ANALISIS HASIL SIMULASI TRIAL MENGGUNAKAN AUTODESK MOLDFLOW INSIGHT UNTUK MENGURANGI CACAT WELD LINES

DIAZ LARASATI, I. Aris Hendaryanto, S.T., M.Eng.

2019 | Tugas Akhir | D3 TEKNIK MESIN

Gauge oil level hasil produksi PT. Dynaplast Cibitung berfungsi unutk menutup lubang oli pada bagian kanan dari crankcase sepeda motor. Gauge oil level diproduksi dengan proses injeksi molding, mesin yang digunakan Toyo SI 100-6/F75D kapasitas 100 ton. Nylon 66 digunakan sebagai raw material untuk memproduksi gauge oil level. Selama proses trial gauge oil level terdapat satu cacat yang selalu timbul, yaitu weld lines. Lebih dari satu faktor yang dapat menyebabkan weld lines oleh karena itu, perlu dilakukan analisis aliran polimer dan analisis penyebab weld lines. Analisis aliran polimer menggunakan perangkat lunak yang dibuat khusus untuk menganalisis aliran material polimer dan memberikan prediksi cacat pada produk, Autodesk Moldflow Insight menjadi pilihan perangkat lunak untuk menganalisis produk gauge oil level. Analisis yang dilakukan adalah mencari lokasi gate yang baik dan melakukan simulasi trial dengan software tersebut. Berdasarkan lokasi gate yang didapatkan software, dilakukan pengubahan posisi gate pada mold. Data yang diperoleh setelah simulasi, yaitu temperatur mold, temperatur leleh polimer, kecepatan injeksi, dan tekanan packing. Data yang diperoleh kemudian diuji coba dengan mesin injeksi 100 ton. Berdasarkan hasil trial, diperoleh hasil weld lines yang jauh lebih baik. Hasil setting yang diperoleh, yaitu temperatur mold sebesar 90 derajat C; temperatur heater 1 sebesar 295 derajat C; temperatur heater 2 sebesar 330 derajat C; temperatur heater 3 sebesar 330 derajat C; temperatur heater 4 sebesar 330 derajat C; dan temperatur heater 5 sebesar 285 derajat C. kecepatan injeksi yaitu, kecepatan 1 sebesar 15 mm per sekon; kecepatan 2 sebesar 150 mm per sekon; kecepatan 3 sebesar 130 mm per sekon. tekanan packing sebesar 80 MPa.

Gauge oil level which manufactured at PT. Dynaplast Cibitung has a function to cover up lubricating oil's hole in the right side of the motorcycle crankcase. Gauge oil level is produced by an injection molding process, 100 tons of the machine's capacity is used on Toyo SI 100-6/F75D for produced gauge oil level. Nylon 66 is used as a raw material for producing a gauge oil level. During the trial process of gauge oil level there are one defect that always occurs, that is weld lines. There are more than one factors that caused weld lines, therefore it is necessary to the analysis of polymer flow and analysis the caused of weld lines. Analysis of the flow of polymer using software that was specifically created to analyze the flow of polymer materials and give predictions defect in a product, Autodesk Moldflow Insight be a software option to analyze gauge oil level. Analysis that did is looking for best gate locations and perform trials simulation with that software. Based on the gate location obtained by the software, the gate position was changed in the mold. The data were obtained then tested in 100-tons of the injection molding machine. Based on the trial result, much better weld lines were obtained. The settings result are, the mold temperature was 90 degree C, heater temperature 1 was 295 degree C, heater temperature 2 was 330 degree C, heater temperature 3 was 330 degree C, heater temperature 4 was 330 degree C, and heater temperature 5 was 285 dergree C. the injection speed are, speed 1 was 15 mm/s, speed 2 was 150 mm/s, and speed 3 was 130 mm/s. packing pressure was 80 MPa.

Kata Kunci : Proses Injeksi Molding, weld lines, moldflow