TI-2121: Proses Manufaktur

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1 TI-2121: Proses Manufaktur Operasi Pemesinan & Mesin Perkakas Laboratorium Sistem Produksi 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 2 1

2 Istilah 3 Klasifikasi Komponen Pemesinan (a) rotational (b) non-rotational (prismatic) 4 2

3 Bentuk Permukaan Potong (a) straight turning (b) taper turning (c) contour turning (d) plain milling (e) profile milling 5 Forming: Bentuk Pemotongan (a) form turning (b) drilling (c) broaching 6 3

4 Kombinasi Forming dan Pergerakan Pahat (a) thread cutting on a lathe (b) slot milling 7 N v = π D D D = 2d 0 f 0 Turning f = Nf r T m L = f MRR = vfd r N = rotational speed, rev/min v = cutting speed, m/min D 0 = original diameter, mm D f = final diameter, mm d = depth of cut f = feed, mm/rev f r = feed rate, mm/min T m = time of actual machining, min L = length, mm MRR = material removal rate mm 3 /min 8 4

5 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 9 Mesin Lathe 10 5

6 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 11 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 12 6

7 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 13 Boring Mill (2) Vertical boring mill 14 7

Boring Mill (3) Boring bar made of cemented carbide 15 Drilling N = spindle speed, rev/min v = cutting speed, mm/min D = drill diameter, mm f = feed, mm/rev F r = feed rate, mm/min T m =

8 Boring Mill (3) Boring bar made of cemented carbide 15 Drilling N = spindle speed, rev/min v = cutting speed, mm/min D = drill diameter, mm f = feed, mm/rev F r = feed rate, mm/min T m = machining time, min T = work thickness, mm A = approach allowance MRR = material rate of return N = v π D f = Nf r φ A = 0.5D tan(90 ) 2 π MRR = D 2 4 f r T T m m = d f t + A = f r r 16 8

9 Operasi Drillling Lainnya (a) reaming (b) tapping (c) counter boring (d) countersinking (e) center drilling (f) spot facing 17 Mesin Drilling Drill press & Radial drill press 18 9

10 Milling Types of milling operation: (a) peripheral or plain milling (b) face milling 19 Peripheral Milling (a) slab milling (b) slotting (c) side milling (d) straddle milling 20 10

11 Tipe Pemotongan Milling (a) up milling (b) down milling 21 Face Milling (a) conventional face milling (b) partial face milling (c) end milling (d) profile milling (e) pocket milling (f) surface contouring 22 11

12 N f T = r A = m v πd = N n MRR = wd f t r f f Parameter Pemesinan Milling r d( D d) L + A = Nt = number of teeth 23 Mesin Milling (1) (a) horizontal (b) vertical 24 12

13 Mesin Milling (2) (a) universal-overarm (b) ram type 25 Machining Centers Automated machine tool capable of performing multiple machining operation under CNC control, having features: Automatic tool-changing Pallet shuttles Automatic workpart positioning 26 13

14 Turning Centers 27 Operasi pada Mill-Turn Centers (1) turn second diameter (2) mill flat with part in programmed angular position (3) drill hole (4) cutoff 28 14

15 Operasi Milling Lainnya (a) shaping (b) planning 29 Bentuk-bentuk Shaping & Planing 30 15

16 Mesin Shaper 31 Mesin Planer 32 16

17 Broaching Operasi Milling Lainnya (a) external broaching (b) internal broaching 33 Sawing (a) power hacksaw (b) bandsaw (c) circular saw 34 17

18 High Speed Machining Solid Tools (end mills, drill) Indexable Tools (face mills) Work Material Conventional Speed (m/min) High Cutting Speed (m/min) Conventional Speed (m/min) High Cutting Speed (m/min) Aluminum Cast iron, soft Cast iron, ductile Steel, free machining Steel, alloy Titanium 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 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

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