BAB III Perencanaan Fix BGT
BAB III Perencanaan Fix BGT
pada unit mesin ini yang direncanakan adalah mesin frais vertikal, dimana
memiliki daya (P) = 40 kw, dengan putaran (n) = 1400 rpm, bahan yang
dikerjakan adalah besi tuang.
Input
z z
z z
z z
z z
z z
Output
1400 rpm
900 rpm
710 rpm
560 rpm
450 rpm
355 rpm
280 rpm
450 z 1 18
i= = =
1400 z 2 56
900 z 29
i= = =
1400 z 45
900 z 40
i= = =
900 z 40
560 z 30
i= = =
900 z 50
710 z 35
i= = =
900 z 45
do = m. z .................................................................................(3.4)
dk = (z + 2) . m
dt = do (2. m)
Dimana :
m = modul
do = m.z
= 5 . 18 = 90 mm
dk = (z + 2)
= (18 + 2) . 5 = 100 mm
dt = do - (2 . m)
= 90 (2 . 5) = 80 mm
Roda Jml Gigi
do (mm) dk (mm) dt (mm)
gigi (z)
1 18 90 100 80
2 56 280 290 270
3 29 145 155 135
4 45 225 235 215
5 40 200 210 190
6 40 200 210 190
7 30 150 160 140
8 50 250 260 240
9 35 175 185 165
10 45 225 235 215
ao . m .............................................................(3.5)
= .5
= 185 mm
= .5
= 200 mm
3.2.3 Tinggi Gigi/Kedalaman Pemotongan Gigi (H)
H = 2 . m + Ck .......................................................................(3.6)
= 0,25 . 5 = 1,25 mm
H = 2 . 5 + 1,25 = 12,5 mm
Jika jumlah gigi (z) tidak tercantum dalam tabel maka dilakukan
interpolasi, sehingga :
Y = 0,208
= 0,416
= 388
Y = 0,388
Y = 0,358
Y = 0,408
= 0,374
= 0,399
.do .np
V = ...............................................................(4.7)
60 .1000
Dimana :
Sebelumnya diketahui
102 .Pd
Ft = ......................................................................(3.8)
V
Fv = ......................................................................(3.9)
Dimana :
Pd = daya rencana = 40 kw
V = kecepatn keliling
= 0,5 10 m/s
Dimana :
m = modul = 5 mm
Fv = faktor dinamis
Fb = a . m . Y . fv
= 6,21 kg/mm
Fb = a . m. Y . fv
=8,38 kg/mm
.
FH1-9 = fv . kH . do . ......................................(3.11)
.
= 0,31 . 0,188 . 90 .
= 7,94 kg/mm
Ft
b1-2 = ............................................................(3.12)
F'H
618,18
=
7,94
= 77,86 mm
= 13 . 5 . 0,355 . 0,30
=6,92 kg/mm
Fb = a . m. Y . fv
= 13 . 5 . 0,399 . 0,30
= 7,78 kg/mm
Beban permukaan yang digunakan persatuan lebar sisi (FH)
.
FH3-4 = fv . kH . do .
.
= 0,30 . 0,188 . 145 .
= 60,03 mm
Lebar sisi roda gigi z-z
Ft
b3-4 =
F'H
597,36
=
9,95
= 60,03
= 13 . 5 . 0,388 . 0,24
= 6,05 kg/mm
Fb = a . m. Y . fv
= 13 . 5 . 0,388 . 0,24
= 60,05 kg/mm
Beban permukaan yang diijinkan persatuan lebar (FH)
.
FH5-6 = fv . kH . do .
.
= 0,24 . 0,188 . 200 .
= 9,024 kg/mm
Lebar sisi roda z-z
Ft
b5-6 =
F'H
,
=
9,024
= 47,99
= 48 mm
- Pasangan roda gigi z - z
= 13 . 5 . 0,358 . 0,30
= 6,98 kg/mm
Fb = a . m. Y . fv
= 13 . 5 . 0,408 . 0,30
= 7,96 kg/mm
Beban permukaan yang diijinkan persatuan (FH)
.
FH7 8 = fv . kH . do .
.
= 0,30 . 0,188 . 150 .
= 10, 575
Lebar sisi roda gigi z - z
Ft
b7 8 =
F'H
564,63
=
10,575
= 54,34 mm
- Pasangan roda gigi z - z
= 13 . 5 . 0,374 . 0,27
= 6,56 kg/mm
Fb = a . m. Y . fv
= 13 . 5 . 0,399 . 0,27
= 7,00 kg/mm
Beban permukaan yang diijinkan persatuan lebar (FH)
.
FH9 -10 = fv . kH . do .
.
= 0,27 . 0,188 . 175 .
= 9,99 kg/mm
Ft
B9 10 =
F'H
495,15
=
9,99
= 49,56 mm
3.3 Pembebanan Roda Gigi Terhadap Poros
PH R1 QH
P Q
PV A QV
- Momen torsi
T = 9,74 . 10 . .......................................................(3.13)
Dimana :
P = daya = 40 kW
n = putaran masuk
= 1400 rpm
T = 9,74 . 105 .
= 27828,57 kg . mm
- Gaya tangensial
.
U =
. ,
=
= 618,41 kg . mm
- Gaya radial
R1 = U1 . tg 20
= 618,41 . tg 20
= 225,08 kg
Gaya bantalan di P
- Arah Vertikal
PV . 500 - U . 100 = 0
.
PV =
, .
=
= 123,68 kg
- Arah Horizontal
PH . 500 - R1 . 100 = 0
.
PH =
, .
=
= 45,02 kg
- Resultan Gaya
P = ( ) +( )
= (45,02)2 +(123,68)2
= 131,62 kg
Gaya bantalan di Q
- Arah Vertikal
QV . 500 U1 . 400 = 0
U. 400
QV =
500
618,41 . 400
=
500
= 494,73 kg
- Arah Horizontal
QH . 500 R1 . 400
.
QH =
, .
=
= 180,06 kg
- Resultan gaya
Q = ( ) +( )
= (180,06) + (494,73)
= 526,48 kg
Momen bending
- Arah vertikal P A
MbV= PV . x
Untuk x = 0 MbV = 0
x = 400 MbV = PV . 400
= 123,68 . 400
- Arah vertikal A Q
MbV . PV (400 + y) - U1 . y
untuk y = 0 MbV = 49472 kg . mm
y = 100 MbV = 0
MbV = 49472 kg
P A Q
- Arah Horizontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
x = 400 MbH = 45,02 . 400
= 18008 kg
- Arah Horizontal A Q
MbH = PH (400 + y) R1 . y
Untuk y = 0 MbH = 18008 kg . mm
Y = 100 MbH = 0
MbH = 18008 kg . mm
P A Q
- momen bending yang timbul di A
Mb = ( ) +( )
= (18008 ) + (49472)
= 52647,57 kg
Tinjauan dari roda gigi 3
PH R3 QH
P A Q
PV QV
- Momen torsi
T = 9,74 . 10 .
= 9,74 . 10 .
= 27828,57 kg . mm
- Gaya tangensial
.
U3 =
. ,
=
= 383,84 kg . mm
- Gaya radial
R3 = U3 . tg 20
= 383,84 . tg 20
= 139,71 kg
Gaya bantalan di P
- Arah Vertikal
PV . 500 - U3 . 320 = 0
.
PV =
, .
=
= 245,66 kg
- Arah Horizontal
PH . 500 - R3 . 320 = 0
.
PH =
, .
=
= 89,41 kg
- Resultan Gaya
P = ( ) +( )
= (89,41) + (245,66)
= 261,42 kg
Gaya bantalan di Q
- Arah Vertikal
QV . 500 - U3 . 180 = 0
.
QV =
, .
=
= 138,18 kg
- Arah Horizontal
QH . 500 - R3 . 180
.
QH =
, .
=
= 50,3 kg
- Resultan Gaya
Q = ( ) +( )
= (50,3) + (138,18)
= 147,05 kg
Momen bending
- Arah Vertikal P A
MbV = PV . x
Untuk x = 0 MbV = 0
x = 320 MbV = 245,66 . 180
= 44218,8 kg . mm
- Arah Vertikal A Q
MbV = PV (180 + y) - U3 . y
Untuk x = 0 MbV = 44218,8 kg . mm
x = 320 MbV = 245,66 (180 + 320) 383,320
=0
MbV = 44218,8 kg
P A Q
- Arah Horizontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
= 16093,8 kg . mm
- Arah Horizontal A Q
MbH = PH (180 + y) R3 . y
Untuk y = 0 MbH = 8334,72 kg . mm
y = 320 MbH = 0
MbH = 8334,72 kg . mm
P A Q
- Momen Bending yang timbul di A
MbV = ( ) +( )
= (8334,72) + (44218,8)
= 44997,44 kg . mm
3.3.2 Pembebanan Roda Gigi Terhadap Poros II
- Tinjauan dari roda gigi 2
PH R2 QH
P A Q
PH QV
- Momen torsi
T = 9,74 . 10 .
Dimana :
P = daya = 40 kW
n = putaran poros II
= 900 rpm
T = 9,74 . 10 .
= 43288,89 kg . mm
- Gaya tangensial
.
U =
. ,
=
= 309,206 kg
- Gaya radial
R = U . tg 20
= 309,206 . tg 20
= 112,542 kg
Gaya bantalan di P
- Arah Vertikal
PV . 800 - U . 100 = 0
.
PV =
, .
=
= 38,65 kg
- Arah Horizontal
PH . 800 - R . 100 = 0
.
PH =
, .
=
= 14,068 kg
- Resultan Gaya
P = ( ) +( )
= (14,068)2 +(38,65)2
= 41,13 kg
Gaya bantalan di Q
- Arah Vertikal
QV . 800 U . 700 = 0
U. 700
QV =
800
309,206 . 700
=
800
= 270,555 kg
- Arah Horizontal
QH . 800 R . 700
R .
QH =
, .
=
= 98,474 kg
- Resultan gaya
Q = ( ) +( )
= (98,474) + (270,555)
= 287,92 kg
Momen bending
- Arah vertikal P A
MbV= PV . x
Untuk x = 0 MbV = 0
x = 700 MbV = 38,65 . 700
= 27055 kg . mm
- Arah vertikal A Q
MbV . PV (700 + y) - U . y
MbV = 27055 kg . mm
P A Q
- Arah Horizontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
x = 700 MbH = 14,08 . 700
= 9847,6 kg
- Arah Horizontal A Q
MbH = PH (700 + y) R . y
P A Q
- momen bending yang timbul di A
Mb = ( ) +( )
= (9847,6 ) + (27055)
= 28791,46 kg
PH R4 QH
P A Q
PV QV
- Momen torsi
T = 9,74 . 10 .
Dimana :
P = daya = 40 kW
n = putaran poros II
= 900 rpm
T = 9,74 . 10 .
= 43288,89 kg . mm
- Gaya tangensial
.
U =
. ,
=
= 384,79 kg
- Gaya radial
R = U . tg 20
= 384,79 . tg 20
= 140,05 kg
Gaya bantalan di P
- Arah Vertikal
PV . 800 - U . 320 = 0
.
PV =
, .
=
= 153,916 kg
- Arah Horizontal
PH . 800 - R. 320 = 0
.
PH =
, .
=
= 56,02 kg
- Resultan Gaya
P = ( ) +( )
= (56,02)2 +(153,916)2
= 163,79 kg
Gaya bantalan di Q
- Arah Vertikal
QV . 800 U . 480 = 0
U . 480
QV =
800
384,79 . 480
=
800
= 230,874 kg
- Arah Horizontal
QH . 800 R . 480
.
QH =
, .
=
= 84,03 kg
- Resultan gaya
Q = ( ) +( )
= (84,03) + (230,874)
= 245,69 kg
Momen bending
- Arah vertikal P A
MbV= PV . x
Untuk x = 0 MbV = 0
x = 700 MbV = 153,916 . 480
= 73879,68 kg . mm
- Arah vertikal A Q
MbV . PV (480 + y) - U. y
MbV = 73879,68 kg . mm
P A Q
- Arah Horizontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
x = 480 MbH = 56,02 . 480
= 26889,6 kg
- Arah Horizontal A Q
MbH = PH (700 + y) R . y
P A Q
- momen bending yang timbul di A
Mb = ( ) +( )
= (26889,6 ) + (73879,68)
= 78620,97 kg
PH R5 QH
P A Q
PV QV
- Momen torsi
T = 9,74 . 10 .
Dimana :
P = daya = 40 kW
n = putaran poros II
= 900 rpm
T = 9,74 . 10 .
= 43288,89 kg . mm
- Gaya tangensial
.
U =
. ,
=
= 432,89 kg
- Gaya radial
R = U . tg 20
= 432,89 . tg 20
= 157,56 kg
Gaya bantalan di P
- Arah Vertikal
PV . 800 - U . 380 = 0
.
PV =
, .
=
= 205,62 kg
- Arah Horizontal
PH . 800 - R . 380 = 0
.
PH =
, .
=
= 74,84 kg
- Resultan Gaya
P = ( ) +( )
= (74,84)2 +(205,62)2
= 218,82 kg
Gaya bantalan di Q
- Arah Vertikal
QV . 800 U . 420 = 0
U . 420
QV =
800
432,89 . 420
=
800
= 227,11 kg
- Arah horinsontal
QH . 800 R5 . 420 = 0
.
QH =
, .
=
= 82,72 kg
- Resultan gaya
Q = ( ) +( )
= (82,72) + (227,11)
= 241,71 kg
Momen bending
- Arah vertikal P A
MbV = PV . x
Untuk x = 0 MbV = 0
= 86360,4 kg . mm
- Arah verikal A Q
MbV = PV (420 + y) U5 . y
y = 380 MbV = 0
MbV = 86360,4 kg . mm
P A Q
- Arah horisontal P A
MbH = PH . x
Untuk x = 0 MbV = 0
= 31432,8 kg . mm
- Arah horisontal A Q
MbH = PH (420 + y ) R5 . y
y = 380 MbH = 0
MbH = 31432,8 kg . mm
P A Q
Mb = ( ) +( )
= (31432,8) + (86360,4)
= 9102,88 kg . mm
PH R7 QH
P Q
PV A QV
- Momen torsi
T = 9,74 . 102 .
= 9,74 . 105 .
= 43288,89 kg . mm
- Gaya tangensial
.
U7 =
. ,
=
= 577,18 kg
- Gaya radial
R7 = U7 . tg . 200
= 577,18 . tg 200
= 210,08 kg
Gaya bantalan di P
- Arah Vertikal
PV . 800 U7 . 555 = 0
.
PV =
577,18 .555
=
800
= 400,42 kg
- Arah horisontal
PH . 800 R7 . 555 = 0
PH =
, .
=
= 145,74 kg
- Resultan gaya
P= ( ) +( )
= (145,74) + (400,42)
= 426,12 kg
Gaya bantalan di Q
- Arah vertikal
QV . 800 U7 . 245 = 0
.
QV =
, .
=
= 176,76 kg
- Arah horisontal
QH . 800 R7 .245 = 0
, .
QH =
= 64,34 kg
- Resultan gaya
Q = ( ) +( )
= (64,34) + (176,76)
= 188,11 kg
Momen bending
- Arah vertikal P A
MbV = PV . x
Untuk x = 0 MbV = 0
x = 245 MbV = 400,42 . 245
=98102,9 kg . mm
- Arah vertikal A Q
MbV = PV (245 + y) U7 .y
Untuk y = 0 MbV = 98102,9 kg . mm
y = 555 MbV = 0
P A Q
- Arah horisontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
= 245 MbH = 145,75 .245
= 35706,3 kg . mm
- Arah horisontal A Q
MbH = PH (245 + y) R7 .y
Untuk y = 0 MbH = 35706,3 kg . mm
y = 555 MbH = 0
MbH = 35706,3 kg . mm
P A Q
= (35706,3) + (98102,9)
= 104398,85 kg . mm
Tinjauan dari roda gigi 9
PH R9 QH
PA Q
PV QV
- Momen Torsi
T = 9,74 . 105 .
= 9,74 .105 .
= 43288,89 kg . mm
- Gaya tangensial
.
U9 =
. ,
=
= 494,73 kg . mm
- Gaya Radial
R9 = U9 . tg 200
= 494,73 . tg 200
= 180,07 kg
Gaya bantalan di P
- Arah vertikal
PV . 800 U9 .730 = 0
.
PV =
, .
=
= 451,44 kg
- Arah horisontal
PH . 800 R9 .730 = 0
.
PH =
, .
=
= 164,31 kg
- Resultan gaya
P= ( ) +( )
= (164,31) + (451,44)
= 480,41 kg
Gaya bantalan di Q
- Arah vertikal
QV . 800 U9 .70 = 0
, .
QV =
= 43,29 kg
- Arah horisontal
QH . 800 R9 . 70 = 0
.
QV =
, .
=
= 15,76 kg
- Resultan gaya
Q= ( ) +( )
= (15,76) + (43,29)
= 46,07 kg
Momen bending
- Arah vertikal P A
MbV = PV .x
Untuk x = 0 MbV = 0
x = 70 MbV = 31600,8 kg . mm
- Arah vertikal A Q
MbV = PV (70 + y ) U9 . y
Untuk y = 0 MbV = 31600,8 kg .mm
y = 730 MbV = 0
MbV = 31600,8 kg . mm
P A Q
- Arah horisontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
x = 70 MbH = 164,31.70
= 1150,1,7 kg . mm
- Arah horisontal A Q
MbH = PH (70 + y ) R9 . y
y = 730 MbH = 0
MbH = 11501,7 kg . mm
P A Q
- Momen bending yang timbul di A
Mb = ( ) +( )
= (11501,7) + (31600,8)
= 33628,85 kg . mm
Roda gigi 6 (z6) berpasangan dengan roda gigi 5 (z5) dengan perbandingan
1 : 1 atau jumlah gigi roda gigi adalah sama yaitu z = 40 buah.
Sehingga roda gigi 6 = roda gigi 5 ditinjau dari beban terhadap poros.
PH R8 QH
P A Q
PV QV
- Momen Torsi
T = 9,74 . 105 .
dimana :
Pd = daya motor = 40 kw
n3 = putaran poros III = 900 rpm
T = 9,74 . 105 .
= 43288,89 kg . mm
- Gaya tangensial
.
U8=
. ,
=
= 346,31 kg
- Gaya radial
R8 = U8. tg 200
= 346,31 .tg 200
=126,05 kg
Gaya bantalan di P
- Arah vertikal
.
PV =
, .
PV =
= 240,25 kg
- Arah Horisontal
PH . 800 R8 . 555 = 0
, .
PH =
= 87,45 kg
- Resultan gaya
P= ( ) +( )
= (87,45) + (240,25)
= 255,67 kg
Gaya bantalan di Q
- Arah vertikal
QV . 800 U8 .245 = 0
.
QV =
, .
=
= 106,06 kg
- Arah horisontal
QH . 800 R8 245 = 0
.
QH =
, .
=
= 38,60 kg
- Resultan gaya
P= ( ) +( )
= (38,60) + (106,06)
= 112,87 kg
Momen bending yang timbul
- Arah vertikal P A
MbV = PV . x
Untuk x = 0 MbV = 0
x = 245 MbV = 240,25 . 245
= 58861,25 kg . mm
- Arah vertikal A Q
MbV = PV (245 + y ) U8 . y
y = 555 MbV = 0
MbV = 588861,25 kg . mm
P A Q
- Arah horisontal P A
MbH = PH . x
Untuk x = 0 MbH = 0
X = 245 MbH = 87,45 .245
= 21425,25 kg . mm
- Arah horisontal A Q
MbH = PH (245 + y ) U8 .y
Untuk y = 0 MbH = 21425,25 kg . mm
y = 555 MbH = 0
MbH = 21425,25 kg . mm
P A Q
- Momen bending yang timbul
Mb = ( ) +( )
= (21425,25) + (58861,25)
= 62639,35 kg . mm
Tinjauan dari roda gigi 10
PH R10 QH
P A Q
PV QV
- Momen Torsi
T = 9,74 . 105 .
= 43288,89 kg . mm
- Gaya tangensial
.
U10 =
. ,
=
= 384,79 kg
- Gaya radial
R10 = U10 . tg 200
= 384,79 . tg 200
= 140,05 kg
Gaya bantalan di P
- Arah vertikal
PV . 800 U10 .730 = 0
.
PV =
, .
=
= 351,12 kg
- Arah horisontal
PH . 800 R10 . 730 = 0
.
PH =
= 127,79 kg
- Resultan gaya
P= ( ) +( )
= (127,79) + (351,12)
= 373,65 kg
Gaya bantalan di Q
- Arah vertikal
QV . 800 U10. 70 = 0
.
QV =
, .
=
= 33,67 kg
- Arah horisontal
QH . 800 R10 . 70 = 0
, .
QH =
= 12,25 kg
- Resultan gaya
Q= ( ) +( )
= (12,25) + (33,67)
= 35,83 kg
Momen bending
- Arah vertikal P A
MbV = PV .x
Untuk x = 0 MbV = 0
x = 70 MbV = 351,12 . 70
= 24578,4 kg . mm
- Arah vertikal A Q
MbV = PV ( 79 + y ) U10 . y
Untuk y = 0 MbV = 24578,4 kg . mm
y = 730 MbV = 0
MbV = 24578,4 kg . mm
P A Q
- Arah horisontal P A
MbH = PH . x
Untuk x = 0 MbV = 0
x = 70 MbV = 127,79.70
= 8945,3 kg . mm
- Arah horisontal A Q
MbH = PH (70 +y ) U10 . y
Untuk y = 0 MbH = 8945,3 kg . mm
y = 730 MbH = 0
MbH = 21425,25 kg . mm
P A Q
- Momen bending yang timbul
Mb = ( ) +( )
= (8945,3) + (24578,4)
= 26155,61 kg . mm
ds = [(5,1/a) ( . ) +( . ) ]
dimana :
km = 1,5 dipilih
M = Momen bending
T = Momen Torsi
Kt = 1,0 1,5
= 1,2 dipilih
a =
.
S1 = faktor keamanan = 6
a =
.
=
. ,
= 4,83 kg/mm2
ds = [(5,1/a) ( . ) +( . )]
= 44,9 mm 45 mm
= 43,0 mm 45 mm
= 55,8 mm 60 mm
= 48,39 mm 50 mm
= 40,96 mm 45 mm
F h
=
. ,
= 4,33 kg/mm2
- Tegangan geser yang terjadi akibat momen (ka)
.
ka =
. .
. ,
=
. .
= 2,21 kg/mm2
Checking ka a
2,21 kg/mm2 4,33 kg/mm2 (Aman)
- Gaya tangensial pada permukaan poros.(F)
F=
( . )
. ,
=
/
= 1236,825 kg
- Perencanaan pasak pada poros II
Berdasarkan diameter poros II (ds) = 55,8 mm 60 mm diambil dari diameter
terbesar.
Dapat diperoleh data sebagai berikut :
Lebar (b) = 18 mm
Tinggi (h) = 11 mm
Alur pasak poros (t1) = 7,0 mm
Alur pasak naf (t2) = 4,4 mm
Panjang Pasak (1) = 50 200 mm
- Tegangan geser yang diijinkan (a)
a =
.
=
. ,
- Tegangan geser yang terjadi akibat momen (ka)
.
ka =
. .
. ,
=
. .
= 1,031 kg/mm2
Checking ka a
1,031 4,33 kg/mm2 (Aman)
- Gaya tangensial pada permukaan poros II (F)
F=
( / )
. ,
=
/
= 927,62 kg
4.6 Perencanaan Bantalan
D D1 d F