Bab 27A Pengantar Proses Penyambungan.pdf
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Transcript of Bab 27A Pengantar Proses Penyambungan.pdf
PengantarPengantar
ProsesProses PenyambunganPenyambungan
Ir. Tri Prakosa , M. Eng.Ir. Tri Prakosa , M. Eng.
ProsesProses ManufakturManufaktur II, II, FebruariFebruari 2011 2011
ProsesProses PenyambunganPenyambungan padapada MobilMobil
2
PengelasanPengelasan padapada bodybody mobilmobil
Types of Vehicle ConstructionTypes of Vehicle Construction
�Body-Over-Frame Construction
– A typical truck frame
Chapter 4
– A typical truck frame with sub-frame components.
Types of Vehicle ConstructionTypes of Vehicle Construction
�A Typical Unibody Design.
Chapter 4
– Typical one piece body and frame assembly with bolt-on components.
PenyambunganPenyambungan tutuptutup kalengkaleng minumanminuman
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.
Schmid.
Snap fit examplesSnap fit examples
� Toys
� Small Appliances
� Automotive
� Electronic Fields
Engine SystemsEngine Systems
�Exhaust system
– The exhaust system is designed to carry toxic exhaust fumes
Chapter 4
away from the passenger compartment, to quiet the exhaust pulses and burn or catalyze pollutants.
Engine SystemsEngine Systems
� Ignition system
– The ignition system must generate a spark to ignite the air/fuel mixture at the correct time.
– The coil transforms battery voltage into a
Chapter 4
– The coil transforms battery voltage into a spike of 30 000 to 100 000 volts to ignite the mixture.
– Ignition must occur before the piston completes its compression stroke.
Drivetrain ComponentsDrivetrain Components
�Clutch
– Used with manual transmissions and transaxles.
Chapter 4
– Mechanically connects the engine flywheel to the transmissions input shaft.
PenyambunganPenyambungan
� Proses-proses:– welding,– brazing,– soldering,– adhesive bonding, dan– adhesive bonding, dan– mechanical fastening.
� Proses-proses tersebut penting dan diperlukan pada proses manufakturing, dengan alasan sebagai berikut:
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.
Schmid.
MengapaMengapa perluperlu prosesproses joining?joining?
a. Produknya tidak mungkin dibuat sebagai dalam “single piece”.
Sebagai contoh, rangka pipa seperti gambar di pipa seperti gambar di samping, masing-masing bagian panjangnya 5m, diameter Ø100 mm dan ketebalan pipa 1mm.
MengapaMengapa perluperlu prosesproses joining?joining?
Struktur Raksasa tidak mungkin dibuat dalam “single piece”
MengapaMengapa perluperlu prosesproses joining?joining?
b. Produk-produk seperti alat masak yang ada pemegangnya, akan lebih mudah dan lebih ekonomis jika dibuat per-komponen, dan kemudian dirakit.
MengapaMengapa perluperlu prosesproses joining?joining?
c. Produk-produk seperti: automobile engines, hair dryers, printers dan soldered-joint electronic devices dapat dilepas komponen-komponennya untuk perawatan (maintenance).
MengapaMengapa perluperlu prosesproses joining?joining?
d. Kadang suatu produk memerlukan sifat material yang berbeda dengan material induknya. Permukaan yang menerima beban gesek/aus, atau korosi dan lingkungan yang ekstrim.
Sebagai contohSebagai contohadalah ujung pahatyang terbuat darikarbida yang disambung ke pahatgurdi dengan prosesbrazing, juga sepaturem atau roda gerindayang sambung kestruktur logampenumpunya.
MengapaMengapa perluperlu prosesproses joining?joining?
e. Pengangkutan produk per komponen individu dan merakitnya setelah sampai di tujuan bisa lebih mudah dan lebih murah. Beberapa sepeda danmainan, kebanyakan mesin perkakas, dan mesin pres hidrolik maupun mekanik diangkut secara per-komponen dan dirakit ditujuan.per-komponen dan dirakit ditujuan.
ProsesProses--prosesproses penyambunganpenyambungan
engine fasteners door
Mechanical ::::‧nuts/bolts ‧rivets ‧c-clips ‧pressure fits
Solid-liquid ::::
‧Adhesives ‧Soldering ‧Brazing
Solid ::::
‧Friction ‧Diffusion ‧Explosion ‧Ultrasound
Liquid ::::
Chemical ::::‧Oxyfuel ‧Thermit
ECUS emission controller windshield plastic fanswindshield
Body muffler
Resistance ::::
‧Spot ‧Seam ‧Flash
door hinges
Consumable electrode ::::
‧Shielded metal arc ‧Submerged arc ‧Gas metal arc
nonConsumable electrode ::::
‧Gas Tungsten Arc ‧Plasma ‧Electron Beam‧Laser Welding
Arc Welding
Adhesive bondingAdhesive bonding
Advantages� Sealing as well as
joining.� Better in fatigue loading.
Disadvantages• Disassembly is
difficult/impossible.• Surface preparation � Better in fatigue loading.
� Good damping. � Low weight penalty.
• Surface preparation required.
• Accurate assembly may be required.
• NDT difficult.• Possibly sensitive to
environment.
Mechanical fasteningMechanical fastening
Advantages� No surface preparation.� Disassembly possible� Simple inspection.
Disadvantages• High stress
concentration at hole.• Additional weight� Simple inspection.
� Better for thick sections.� No ‘chemistry’.
• Additional weight• Loss of smooth
surface.• Possible galvanic
corrosion.
Both types of joint result in Both types of joint result in stress concentrations:stress concentrations:
fasteners in shear; local stress concentrations around hole
peel in adherends: shear and through-thickness tension in adhesive - highest at joint edges
Mechanical FasteningMechanical Fastening�������� � Any shape and material almost�������� � Disassemblable (except Rivets, etc.)�������� � Least expensive for low volume (standardized)�������� � Problems: strength, seal, insertion, loosening
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Threaded Bolted Rivets Snap fit
Figures, B. Benhabib2.008-spring-2004 S.Kim
RivetsRivets
� Cheap, light weight, don’t get loose� Permanent, less strong than bolts� Rule of thumb
– Minimum spacing = 3 x d– Maximum spacing = 16 x thickness of the
outer plate
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outer plate
Rivets
2.008-spring-2004 S.Kim
Mechanical fasteningMechanical fastening
� Crimping� Embossed protrusions
– Plastic deformation/ interference
– Appliance– Automotive
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– Automotive
Lego assembly, elastic averaging
M. Culpepper, MIT2.008-spring-2004 S.Kim
Mechanical JoiningMechanical Joining
� Hemming, seaming– Bend edge of one component over
another– Automobile door stampings and
trunk lids
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Adhesive BondingAdhesive Bonding
� Quick and non-invasive� Most materials with high surface to volume ratio� Insulation (thermal, electrical), conducting
adhesives available� Good damping� Clean surface preparation
26
� Clean surface preparation� Long curing, hold time, low service T� Reliability, quality?� Disassembly?
� Weak to tensile loading, strong to shear and compressive� Organic
– epoxy, acrylic, etc..� Inorganic
Adhesive BondingAdhesive Bonding
� Inorganic– solder, cement, etc..
SolidSolid--Liquid: Brazing and SolderingLiquid: Brazing and Soldering
� In brazing, the filler material (silver, brass, bro nze) has a melting point above 425 ºC; and, in soldering, the filler m aterial (lead, tin) has a melting point well below 425 ºC.
� Capillary forces for the wetting and flow of the li quid metal into the gaps.
� Proper fluxes for lowering surface tension, remove oxides, and prevent oxidation.prevent oxidation.
Wave solderingWave soldering
� Exposed metal joints are passed over a wave in a continuous motion, where liquid solder penetrates into the joint by capillary forces:
Enlarged area
Circuitboard
Solder
Enlarged area
boardSolderfountain
Moltensolder
Heater Pump
OxyacetyleneOxyacetylene
Joining ProcessesJoining Processes
Types of Joints:1. Joints that allow relative motion (kinematic joints)2. Joints that disallow any relative motion (rigid joints)
Uses of Joints:1. To restrict some degrees of freedom of motion2. If complex part shape is impossible/expensive to manufacture3. To allow assembled product be disassembled for maintenance.4. Transporting a disassembled product is sometimes easier/feasible
Joining ProcessesJoining Processes
Fusion welding: joining metals by melting � solidification
Solid state welding: joining metals without melting
Brazing: joining metals with a lower mp metal
Soldering: joining metals with solder (very low mp)
Adhesive Bonding: joining with glue
Mechanical joining: screws, rivets etc.
Arc welding
Oxy-acetylenewelding
Flame: 3000°C
manual
robotic
Fusion weldingFusion welding
arc: 30,000°C
Gas shieldedarc welding Argon
MIG TIG
Al Ti, Mg,Thin sections
Plasma arc welding
Laser beam welding
Deep, narrow welds
Aerospace, medical, automobile body panels
Faster than TIW, slower than Laser
Nd:YAG and CO2 lasers, power ~ 100kW
Fusion welding..Fusion welding..
Electron beam welding
Laser beam weldingFast, high quality, deep, narrow welds
deep, narrow welds, expensive
Solid state weldingSolid state welding
Diffusion welds between very clean, smooth pieces of metal, at 0.3~0.5Tm
Cold welding (roll bonding)coins, bimetal strips
Solid state welding..Solid state welding..
Ultrasonic welding
25µm Al wire on IC Chip
Ultrasonic wire bonder
Medical, Packaging, IC chips, Toys
Materials: metal, plastic
- clean, fast, cheap
Resistance weldingResistance weldingWelding metal strips: clamp together, heat by current
Spot welds on a panSpot welding Robotic Spot welding on auto bodySpot welds on a panSpot welding Robotic Spot welding on auto body
Spot welding
Spot welding Robotic Spot welding on auto bodySpot welding Robotic Spot welding on auto body
Seam welding
resistance seam weldingresistance welded petrol tank
resistance seam weldingresistance welded petrol tank
BrazingBrazingTm of Filler material < Tm of the metals being joined
Torch brazing Furnace brazing
Common Filler materials: copper-alloys, e.g. bronze
Common applications: pipe joint seals, ship-construction
SolderingTin + Lead alloy, very low Tm (~ 200C)
Main application: electronic circuits
Adhesive Bonding/GluingAdhesive Bonding/GluingAdhesive type Notes Applications Acrylic two component thermoplastic; quick
setting; impact resistant, strong impact and peel strength
fiberglass, steel, plastics, motor magnets, tennis racquets
Anaerobic thermoset; slow, no-air curing – cures in presence of metal ions
sealing of nut-and-bolts, close-fitting holes and shafts, casting micro-porosities etc.
Epoxy strongest adhesive; thermoset; high tensile strength; low peel strength
metal parts (especially Nickel), ceramic parts, rigid plastics
Cyanoacrylate thermoplastic; high strength; rapid aerobic curing in presence of humidity
[common brand: Crazy glue™] plastics, rubber, ceramics, metals curing in presence of humidity plastics, rubber, ceramics, metals
Hot melt thermoplastic polymers; rigid or flexible; applied in molten state, cure on cooling
footwear, cartons and other packaging boxes, book-binding
Polyacrylate esters (PSA)
Pressure sensitive adhesives all types of tapes, labels, stickers, decals, envelops, etc.
Phenolic thermoset, oven curing, strong but brittle acoustic padding, brake lining, clutch pads, abrasive grain bonding
Silicone thermoset, slow curing, flexible gaskets and sealants Formaldehyde thermoset joining wood, making plywood Urethane thermoset, strong at large thickness fiberglass body parts, concrete gap
filling, mold repairs Water-based cheap, non-toxic, safe wood, paper, fabric, leather
Mechanical fastenersMechanical fasteners
(a) Screws (b) Bolts, nuts and washers (c) Rivets
(a) pneumatic carton stapler (b) Clips (c) A circlip in the gear drive of a kitchen mixer
Plastic wire clips
Wire �� conductor: crimping
Plastic snap-fasteners