PRAKTIKUM PROSES PRODUKSI PRAKTIKUM PERMESINAN
LAPORAN
Oleh Muhammad Mey Ade Ansyori NIM 091910101047
PROGRAM STRATA 1 TEKNIK JURUSAN TEKNIK MESIN FAKULTAS TEKNIK UNIVERSITAS JEMBER 2011 1
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KATA PENGANTAR
Puji syukur penulis panjatkan kehadirat Allah SWT, karena limpahan rahmat dan hidayah-Nya, penulis dapat menyelesaikan penyusunan Laporan Permesinan. Laporan Praktek Pengelasan ini disusun guna melengakapi tugas mata kuliah Praktikum Proses Produksi di Universitas Jember. Dalam penyusunan laporan ini, penulis menyadari banyak kekurangan dan kekeliruan yang taerjadi, serta penulis menyadari laporan ini jauh dari sempurna karena
keterbatasan
kemampuan
yang
penulis
miliki.
Penulis
banyak
mendapatkan mendapat kan dukungan dan bantuan bant uan baik moril maupun materiil ater iil dari berbagai berbaga i pihak. Atas segala bantuan, bimbingan, dan motivasi, serta kritik dan saran dari semua pihak, penulis hanya dapat menyerahkan kepada Allah SWT, semoga Allah SWT membalas kebaikannya, dan mudah-mudahan laporan ini bermanfaat.
Jember, Mei 2011
Penulis
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BAB 1. PENDAHULUAN
1.1 Latar Belakang
Pada zaman modernisasi seperti sekarang ini telah banyak ditemukan berbagai macam teknologi, dengan teknologi dapat meringankan tugas manusia dalam membuat ataupun membentuk sesuatu, misalnya teknik pembentukan dan pengerjaan logam dari yang konvensional sampai non-konvensional. Permesinan konvensional merupakan proses pembentukan benda kerja logam yang telah cukup lama dikenal. Permesinan Permes inan konvensional banyak dilakukan dilakuka n sebelum para ahli mesin menemukan mesin-mesin otomatis non-konvensional dalam proses pembentukan dan pengerjaan logam. Proses pemotongan logam merupakan suatu proses yang digunakan untuk mengubah bentuk suatu produk (komponen mesin) dari logam dengan cara memotong. Proses permesinan dengan menggunakan prinsip pemotongan logam dapat dikelompokkan menjadi tiga kelompok dasar, yaitu : proses pemotongan dengan mesin pres, proses pemotongan konvensional dengan mesin perkakas, dan proses pemotongan non konvensional. Proses pemotongan dengan menggunakan mesin pres meliputi pengguntingan ( shearing ( shearing ), ), pengepresan ( pressing ( pressing ) dan penarikan (drawing, elongating). Proses pemotongan konvensional dengan mesin perkakas meliputi proses bubut (turning), proses frais (milling), dan sekrap (shaping). Proses pemotongan non konvensional contohnya dengan mesin EDM (Electrical Discharge Machining) dan wire cutting. Praktikum permesinan merupakan proses pembentukan benda kerja yang lebih sederhana di bandingkan permesinan non-konvensional. Sederhana bermakna pemakaian peralatan-peralatan yang digunakan dalam permesinan dibandingkan peralatan yang digunakan dalam permesinan non-konvensional. Peralatan-peralatan yang digunakan dalam praktikum permesinan antara lain,
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yang modern dan canggih tetapi kita tetap perlu untuk mempraktekan teknik permesinan konvensional agar kita lebih mengetahui dan memahami permesinan konvensional.
1.2 Rumusan masalah
Dalam penyusunan laporan ini, terdapat beberapa rumusan masalah yang menjadi landasan permasalahan pada praktikum permesinan ini adalah sebagai berikut: 1. Bagaimana urutan uruta n dalam dala m proses proses pengerjaan pada mesin bubut. 2. Berapa lama waktu yang diperlukan dalam proses pembubutan benda kerja. 3. Bagaimana urutan proses pengerjaan pada mesin milling (frais) vertical. 4. Berapa lama waktu yang diperlukan dalam proses pengerjaan benda kerja pada mesin milling (frais) vertical. 5. Bagaimana urutan uruta n proses pengerjaan pengerjaan pada mesin milling (frais) horizontal. 6. Berapa lama waktu yang diperlukan dalam proses pengerjaan benda kerja pada mesin milling (frais) (frais) horizontal. 7. Bagaimana urutan uruta n proses pengerjaan pengerjaan pada mesin sekrap. 8. Berapa lama waktu yang diperlukan dalam proses pengerjaan benda kerja pada mesin milling (frais) (frais) sekrap.
1.3 Tujuan dan Manfaat
Tujuan dan manfaat yang dapat diambil setelah penyusunan laporan ini adalah: 1. Kita dapat mengetahui urutan proses dalam dala m pembubutan pembubutan benda kerja. 2. Kita dapat mengetahui waktu yang dibutuhkan dalam proses pengerjaan benda kerja pada mesin bubut. 3. Kita dapat mengetahui urutan proses dalam pengerjaan benda kerja pada mesin milling (frais) vertikal.
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5. Kita dapat mengetahui urutan proses dalam pengerjaan benda kerja pada mesin milling (frais) horisontal. 6. Kita dapat mengetahui waktu yang dibutuhkan dalam proses pengerjaan benda kerja pada mesin milling (frais) horisontal. 7. Kita dapat mengetahui urutan proses dalam pengerjaan benda kerja pada mesin sekrap. 8. Kita dapat mengetahui waktu yang dibutuhkan dalam proses pengerjaan benda kerja pada mesin sekrap.
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BAB 2. TINJAUAN PUSTAKA
2.1 Modul I (Praktikum Mesin Bubut)
Proses bubut adalah adala h proses permes permesinan inan untuk menghasilkan menghasilka n bagian bagia n-bagian -bagi an mesin berbentuk silindris yang dikerjakan dengan menggunakan Mesin Bubut. Prinsip dasarnya dapat didefinisikan sebagai proses permesinan permukaan luar benda silindris atau bubut rata. Prinsip kerja pada mesin bubut adalah poros spindel memutar benda kerja melalui piringan pembawa sehingga memutar roda gigi pada poros spindel. Melalui roda gigi penghubung, putaran akan disampaikan ke roda gigi poros ulir. Oleh klem berulir, putaran poros ulir tersebut diubah menjadi gerak translasi pada eretan yang membawa pahat. Akibatnya pada benda kerja akan terjadi sayatan yang berbentuk ulir.
2.1.1 Landasan Teori Mesin bubut adalah mesin yang dapat digunakan untuk berbagai proses permesinan seperti pemotongan, pengeboran, pengerjaan tepi, pembuatan ulir, pembuatan tirus, dll. Secara umum mesin bubut terdiri dari, Bed Mesin, Kepala Tetap, Kepala Lepas, Supor (Saddle), Apron, Eretan dan Pahat. Pahat merupakan bagian dari mesin bubut yang mempunyai fungsi sebagai pengikis atau pengambil serpih. Kecepatan putaran mesin bubut ditentukan berdasarkan kecepatan potong dan diameter benda kerja yang dibubut. Supaya pengoperasian mesin bubut dapat efisien, efisi en, operator harus memperhitungkan memperhit ungkan pemilihan pemiliha n kecepata n potong, pengumpanan ( f f eeding ) dan kedalaman pemotongan, banyaknya waktu yang hilang pada proses pembubutan disebabkan pemilihan kecepatan potong dan pemakanan yang tidak tepat.
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Gambar 1. Mesin Bubut
2.1.2 Bagian-bagian mesin Bagian-bagian mesin bubut antara lain : 1.
Bed Mesin Bagian ini dibuat dari besi tuang. Fungsi dari bagia n ini adalah untuk menopang komponen-komponen mesin lainnya.
2.
Kepala Tetap Bagian ini dipasang secara tetap pada bad mesin. Bagian ini mempunyai spindle bolong yang tirus atau berulir untuk memasang benda
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Apron ialah bagian supor yang membawa roda tangan untk memindahkan eretan. Transportir juga menembus apron dan dikaitkan dengan perantaraan engkol yang dipasang didepan apron. 6.
Eretan Eretan ialah bagian dari supor yang membawa eretan lintang dan eretan atas. Eretan dipindahkan sepanjang bed mesin demean perantaraan batang bergigi yang dipasang didepan bad mesin.
7.
Pahat Bubut Bagian ini mempunyai fungsi sebagai pengikis atau pengambil serpih. Pahat bubut dibuat dari baja HSS.
2.1.3 Parameter yang dapat diatur pada mesin bubut bubut Pada proses bubut ada parameter yang harus diperhatikan seperti kecepatan potong, pemakanan (Feeding), dan kedalaman pemotongan (Depth of Cut). a. Kecepatan potong potong Kecepatan potong adalah kecepatan keliling dari benda kerja melintasi ujung pahat potong, kecepatan potong umumnya dinyatakan dalam satuan meter per menit. Pemilihan kecepatan potong yang benar adalah harus disesuaikan dengan bahan dari benda kerja yang dibubut dan bahan dari pahat potong yang
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Dimana : n : putaran spindle putaran spindle mesin (rpm) V : kecepatan potong bahan (m/menit) D : diameter diamet er benda kerja (mm)
b. Pemakanan (Feeding) Pemakanan adalah jarak yang ditempuh oleh pahat potong untuk memotong dalam satu putaran benda kerja. Contoh : apabila mesin bubut pemakanannya diatur 0,4 mm maka pahat potong akan menempuh jarak 0,4 mm dalam setiap putaran benda kerja. Dalam proses pembubutan dikenal dua jenis pemotongan, yaitu pemotongan kasar ( Roughing c Roughing cut ) dan pemotongan akhir ( Finishing c Finishing cut ). ). Pada
pemotongan
kasar
pengurangan
benda
kerja
dilakukan
dengan
mempertimbangkan kualitas permukaan (nilai kekasaran permukaannya), sehingga pemakanan yang digunakan adalah pemakanan untuk pengasaran. Pada pemotongan akhir digunakan untuk mendapatkan hasil akhir permukaan dengan nilai kekasaran yang baik dan pemakanan yang digunakan adalah yang kecil. Pada proses pembubutan umumnya pemakanan untuk pengasaran yang digunakan berkisar antara 0,25 ± 0,4 mm. Dan untuk pemotongan akhir
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a. Kondisi mesin bubut, b. Jenis dan bentuk pahat bubut bubut yang digunakan, c. Kekakuan benda kerja, d. Kecepatan pemotongan. Kedalaman pemotongan untuk proses pengerjaan akhir tergantung pada tipe benda kerja dan kualitas permukaan yang diinginkan dari pada umumnya tidak lebih dari 0,13 mm.
2.1.4 Skala Pengukuran pada mesin bubut Skala pengukuran pada mesin bubut dipasang pada coumpound rest dan cross f eed . Skala pengukur digunakan untuk membantu operator mesin bubut dalam menentukan kedalaman pemotongan pahat dengan tepat sehingga tatal yagn terlepas oleh pahat potong dapat teridentifikasi dengan akurat (pengurangan diameter dapat t erukur). erukur). Skala pengukur dengan sistem metris umumnya dibagi kedalam 200 pembagian artinya setiap strip skala skala pengukur adalah 0,02 mm. mm. Contoh : untuk skala metris apabila handel pemutar skala pengukur diputar searah dengan jarum jam untuk 10 pembagian (10 strip) maka pahat potong akan maju 10 . 0,02 = 0,2 mm. Berikut beberapa petunjuk dalam menggunakan skala pengukur : a. Apabila skala pengukur dilengkapi dengan skrup pengunci, sebelum
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Keterangan gambar:
1. Pahat potong potong kiri
6. Pahat sudut kanan
2. Pahat ujung bulat
7. Pahat sisi kiri
3. Pahat potong kanan
8. Pahat potong rata
4. Pahat potong potong sudut kanan
9. Pahat sisi kanan
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Gambar 6.6. Geometri pahat bubut HSS (pahat diasah dengan mesin gerinda pahat).
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Gambar 6.8. Pahat tangan kanan dan pahat tangan kiri.
Pahat bubut di atas apabila digunakan untuk proses membubut biasanya dipasang pada pemegang pahat (tool (tool holder ). ). Pemegang pahat tersebut
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Gambar 6.10. Pahat bubut sisipan (inserts (inserts), ), dan pahat sisipan yang dipasang pada pemegang pahat (tool (tool holders). holders).
Bentuk dan pengkodean pahat sisipan serta pemegang pahatnya sudah distandarkan oleh ISO. ISO. Standar ISO untuk untuk pahat sisipan sisipan dapat dilihat pada pada Lampiran, dan pengkodean pengkodean pemegang pahat dapat dilihat dili hat juga pada Lampiran. La mpiran.
2.1.7 Material pahat Pahat yang baik harus memiliki sifat-sifat tertentu, sehingga nantinya
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Gambar 6.12. (a) Kekerasan dari beberapa macam material pahat sebagai fungsi dari temperatur, (b) jangkauan sifat material pahat.
Material pahat dari baja karbon (baja dengan kandungan karbon 1,05%) pada saat ini sudah jarang digunakan untuk proses pemesinan, karena bahan ini tidak tahan panas (melunak pada suhu 300-500o F). Baja karbon ini sekarang
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Pahat dari HSS biasanya dipilih jika pada proses pemesinan sering sering terjadi beban kejut, atau proses pemesinan yang sering dilakukan interupsi (terputus putus). Hal tersebut misalnya membubut benda segiempat menjadi silinder, membubut bahan benda kerja hasil proses penuangan, membubut eksentris (proses pengasarannya). Pahat
dari
karbida
dibagi
dalam
dua
kelompok
tergantung
penggunaannya. Bila digunakan untuk benda kerja besi tuang yang tidak liat dinamakan cast iron cutting grade . Pahat jenis ini diberi kode huruf K (atau
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2.1.8 Perencanaan Pembuatan Ulir
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pemotong. Alat ini dikenal sebagai pisau frais. Ada dua jenis pisau frais yang paling banyak digunakan yaitu: horizontal, pisau frais dipasang pada sumbu utama horizontal yang kedua vertikal pisau frais dipasang pada ujung spindel vertikal. Frais atau milling horisontal merupakan suatu proses pemakanan benda kerja yang pengerjaannya atau penyatannya dilakukan dengan menggunakan pahat yang diputar oleh poros spindel mesin. Pahat Frais (milling cutter) termasuk jenis pahat bersisi potong banyak (multiple point tool).
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bagian bawah Benda kerja dan melakukan penyayatan yang berat pada waktu benda kerja digerakan ke dala mpisau mpisau frais.
Gambar 2.2.2 mengefrais ke atas
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d. Tingkat kehalusan yang diinginkan e. Pencekaman benda kerja f. Media pendinginan. Rumus putaran pisau mesin milling adalah :
Dimana :
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Pisau frais kepala hampir serupa dengan pisau mantel yang sisi pemotongnya ditambah pada salah satu muka dan lubang arbornya dibagian
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Circular Pitch (CP) : CP = M ×
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Proses frais gigi gigi (Gambar 7.29), 7.29), sebenarnya sama dengan dengan frais bentuk pada Gambar 7.28., tetapi karena bentuknya yang spesifik, serta proses
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gigi cacing dan ulir cacing dengan perbandingan 1:40. Dengan demikian apabila engkol diputar satu kali, maka spindelnya berputar 1/40 kali. Untuk
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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The world’s largest digital library
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