PE4652 Teknologi Manufaktur (Manufacturing Technology)

Bab : Pendahuluan

TUJUAN INSTRUKSIONAL UMUM :

Setelah menyelesaikan mata kuliah ini mahasiswa akan dapat: o Merencanakan dan mengelola suatu pembuatan produk komponen mesin melalui pendekatan near net shape. o Mengerti topik-topik mengenai pembuatan produk melalui proses pengecoran dan pembentukan material t i l logam l d non logam dan l o Mengerti pembuatan komponen inti cetakan dengan menggunakan strategi proses pemesinan modern

PENGERTIAN MANUFAKTUR
Secara Teknologi

Secara Ekonomi

PENGERTIAN MANUFAKTUR

Manufaktur a u a u melibatkan e ba a p proses oses mekanis e a s ya yang g mengubah bentuk material melalui proses pemisahan, pembentukan, penggabungan, dan pengkondisian nya.

Manufacturing definition

Milik LSPITB

Tujuan : 1. Mengetahui keterkaitan alat potong dan produk 2. Mengetahui gaya potong yang terjadi saat pemotongan 3. Mengetahui energi pemotongan yang terkait dengan kemampuan mesin 4. Mengetahui karakterisasi umur pahat 5. Mengetahui pemilihan alat potong carbide

Klasifikasi Proses Manufaktur

Selecting Manufacturing Processes

Casting g and Shaping p g (rolling, ( g forging, g g extrusion, drawing, g Forming sheetforming, powder metalurgy, molding) Machining (turning, drilling, milling, planning, shaping, broaching, grinding, ultrasonic machining; chemical, electrical, and electrochemical machining; and high energy beam machining) Joining (welding, brazing, soldering, diffusion bonding, adhesive bonding and mechanical joining) Finishing operations (honing, lapping, polishing, burnishing, deburring, surface treating, coating and plating)

Developing a Manufacturing Process

1 1.

Understand Function/Geometry / y

Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative.

2. 3.

Properties

Identify candidate Material(s)

Material: structure, composition.

Material Identify required Processing

Processing: changes structure and overall shape Material and Geometry compatibility Other considerations

Operasi Pemrosesan
Tiga kategori operasi pemrosesan: 1. Shaping operations mengubah geometri bahan kerja awal 2. Propertyenhancing operations memperbaiki sifat fisik materi tanpa mengubah bentuk 3. Surface processing operations membersihkan, perlakuan, melapisi, atau menambah materi ke permukaan luar benda kerja

1. Shaping Empat Kategori Utama

Solidification Processes bahan awal adalah cairan di dipanaskan k yang akan k mengeras d dan membentuk b t kb bagian i geometri Deformation Processes bahan awal adalah ulet padat yang dibentuk Material M t i l Removal R l Processes P starting t ti material t i li is a ductile/brittle solid, from which material is removed Assembly Processes dua atau lebih bagian yang terpisah yang digabungkan untuk membentuk sebuah produk baru

Solidification Processes
Bahan awal dipanaskan cukup untuk mengubahnya menjadi keadaan cair atau sangat plastis Contoh: casting untuk metals, molding untuk plastics

Deformation Processes
Benda kerja awal dibentuk oleh suatu kekuatan yang melebihi kekuatan yield materialnya Contoh: (a) forging, (b) extrusion

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Material Removal Processes

Excess material removed from the starting workpiece so what remains is the desired geometry Contoh: proses pemesinan seperti turning, drilling, dan milling; juga gerinda and proses nontraditional

Turning
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Drilling

Milling

Assembly Operations
dua atau lebih bagian yang terpisah yang digabungkan untuk membentuk sebuah produk baru Tipe operasi assembly / perakitan:
1. Joining processes create a permanent joint.
Contoh : welding, brazing, soldering dan adhesive bonding

2. Mechanical assembly fastening by mechanical methods

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Contoh : ulir, baut, mur, dan pengencangan ulir lainnya; press fitting, expansion fits

2. PropertyEnhancing Processes
Dilakukan untuk memperbaiki sifat mekanik atau t fisik fi ik dari d i benda b d kerja k j Bagian bentuk tidak berubah, kecuali tidak sengaja Contoh:
Heat treatment bahan metal dan glass Sintering dari bahan serbuk metal dan ceramic

3.Surface Processing
1 1.

2. 3.

Membersihkan proses kimia dan mekanik untuk menghilangkan kotoran, minyak, dan kontaminan lainnya dari permukaan Perawatan permukaan kerja mekanik seperti sand blasting, dan proses fisik seperti difusi Pelapisan dan deposisi film tipis pelapisan bagian permukaan k eksterior k t i benda b d kerja k j Beberapa operasi pengolahan permukaan digunakan untuk membuat integrated circuits

Pembuatan MurBaut

How do we characterize processes?

Quality
Dimensional bulk and surface Properties bulk and surface

Economics
Cycle time Materials utilization

Flexibility
Tooling development Setup time Cycle time

Material dalam proses manufaktur

Material teknik dapat diklasifikasikan kedalam empat kategori dasar :
1. 2. 3. 4. Metals Ceramics Polymers l Composites

Waste in Shaping Processes

Keinginan untuk meminimalkan limbah dan scrap pada pembentukan produk agar utilisasi material tinggi
Proses pemotongan material cenderung boros per unit operasinya Casting and molding mengurangi limbah pemotongan

Terminologi:

Net shape processes ketika sebagian besar material awal digunakan dan tidak ada proses pemesinan berikutnya b k yang dibutuhkan d b hk untuk k mencapai geometri akhir Near net shape processes pembuatan produk diinginakan mendekati ukuran geometri akhir.

PROSES NEAR NET SHAPE

Proses manufaktur Near Net Shape menjadi penting : o Reduksi ongkos proses o Peningkatan fleksibilitas operasi o Mempersingkat waktu kirim ke pasar

Comparing Processes

Proses proses yang mendukung pembuatan produk near net shape

o Casting o Hot Working Process o Metal Forming o Powder Metalurgi o Rapid Prototyping

Casting
Process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape h of f th the mold ld cavity it

Steps in casting seem simple: Melt the metal Pour P it i i into a mold ld Let it freeze

Advantages of Casting: Can create complex part geometries Can create both external and internal shapes Some casting processes are net shape; others are near net shape p Can produce very large parts Some casting methods are suited to mass production Disadvantages of Casting Limitations on mechanical properties y and surface finish Poor dimensional accuracy for some processes; e.g., sand casting Safety hazards to workers due to hot molten metals Environmental problems

Overview of Casting Technology

Casting is usually performed in a foundry Foundry = factory equipped for making molds, melting and handling molten metal, performing the casting process, and cleaning the finished casting Workers who perform casting are called foundrymen

Hot Working Process :

o Rolling, o Forging, o Extrusion

Rolling

Rolling

Open Die Drop Hammer Forging

Open Die Drop Hammer

Forging

Extrusion

Extrusion

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Powder Metallurgy (PM)

Usual PM production sequence:
1. Mixing powders (alloys, lubricants, sizes, etc) 2. Pressing powders are compressed into desired shape to produce green compact
Accomplished in press using punchanddie tooling designed for the part

3 Sintering green compacts are heated to bond the 3. particles into a hard, rigid mass
Performed at temperatures below the melting point of the metal

Why Powder Metallurgy is Important Main advantage: PM parts are produced to net shape or near net shape, eliminating or reducing the need for subsequent machining
PM process wastes very little material ~ 97% of starting powders are converted to product

Distinct characteristic: PM parts can be made with a specified level of porosity, to produce porous metal parts
Examples: filters, oilimpregnated bearings and gears

Limitations and Disadvantages High tooling and equipment costs for die Some metallic powders are expensive and slowly oxidize (degrade) over time Limitations on part geometry because metal powders do not readily flow laterally in the die during pressing Variations in density throughout part may be a problem, especially for complex geometries Used typically only for small sized parts

PM Work Materials Pure metals and alloys of iron, steel, aluminum, copper, nickel, molybdenum and tungsten Also Al metallic t lli carbides bid such h as t tungsten t carbide bid

Rapid Prototyping
The key concept is RAPID generally this is an allin onestep t production d ti of f a part t geometry. t

Parts are used for Prototypes to allow fast review of part shape, simple assembly, aesthetics, manufacturability, etc. Low L volume l production d ti very small ll numbers b of f parts can be made using this technology.

General Disadvantages :
1 Very 1. V expensive i capital it l costs t 2. Tolerances are generally > 0,13 mm 3. Primary materials are specialized, and other steps are required to produce metal parts

RP Types :

Fused Deposition Modeling

The concept is that material is heated and then in controlled quantities deposited directly on previous layers. Eventually layers are built up to complete the entire part.

Electron Beam MeltingEB

Principle
Electron Beam Melting (EBM) is a type of rapid prototyping for metal parts. It is often classified as a rapid manufacturing method. The technology manufactures parts by melting metal powder layer per layer with an electron beam in a high vacuum. Electron Beam Melting is also referred to as Electron Beam Machining (Thermoelectric machining)

Rencana Pengajaran
Minggu 1 Pokok Bahasan Pendahuluan dan pengenalan : Materi Gambaran tentang Tool Design dan Produk near net shape Penjelasan materi kuliah dan t tugas 2 Proses pengecoran logam 3 Proses pengecoran logam Dasar-dasar pengecoran logam Tinjauan serta definisi dalam teknologi pengecoran logam Penamaan dalam pengecoran logam Pemanasan dan penuangan Pemadatan dan pendinginan Jenis cetakan permanen Rancangan untuk cetakan permanen 1/ch 11 1/ch 10 ; 2/ch 1 Referensi Berbagai referensi

Merancang cetakan

Permanent Mould casting

Proses pembentukan logam

Tinjauan proses pembentukan logam Proses perubahan bentuk bulk/limbak

1/ch 18 2/ ch 21

Proses pembentukan l logam

Dasar dasar Proses Forging

1/ch18

Cetakan pada proses forging

Proses pembentukan logam

Proses Ekstrusi Wire drawing

1/ ch 18

9 10

Ujian Tengah Semester Proses pemesinan non tradisional Proses pemesinan non tradisional: Mekanik Kimia Thermo electric 1/ ch 26; 2/ ch 27 Wire electric discharge machining (WEDM) 1/ ch h 26; 26 2/ ch 27 1/ ch h 26; 26 2/ ch 27

11 12

Proses pemesinan non tradisional Proses pemesinan non tradisional

Electric discharge machining (EDM)

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Abrasive Machining and Finishing

Abrasive and bonded abrasives 1/ch 25; Proses gerinda Operasi penggerindaan Honing lapping P li hi Polishing Surface roughness Konsep dan karakter proses pemesinan dengan machining dan turning centers 2/ ch25 2/ ch 26 1/ch 25; 2/ ch 26

14

Abrasive Machining and Finishing

15

Proses pemesinan lanjut

16

High Performance M hi i Machining

Pemanfaatan strategi high feed machining hi i dan d high hi h speed d machining

3;4

17 18

Design for Cost Ujian Akhir Semester

Economics of near net shape products

Metoda Evaluasi

Tugas-tugas : 30 %; : 30 % Ujian akhir semester

Praktikum : %;

Ujian tengah semester

: 40 %

Diktat / Modul Referensi

1. 2. 3. 4.

Mikell P. Groover,Fundamental of Modern Manufacturing, Material, Processes and Systems,3rd , 2007, John Wiley Serope Kalpakijan, Manufacturing Engineering and Technology, 5th Ed., ,2006, Addison-Wesley Sandvik e-catalogue 2009 dari www.coromant.sandvik.com Coromant Sandvik, Die & Mould Making, application guide