By Didit Ritanto
21752012
MASTER’S DEGREE
in
MASTER OF MECHANICAL ENGINEERING – MANUFACTURING concentration ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
August 2018
Revision after the Thesis Defense on 30 July 2018
Didit Ritanto
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Didit Ritanto
Student Date
Approved by:
Dr. Ir. Hanny J. Berchmans, M.T., M.Sc.
Thesis Advisor Date
Dena Hendriana, B.Sc., S.M., Sc.D.
Thesis Co-Advisor Date
Dr. Irvan Setiadi Kartawiria, S.T., M.Sc.
Dean Date
Didit Ritanto
ABSTRACT
REVERSE ENGINEERING OF AN OUTSIDE JAW OF SELF-CENTERING CHUCK
By
Didit Ritanto
Dr. Ir. Hanny J. Berchmans, M.T., M.Sc., Advisor Dena Hendriana, B.Sc., S.M., Sc.D., Co-Advisor
SWISS GERMAN UNIVERSITY
In this study using reverse engineering method for outside jaw. Outside jaw is a spare part of the self-centering chuck part of the turning machine. Replacement Outside jaw must be imported from Germany, take a long time and a decent fee. Therefore, outside jaw from the physical form is taken data to be processed data can be used in the process of making it. Data taken from the part using 3D scanner result is point cloud. In addition to 3D scanners are also done data retrieval by Coordinate Measuring Machine. Data from CMM used in processing into 3D model. Point cloud is processed into 3D model in solid form using CAD design software Solidworks, of course previously done the cleaning processes of noise and verification of physical objects. 3D model is used for materials analysis process. The analysis process selected four types of materials and then analyzed using the properties of all materials. the result is an alloy steel material that is close to the limit of the permitted yield strength of the material. Then to be better then done a little change in the form of detail design. Then done again the analysis so that the results get better than before. The process of cost savings analysis is also done and the result is more efficient than having to import. Then the process for manufacturing outside jaw is ready to be done with all data obtained from this process.
Keywords: reverse engineering, 3D scanning, shape reconstruction, strength analysis
Didit Ritanto
© Copyright 2018 by Didit Ritanto All rights reserved
Didit Ritanto
DEDICATION
I dedicate this works for the future of my family, ATMI St.Michael Group and INDONESIA
Didit Ritanto
ACKNOWLEDGEMENTS
Gott sei Dank, I am grateful to the God for the good health and wellbeing that were necessary to complete this book.
I wish to express my sicere thanks to my advisors Mr. Dr. Ir. Hanny J. Berchmans, M.T., M.Sc. and Dena Hendriana, B.Sc., S.M., Sc.D. for the continuous support of my Master’s Thesis. I place on record, my sincere thank you to Mr. Dr. Irvan Setiadi Kartawiria, S.T., M.Sc. Dean of Faculty of Engineering and Information Technology, for the continuous encouragement.
I am also grateful to Mr. Dr. Ir. Gembong Baskoro, M.Sc., the best lecturer. I am extremely thankful and indebted to him for sharing expertise, and sincere and valuable guidance and encouragement extended to me.
I take this opportunity to express gratitude to all of my friends member of the fast track program in ATMI-SGU for their help, support and togetherness. I also thank my family and my parents for the unceasing encouragement, support and attention. I am also grateful to Karya ATMI Foundation, Johann Casutt Memorial Institute (JCMI) and Alumus of ATMI who supported me throught this venture.
Didit Ritanto
TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS... 7
LIST OF FIGURES ... 8
LIST OF TABLES ... 10
1. INTRODUCTION ... 11
1.1 Background ... 11
1.2 Research Problems ... 12
1.3 Research Objectives ... 12
1.4 Research Questions... 12
2. LITERATURE REVIEWS ... 13
2.1 Literature Reviews ... 13
2.2 Theoretical Perspective ... 17
3. RESEARCH METHODS ... 19
3.1 Material and Equipment ... 19
3.1.1 Material ... 19
3.1.2 Equipment ... 26
3.2 Analytical Method ... 31
4. RESULTS AND DISCUSSIONS ... 41
4.1 Initial Evaluation ... 41
4.2 Data Analysis ... 44
4.3 Optimization Design ... 47
Didit Ritanto
4.4 Implementation ... 51
4.5 Cost Saving Analysis ... 54
4.6 Discussions ... 55
5. CONCLUSIONS AND RECOMMENDATIONS ... 56
5.1 Conclusions ... 56
5.2 Recommendations ... 56
REFERENCES ... 57
APPENDICES ... 59
CURRICULUM VITAE ... 60
LIST OF FIGURES Figure 1. Coordinate Measuring Machine ... 13
Figure 2. 3D scanner ... 14
Figure 3. X-ray computed tomography... 14
Figure 4. Finite Element Analysis ... 15
Figure 5. Stereolithograpy ... 16
Figure 6. Stress Strain Curve ... 17
Figure 7. Self-centering chuck ... 19
Figure 8. Outside jaws ... 20
Figure 9. The microstructure testing result of the original outside jaw ... 21
Figure 10. Hardness Testing of the original Outside Jaw ... 22
Figure 11. The test certificate of raw material 1.6582 ... 24
Figure 12. Hardness Testing of raw material 1.6582 ... 25
Figure 13. 3D laser scanner - Matter & Form... 26
Figure 14. Brown & Sharpe Coordinate-measuring Machine ... 27
Figure 15. Scanning process by CMM ... 28
Figure 16. MF Studio software ... 29
Figure 17. Solidworks 3D CAD design software ... 30
