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Tahap dari desain hingga proses manufaktur

Conceptual design

Preliminary design

Design
Prototype

Verification

Revised design

Final design

Process selection, design and Tool selection and design

planning

Tooling
production

Production planning Tool construction and

Plan for

and scheduling installation

Manufacturing

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Material untuk proses manufaktur

Evolusi Material
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Jenis Material dan Proses Manufaktur
Manufacturing
Processes
Materials Heat treatment

Non-Ferrous Casting
Ferrous • Alumunium Forging
•Cast Iron • Copper Rolling
•Steel • Zinc
• Titanium Extrusion
• Magnesium
Alloys Forming
• Nickel
Machining
Composites Polymers Joining
Surface treatment
Ceramics
Rapidprototyping
(Material Incress
Manufacturing)

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PROPERTIES OF MATERIALS

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MATERIALS

METALLIC NONMETALLIC

Ferrous (Stainless Steel,
Wood

Cast Iron, etc)
Polymer

Non Ferrous (Copper,
Composite
Bronze, Aluminium, etc)

• Physical Properties
• Mechanical Properties
Static Properties
Dynamic Properties

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PHYSICAL PROPERTIES
Beberapa properties fisik penting dari material yang harus dipertimbangkan adl:

Physical Properties Metallic Materials Nonmetallic Materials

Specific Heat <<< >>>

Thermal Conductivity >>> <<<

Thermal Expansion >>> <<<

Electrical Conductivity >>> <<<

Magnetic Response >>> <<<

Density >>> <<<

Melting Point >>> <<<

Light Reflection >>> <<<

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UNIAXIAL TENSILE TEST
Why ???

Parameter yang akan didapat :

• Engineering Stress-Strain Curve
• Yield Strength
• Ultimate Tensile Strength
• Percent Elongation
• Young Modulus
• Calculated Fracture Energy
• Modulus of Resilience

Standards :
ASTM D638, D882

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ENGINEERING STRESS-STRAIN CURVE

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STRAIN HARDENING
What is strain hardening?
What is Damping Capacity?

σ= K εn

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HARDNESS
Hardness : Ketahanan suatu metal untuk mengalami deformasi plastik,
biasanya dilakukan dengan cara indentasi; ketahanan goresan, abrasi
atau pemotongan.

Hardness Measurements :

Brinell Hardness Tests

Rockwell Test

Vickers Hardness Tests

Knoop Hardness Test

Mohs HardnessTest

Durometer Hardness Test (rubber, ASTM D2240)

IRHD Test (rubber, ASTM D1415, ISO S48)

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BRINELL HARDNESS TESTS
• Invented by J.A. Brinell in 1900 (the oldest hardness testing method)
• Using Standard : ISO 6506 (part 1,2,3), ASTM E10
• Dingunakan hanya untuk material dan kondisi yang spesifik. Brinell Test tidak dapat
digunakan bila a.l. :
oMaterial terlalu lunak/keras
oSpecimen tidak cukup tebal
oTest dikenakan hampir berada di tepi material/specimen
oBila diinginkan tidak ada indentasi pada produk/part akhir
oTepi dari indentasi susah untuk dilihat
• 15HBW10/100, 15 HBS 10/100, Apa artinya ??

Material Load (kg)

Besi (Fe) 187.5
Tembaga (Cu) 62.5
Aluminium (Al) 31.25 Mengapa berbeda ?

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ROCKWELL HARDNESS 15T
SUPERFICIAL TEST
• Keuntungan/keunggulan :
Rapid test, biasanya kurang dari 10 detik
Direct readout, no questionable optical measurements required.
Non-destructive, part normally can be used
• Kekurangan :
Multiple test scales (30) needed to cover the full range of metal hardness.
Conversions between scales can be material dependant.
Samples must be clean and have a smooth test point to get good results.
• Standards:
ASTM E18
ISO 6508-1

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VICKERS HARDNESS TESTS

• HV = Constant x test force / indent diagonal squared ; HV = 1.854(F/D2)

• HV are then kilograms force per square millimetre (kgf/mm²)
• To convert HV to MPa multiply by 9.807
• 356HV0.5, what does it mean?
• Dapat digunakan hampir oleh semua material, hanya terbatas oleh ukuran
• Standards yang digunakan :
ASTM E384 - 10g to 1kg
ASTM E92 - 1kg to 100kg
ISO 6507-1,2,3 – micro and macro ranges
• Digunakan untuk mengecek kekerasan phase

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KNOOP TEST
• Digunakan untuk menentukan area suatu permukaan
material dengan akurat
• HK = 14.229(F/A) (kg/mm2)
• Standards :
ASTM D1474 organic coatings
ASTM D785

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HARDNESS TESTS SELECTION

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HARDNESSES COMPARISONS

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DYNAMIC PROPERTIES
Dynamic properties is the properties of material due to dynamic
load. In mechanical engineering, many components work in dynamic
load.

Impact test

Fatigue and the endurance limit

Fatigue failures

Beach mark failure type

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IMPACT TEST
• Charpy Impact Test (U, V notched) (EN 10045)
• Izod Impact Test (ASTM D256)
• Transition temperature ??
Mengapa
berbentuk
seperti ini ?

Transition temp.
range
Ductile failures

Energy
to rupture

Brittle failures
Mixed failures

Temperature

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FATIGUE , ENDURANCE LIMIT,
AND TEMPERTURE EFFECT
Fatigue : Failure due to CYCLIC loads (S<Sfat, failure)
Endurance Limit : Reduced material strength due to CYCLIC loads
Higher Temperature  More ductile, more toughness, less strength

S = stress amplitude
case for
unsafe steel (typ.)

Sfat
safe

103 105 107 109

N = Cycles to failure

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CREEP

First stage
(primary) :
Creep rate decrease
due to strain
hardening

Second stage
(secondary) :
Creep at constant
rate

Third stage
(tertiary) :
Creep rate
(c)2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used acceleration
herein under license.

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CREEP (CONT.)

(c)2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license.

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