembuatan model dengan CAD tiap pengguna memiliki
teknik tersendiri dalam membuatnya, sehingga penulis merasa tidak perlu ada
yang dianalisanya. Proses CAM yang penulis amati adalah Pemrograman NC,
yang digunakan untuk membuat komponen bracket top plate. Pembuatan program
NC dengan menggunakan software Pro/Engineer pada dasarnya adalah
mengetahui parameter cutter dan parameter pemotongan terhadap suatu stock
material agar menjadi komponen dengan tingkat kesalahan sekecil mungkin
hingga mendekati nol persen. Untuk dapat menghasilkan komponen dengan
tingkat kesalahan mendekati nol persen perlu dilakukan perancangan program.

130

Dalam

pembuatan

program

dengan

menggunakan

Pro/Engineer

harus

mempertimbangkan bentuk dan dimensi stock material, perencanaan kondisi

pemotongan, perencanaan metode pemotongan, perencanaan jenis dan jumlah
cutter yang digunakan, dan sebagainya.

4.2.1. Analisa perencanaan cutter

Berdasarkan diskusi dengan teknisi tempat melakukan kerja praktik, cutter yang
digunakan adalah end-mill berjenis karbida dengan diameter cutter sebesar 20
mm. Cutter ini memiliki kemampuan pemakanan 0,1 sampai dengan 0,5 mm.
Namun dalam perencanaan, tebal pemakanan yang digunakan adalah 0,4 mm. Hal
ini bertujuan untuk mengurangi getaran pada mesin saat melakukan pemotongan.
pada bagian diagonal komponen direncanakan dibuat dengan menggunakan cutter
ball.

4.2.2. Analisa perencanaan cutting condition

Faktor yang menentukan perencanaan cutting condition antara lain jenis material
yang akan dipotong, kualitas permukaan yang akan dihasilkan, kedalaman potong,
dan umur cutter. Dari faktor-faktor tersebut kita dapat menentukan besarnya
putaran spindle dan feeding. Besarnya putaran spindle dan feeding saling
berkaitan. Jika salah satu diubah maka akan merubah yang lainnya. Untuk itu
diperlukannya pertimbangan untuk merencanakan cutting condition suatu material
dalam hal ini mild steel.

Material yang digunakan adalah mild steel ST50-2, yang sebelumnya telah
dilakukan facing terlebih dahulu hingga memiliki dimensi sebesar 101x85x61
mm. Berdasarkan hasil diskusi dan studi literatur, besarnya kecepatan potong
untuk material mild steel adalah sebesar 35 m/menit sampai dengan 45 m/menit
dan feed per tooth sebesar 0,04 mm/gigi sampai dengan 0,1 mm/gigi. Kemudian
melakukan perhitungan dengan menggunakan data-data yang telah didapat.

131

Setelah melakukan perhitungan besarnya kecepatan spindle untuk pemotongan

adalah sebesar 716,791 rpm dengan feeding sebesar 57,295 mm/menit. Kecepatan
tersebut dihasilkan untuk penggunaan cutter berdiameter 20 mm. Pada kondisi
aktual dilapangan kecepatan spindle untuk melakukan pemotongan sebesar 1000
rpm, angka ini jauh lebih besar dari perhitungan sebelumnya. Sehingga pada saat
melakukan pemotongan terjadi getaran yang cukup besar pada mesin. Untuk
mengatasinya dilakukan pengurangan kedalaman feeding.
Pada proses pengeboran, besar kecepatan spindle adalah 2387,324 rpm dengan
feeding sebesar 190,98 mm/menit. Pada kondisi aktual kecepatan yang digunakan
sebesar 3000 rpm. Namun pada proses pengeboran tidak terjadi terjadi getaran
yang berlebihan. Hal ini dikarenakan posisi cutter yang bergerak vertikal dan
berputar dengan kecepatan tinggi, sehingga benda kerja secara langsung bertumpu
pada mesin. Berbeda pada saat pemotongan berda kerja yang hanya tertumpu oleh
ragum pada bagian samping benda kerja.

Pada proses pembuatan simulasi dan generate code parameter yang digunakan
adalah parameter pada kondisi aktual, hal ini bertujuan agar didapat program yang
sesuai dengan kondisi yang terjadi ditempat kerja.

4.2.3. Analisa program dari hasil generate code Pro/Engineer

4.2.3.a. Pembuatan lubang baut pada sisi miring Bracket
Pembuatan lubang baut pada sisi miring bracket disimulasikan menggunakan dua
jenis pahat, yang pertama bor untuk membuat lubang dan kemudian menggunakan
endmill berdiameter 10 mm untuk membuat lubang tap. Dari simulasi didapat GCode seperti pada sub bab 4.1.8.a. code yang digunakan pada proses pengeboran
adalah G83 atau peck drilling cycle yaitu pengeboran dilakukan secara berulang
hingga kedalaman yang ditentukan. Atau dengan kata lain mata bor akan
mengebor dengan kedalaman Q dan kembali lagi keatas sejauh R dan kemudian
kembali lagi mengebor dengan kelipatan nilai Q hal ini terus berlanjut hingga
mencapai kedalaman Z. Selain itu kode yang digunakan adalah G90 yang
merupakan program absolute. G90 juga digunakan dalam proses pembuatan

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lubang tap. Pada simulasi pembuatan lubang tap terlihat posisi pahat bergerak
zigzag dan melingkar. Hal ini berbeda dengan yang direncanakan sebelumnya
bahwa posisi bergerak melingkar untuk membuat lubang tap. Namun, pada saat
simulasi dilakukan tidak terdapat sisa material dari part, sehingga program yang
dihasilkan dari simulasi masih dapat digunakan.

4.2.3.b. Pembuatan lubang baut pada sisi bawah Bracket

Untuk pembuatan lubang baut pada sisi bawah Bracket digunakan parameter yang
sama dengan parameter pembuatan lubang baut pada sisi miring Bracket. Yang
membedakan hanya kedalaman pengeboran dan posisi lubang berada. Pengeboran
dilakukan hingga kedalaman Z= -22,5 mm sedangkan untuk sisi yang miring
pengeboran dilakukan hingga kedalaman Z= -30 mm.

4.2.3.c. Proses cutting material

Proses pemotongan material digunakan G01 yaitu pahat bererak secara linear
sesuai dengan koordinat yang telah ditetapkan. Selain itu kode yang digunakan
adalah G90 yaitu program absolute. Karena menggunakan kode G90 program
yang dihasilkan terlihat lebih panjang dan lebih rumit untuk diperiksa. G90 dapat
diganti dengan G91 yaitu program inkremental dan ditambah dengan M98 dan
M99. M98 merupakan perintah untuk memanggil sub-program yang telah dibuat
berdasarkan nomor program, sedangkan M99 merupakan sub-program dari M98.
Dengan menggunakan perintah ini proses cutting material dapat dipersingkat dan
lebih mudah untuk diperiksa programnya.

Pada program cutting material terdapat kesalahan dalam penulisan program.

Dalam program hasil generate terdapat G0, G1 dan G3, yang seharusnya ditulis
G00, G01 dan G03. Namun saat dilakukan proses simulasi dengan menggunakan
software yang berbeda dengan software Pro/Engineer, program hasil generate
dapat berjalan tanpa error. Sehingga program tersebut masih dapat digunakan.

133

Pada simulasi proses pemotongan sisi miring Bracket terdapat sisa material dari
hasil pemotongan (seperti pada gambar 4.33). Dari hasil pemeriksaan parameter
pemotongan, tidak ditemukan kesalahan dalam menentukan parameter. Dengan
kata lain, program tidak mampu mensimulasikan beberapa posisi pemotongan
pada material, sehingga perlu dilakukan perubahan program untuk melakukan
pemotongan ini. Dalam kondisi aktual, proses pemotongan ini masih dapat
dilakukan dengan menggunakan program yang sama tanpa harus merubahnya
yaitu dengan menganti ragum yang terdapat pada mesin CNC dengan ragum
radius. Ragum radius memungkinkan material diubah posisinya dari horizontal ke
posisi miring beberapa derajat sesuai kebutuhan.

Gambar 4.33. Sisa material pada saat simulasi pemotongan sisi miring.

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BAB V. PENUTUP

5.1. Simpulan
Setelah dilakukan analisa penulis mendapatkan kesimpulan sebagai berikut:
5.1.1. Dari hasil perhitungan didapat kecepatan spindel sebesar 716,791 rpm
namun berdasarkan hasil diskusi dengan teknisi yang ada kecepatan
spindel dinaikkan sebesar 1000 rpm, namun hal ini akan menyebabkan
meisn akan bergetar cukup besar. Sehingga untuk mengatasinya
dibutuhkan pengurangan kedalaman feeding.
5.1.2. Perbedaan penulisan G0, G1, dan G3 pada hasil generate code, tidak
memberikan efek berbeda pada penulisan program yang sebenarnya,
artinya program masih dapat digunakan. Hal ini berdasarkan pada
pengujian program dengan menggunakan software yang berbeda seperti
software CIMCO Edit 5 dan Vericut.
5.1.3. pada proses pemotongan sisi atas tempat dudukan plat, program dapat
disingkat

dengan

menggunakan

program

inkremental

dengan

menambahkan kode M98 dan M99. Tujuannya agar pemeriksaan program

dapat lebih optimal tanpa terjadi kesalahan.
5.1.4. Terdapat sisa material yang tidak terpotong pada saat melakukan simulasi
pembuatan sisi miring bracket. Hal ini menunjukkan bahwa program tidak
mampu mensimulasikan pemotongan pada posisi tertentu sehingga perlu
dilakukan perubahan program atau menggunakan ragum radius untuk
melakukan pemotongan.

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5.2. Saran
Untuk kemajuan Balai MEPPO BPPT di masa depan terutama di Divisi Produksi,
penulis menyarankan :
5.2.1. Dalam melakukan perencanaan sebaiknya melakukan perhitungan
mengenai kecepatan spindle, feeding, dan lainnya untuk jenis material
yang akan dilakukan pemotongan.
5.2.2. perlunya pemeriksaan program saat melakukan generate code dengan
menggunakan software CAM sehingga dihasilkan produk yang sesuai
dengan kriteria yang ada.

136

DAFTAR PUSTAKA

Ahmad, Suhairi Bin. 2009. The Application of Pro/ENGINEER in CADCAM.

Politeknik Tuanku Syed Sirajuddin: Malaysia
Groover,P, Mikell. 1999. Fundamental of Modern Manufacturing Materials,
Processes,and Systems. Jhon Wiley & Sons.Inc: New York
Nanfara, Frank, Tony Uccello, Derek Murphy. 1995. The CNC Workbook An
Introduction to Computer Numerical Control. Addison-Wesley Publishing
\Company: USA.
Pinem, Mhd Daud. 2009. CATIA Si Jago Desain Tiga Dimensi Versi 5R-16.
Lingua Kata: Surabaya
Pusztai, Joseph and sava michael. 1983. Computer Numerical Control. Virginia:
Reston Publishing Company, Inc
Zeid, Ibrahim. 1991. CAD/CAM Theory and Practice. McGraw Hill International
edition: USA

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LAMPIRAN

138

Lampiran 1
Tabel Mild steel ST50 Properties

Sumber: http://www.steel-plate-sheet.com/Steel-plate/DIN/St-502.html

139

Lampiran 2
Spesifikasi Mesin CNC

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