PERANCANGAN DRILL JIG ROTARY PLATE

UNTUK PEMBUATAN LUBANG JERUJI

PADA FIXIE HUB BIKE 32 HOLE

TUGAS AKHIR

Diajukan kepada

Universitas Muhammadiyah Malang Sebagai Salah Satu

Persyaratan Untuk Memperoleh Gelar Sarjana Teknik

Program Strata Satu (S1) Jurusan Teknik Mesin

Disusun Oleh :BUDIARTO ALIF RAMADHAN

201520120312244

JURUSAN TEKNIK MESINFAKULTAS TEKNIK

UNIVERSITAS MUHAMMADIYAH MALANG2018

xi

DAFTAR ISI

HALAMAN JUDUL ....................................................................................... i

POSTER ........................................................................................................... ii

LEMBAR PENGESAHAN TUGAS AKHIR ................................................ iii

LEMBAR BERITA ACARA BIMBINGAN ................................................ iv

LEMBAR SURAT PERNYATAAN TIDAK PLAGIAT ............................ vi

ABSTRAK ........................................................................................................ vii

ABSTRACT ...................................................................................................... viii

KATA PENGANTAR ..................................................................................... ix

DAFTAR ISI .................................................................................................... xi

DAFTAR GAMBAR ....................................................................................... xiv

DAFTAR TABEL ........................................................................................... xvi

BAB I PENDAHULUAN

1.1 Latar Belakang ...................................................................................... 1

1.2 Rumusan Masalah ................................................................................. 2

1.3 Tujuan Perancangan .............................................................................. 3

1.4 Manfaat Perancangan ............................................................................. 3

1.5 Batasan Masalah..................................................................................... 3

BAB II TINJAUAN PUSTAKA

2.1 Tinjauan Pustaka ................................................................................... 5

2.2 Tinjauan Patent ...................................................................................... 5

2.3 Dasar Teori ............................................................................................ 6

2.4 Analisa Gaya pada Proses Drilling ........................................................ 6

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2.5 Elemen pada Jig dan Fixture .................................................................. 8

2.5.1 Penempatan Bemda Kerja ........................................................... 9

2.5.2 Pencengkaman Benda Kerja ........................................................ 12

2.5.3 Bodi, Base, Frame........................................................................ 15

2.5.4 Penandaan Benda Kerja ............................................................... 15

2.5.4.1 Rotary Indexing ................................................................. 15

2.5.4.2 Plat Indeksi ........................................................................ 16

2.5.5 Drill Bush .................................................................................... 18

2.5.6 Jenis Drill Jig............................................................................... 21

2.6 Pengelasan ............................................................................................. 22

2.7 Pengerasan Total ................................................................................... 25

2.8 Tegangan Pada Elemen Jig ................................................................... 28

BAB III METODOLOGI PERANCANGAN

3.1 Diagram Alir Proses Perancangan ........................................................ 31

3.2 Perancangan dan Penjelasan ................................................................. 31

3.3 Perancangan Konsep .............................................................................. 34

3.4 Pemilihan Konsep Produk...................................................................... 34

3.4.1 Menyusun kriteria untuk membandingkan konsep.......................... 35

3.4.2 Pemilihan konsep produk yang dibandingkan................................. 36

3.5 Morfologi ............................................................................................... 37

BAB IV PERHITUNGAN DAN PEMBAHASAN

4.1 Konsep Desain ...................................................................................... 39

4.2 Pemilihan Material ................................................................................. 40

4.3 Gaya Pengeboran ................................................................................... 41

4.4 Perancangan Komponen Mekanik ......................................................... 45

4.4.1 Analisa Komponen Mekanik Cekam Drill Jig .............................. 45

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4.4.2 Analisa Komponen Bodi, Base, Frame .......................................... 53

4.4.3 Analisa Komponen Klem Penempat .............................................. 55

4.4.4 Analisa Komponen Bodi, Base, Frame .......................................... 57

4.4.5 Perencanaan Poros Penempat & Mur............................................. 58

4.4.6 Pen & Baut ..................................................................................... 62

BAB V KESIMPULAN ............................................................................ 63

DAFTAR PUSTAKA ...................................................................................... 65

LAMPIRAN ..................................................................................................... 66

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DAFTAR GAMBAR

Gambar 2.1 Rotary drill jig assembly................................................................... 5

Gambar 2.2 Gaya-gaya yang bekerja pada drill ................................................... 7

Gambar 2.3 Button dan pin standart ................................................................... 9

Gambar 2.4 Penempat silinder dalam................................................................. 10

Gambar 2.5 Pencegah kemacetan pemasukan.................................................... 10

Gambar 2.6 Penempat Diamond......................................................................... 11

Gambar 2.7 Penempat tirus dalam dan luar........................................................ 11

Gambar 2.8 Screw Clamp................................................................................... 12

Gambar 2.9 Floting Pad ..................................................................................... 13

Gambar 2.10 Rotary Indexing Drill Jig................................................................ 16

Gambar 2.11 Drill jig dengan plat indeksi ........................................................... 17

Gambar 2.12 Pengindeksi..................................................................................... 17

Gambar 2.13 Renewable bush .............................................................................. 18

Gambar 2.14 Slip bush ......................................................................................... 18

Gambar 2.15 Jenis lain slip bush.......................................................................... 19

Gambar 2.16 Treaded bush .................................................................................. 19

Gambar 2.17 Bush berkepala & bush tanpa kepala .............................................. 20

Gambar 2.18 Bush untuk bidang miring .............................................................. 20

Gambar 2.19 Bush dengan modifikasi.................................................................. 20

Gambar 2.20 Keseimbangan pengelasan.............................................................. 24

Gambar 2.21 Diagram Fe3c ................................................................................. 25

Gambar 2.22 Pembentukan Martensit .................................................................. 26

Gambar 2.23 Perbandingan kekerasan martensit dan Fe3c.................................. 27

Gambar 2.24 Kurva perlakuan panas baja paduan Mn rendah............................. 27

Gambar 3.1 Diagram alir perancangan konsep alat tahap awal ......................... 32

Gambar 3.2 Diagram alir perancangan konsep alat tahap akhir......................... 33

Gambar 4.1 Penampang orthogonal posisi pemasangan benda kerja ................ 39

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Gambar 4.2 Parameter proses gurdi (drilling) .................................................... 41

Gambar 4.3 Konsep desain drill jig rotary plate................................................ 45

Gambar 4.4 Arah gaya yang terjadi pada proses pencekaman........................... 46

Gambar 4.5 Diagram gaya cekam fixture pada benda kerja ............................. 47

Gambar 4.6 Gaya yang bekerja pada bagian bodi .............................................. 54

Gambar 4.7 Gaya yang bekerja pada bagian klem penempat ............................ 55

Gambar 4.8 Gaya yang bekerja pada bagian pembawa kait............................... 57

Gambar 4.9 Komponen poros penempat dan mur.............................................. 58

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DAFTAR TABEL

Tabel 2.1 Konstanta gaya drilling .................................................................... 8

Tabel 2.2 Tekanan kontrak Ulir ....................................................................... 14

Tabel 2.3 Tabel kampuh las ............................................................................. 23

Tabel 3.1 Matriks pengambil keputusan untuk drill jig ................................... 36

Tabel 3.2 Matriks morfologi Drill Jig Rotary Plate ........................................ 38

65

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Jensen, Heisel. 1983. Engineering Drawing and Design, Third Edition.

Justz, Herman. Scharkus, Edward. 1985. Westerman Table For The Metal Trade.Willey Eastern Ltd. New Delhi.

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