MULYANTO, BAMBANG (2020) INVESTIGASI WRINKLE DAN SPRINGBACK PADA PROSES DEEP DRAWING BAHAN LEMBARAN BAJA KARBON SPCC. S2 thesis, Universitas Mercu Buana Jakarta.
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Abstract
Sheet metal forming (SMF) process, especially deep drawing is one of the manufacturing processes that important and commonly used in automotive industry. Compared with casting and forging, forming process into the metal sheet obtain several advantages including less weight materials and variations in shapes that can be made. One of the challenges in the SMF process is the wrinkle and springback phenomenon which can cause a deviation in the size and appearance defects of sheet products. The wrinkle occurs because of the mechanical properties of the material, product geometry and blank holder force (BHF). Several variations of BHF were applied in this simulations and experiments to eliminate wrinkle defects of cylinder flange cup test products from the cold rolled coiled steel plate (SPCC) type of material with thickness of 0.8 and 1.0 mm, height of 10 mm, inner diameter of 58 mm and flange diameter of 76 mm. Simulations of the SMF process were carried out using ABAQUS/Explicit version 6.14-2 at dry (without lubricant) and wet condition. Experiment was carried out on a 600 kN press with a punch velocity of 40 strokes per minute, blank holder force variations from 0 to 21 kN and variation of the coefficient of friction with values of 0.05, 0.10 and 0.15. The experimental data performed with a single die on a flange cup cylindrical test material shows that the greater the blank holder force (BHF) number, the smaller wrinkle defect and it can be eliminated starting from the BHF number of 15 kN. The springback occurs due to the reverse force phenomena due to the effect of its elasticity of sheet carbon steel material that have experiencing the formation process. Ironing of SPCC sheet metal with a thickness of 0.8 and 1.0 mm is carried out in a pressure of 2.9 MPa. The experimental data that carried out with a single die on the cylinder cup sample test showed that the lower the value of ironing, the greater the value of the springback material. Therefore, the springback phenomenon can be reduced 0.03 to 0.07 mm by engineering the ironing process with a range of 4 - 13%. Keywords: SMF, Deep drawing, Springback, Ironing, Wrinkle, BHF, Carbon Steel SPCC Proses pembentukan lembaran logam (SMF), khususnya deep drawing, adalah salah satu proses manufaktur yang umum digunakan dalam industri otomotif. Dibandingkan dengan casting dan forging, proses SMF memiliki beberapa keunggulan termasuk bahan yang lebih ringan dan variasi bentuk yang lebih luas dapat dibuat. Beberapa masalah dalam proses SMF adalah fenomena wrinkle dan springback. Wrinkle dan springback dapat menyebabkan cacat ukuran dan penampilan produk lembaran. Wrinkle terjadi karena sifat mekanik bahan, geometri produk, dan gaya blank holder (BHF). Beberapa variasi BHF diterapkan dalam simulasi dan eksperimen untuk menghilangkan cacat wrinkle produk uji silinder flange cup dari bahan SPCC tebal 0.8 dan 1.0 mm dengan geometri tinggi 10 mm, diameter dalam 58 mm dan diameter flange 76 mm. Simulasi otomasi proses SMF dilakukan menggunakan ABAQUS / Eksplisit versi 6.14-2 pada kondisi kering (tanpa pelumas) dan basah. Eksperimen dilakukan pada mesin press 600 kN dengan kecepatan pukulan 40 stroke per menit, variasi gaya blank holder dari 0 hingga 21 kN dan variasi koefisien gesekan dengan nilai 0,05, 0,10 dan 0,15. Data eksperimental yang dilakukan dengan die tunggal pada bahan uji silinder flange cup menunjukkan bahwa semakin besar jumlah blank holder force (BHF), semakin kecil cacat kerutan dan dapat dihilangkan mulai dari nomor BHF 15 kN. Springback terjadi karena adanya gaya balik yang disebabkan oleh elastisitas bahan lembaran baja karbon yang mengalami proses pembentukan. Ironing lembaran baja karbon SPCC dengan ketebalan 0,8 dan 1,0 mm dilakukan dengan tekanan 2,9 Mpa. Data eksperimen yang dilakukan dengan die tunggal pada bahan uji berbentuk Silinder Cup menunjukkan bahwa semakin kecil nilai ironing maka semakin besar nilai springback bahan. Oleh karena itu, fenomena springback dapat direduksi 0.03 sampai 0.07 mm dengan perekayasaan proses ironing dengan rentang 4 - 13%. Kata kunci: SMF, Deep drawing, Springback, Ironing, Wrinkle, BHF, Karbon Steel SPCC
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