The gears are an important part of a mechanism. Making gears requires high precision to avoid backlash. The machining process that can produce high precision is the process of Wire cut EDM. This study aims to determine the roughness of the workpiece surface and investigate the effect of current and wire speed on the roughness of the straight gear surface through wire cut machine EMS 45. The wire cut machining parameters used are 3, 5, and 7 amperes for current, and wire speed of 8, 10, and 12 mm/min. While the Wire material is a type of brass with 0.25 mm in diameter. The results presented that the increased use of current and wire speed will result in lower surface roughness, and vice versa. Therefore, it can be concluded that use low machine parameters to produce a smooth workpiece surface.
The purpose of this research is to know the mechanical properties of the welds due to the current variation of welding joint API 5L using TIG and SMAW welding root methods. Preparation of specimens of pipe API 5L PSL1 grade X56 (Ø 177.8 mm, length 200 mm, width 7 mm), then specimens preparation were made in a single V 600, root gap 2mm, root face 2mm. Filling the welding roots with TIG welding and SMAW using electrodes E7018 with a current variation 70A, 80A, 90A. Mechanical tests consist of tensile, bending and hard test. The results showed that the quality of a good TIG root weld at 70A, the highest tensile strength of the weld joint 52.27 kgf/mm2 (70A), the highest hardnest 164,217 HRB (90A), the bending strength 1.123,061 N/mm2 (70A) using face bend method and 1,172,959 N/mm2 with root bend. In SMAW root welding, the highest tensile strength 54.27 kgf/mm2 (70 A) , the highest hardnest 158.717 HRB (70 A), the highest bending strength 1.115,611 N/mm2 (70 A) using face bend method, and 1.161,748 N/ mm2 with root bend.
Salah satu komponen turbin yang penting untuk diperhatikan dalam pembuatanya adalah komponen runner dan casing turbin. Banyaknya bagian yang harus dilas dan penggunaan alat bantu yang belum memenuhi syarat fungsional menyebabkan terjadinya beberapa masalah ketika proses perakitan, permasalahan tersebut disebabkan sulitnya mendapatkan ketegak lurusan antara piringan dan poros runner dimana pada kedua komponen tersebut terjadi penyimpangan runout yang melebihi toleransi yang diijinkan, seperti halnya perakitan komponen casing yang dimana hampir seluruh sambungan mengalami proses pengelasan dan penggunaan alat bantu yang sederhana sehingga menyebabkan penyimpangan dimensi yang sangat besar dari toleransi yang ditentukan. Penggunaan alat bantu yang sangat sederhana akan menimbulkan kesulitan dalam mengontrol dimensi atau keseragaman bentuk selama berlangsungnya proses produksi. Untuk itu dibutuhkan fixture yang cocok untuk proses perakitan runner maupun casing turbin untuk mendapatkan proses perakitan yang sesuai toleransi geometri yang ditentukan. Penelitian ini membuat rancang bangun fixture untuk digunakan dalam perakitan runner dan perakitan casing turbin dengan metode perakitan dilakukan secara bertahap. Perancangan dilakukan dalam lima tahap yaitu tahap pernyataan persoalan, tahap pembuatan analisa kebutuhan, tahap pengumpulan informasi dan gagasan, tahap pembuatan rancangan sementara dan tahap pembuatan rancangan akhir. Sedangkan pembuatan fixture dilakukan dalam dua tahap yaitu pemesanan material (pembelian material) dan pembuatan komponen fixture. Hasil akhir dari pembuatan runner dan casing dengan menggunakan fixture adalah mampu menurunkan penyimpangan pada komponen runner dan casing turbin dengan menghasilkan runout pada runner sebesar 2.0 mm dan ketegak lurusan casing sebesar 1.6 mm, tetapi belum mampu mencapai penyimpangan dari yang ditargetkan yaitu 1 mm.
Scattred industrial trash on mechanical company’s workshop will be dangerous for operator and employee. The aims of this research are to design, analyze and compare the function of automatic press tool of machining trash to a manual process. Method of this research are designing, manufacturing and testing. A tool was designed using inventor software, assembled and manufactured, then tested. As results, trash becomes neater, smaller, thus easier moved to the recycle process. It can operate with 2 ton maximum pressure and dimention 28,6 cm x 28,6 cm with 25 cm depth. Press tool produces an average pressing time with an automatic system 21.89 sec and reduction in space volume 7.670,7 mm3,whereas manual process, average pressing time 34,38 sec, space volume reduction 5.887,3 mm3.
Wire cut is a high-tech machining process and can be used to make high-precision products. This study aims to analyze the results of the workpiece surface and study the effect of current strength and wire speed on wire cut machining of EMS 45 on the surface roughness of straight gears. The results analyzed were the surface roughness values obtained by testing the surface roughness. The variations in the current used were 3 amperes, 5 amperes, and 7 amperes, while the wire speed used was 8 mm / min, 10 mm / min, and 12 mm / min. In the wire cut machining process, brass cutting materials are used with a wire diameter of 0.25 mm. The results showed that the greater the current and wire speed used, the lower the surface roughness value, conversely the smaller the current and the wire speed used, the higher the surface roughness value. The results of data analysis using the ANOVA analysis method, correlation, and regression get the optimal conditions for obtaining low surface roughness values and fast cutting time, namely at a current of 7 amperes with a wire speed of 10 mm/min.
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