Engineering Design of A Gang Drilling Machine Equipped with Jig and Fixtures to Make A Prototype Machine in Birdcage Production

Abstract

This paper is dealing with the engineering design of a gang drilling machine with jig & fixtures to make a prototype machine. This effort has been done in order to solve the problem which aroused in small business enterprises producing birdcages. The problem was how to minimize the production time in making a lot of holes that have same distance and straightness. Hopefully, the prototype machine can help the small business enterprises to increase their production rate.The design engineering process has been carried out by variant approximation on dowel pin modular fixtures in order to simplify fixtures design. CAD CAM software has also been used as fixtures synthesized method including geometric analysis and three dimensional fixtures assembling. The resulting prototype machine can be well operated and based on the running test, it can be concluded that the greater the motor rotation the greater the power needed. As for teak wood, at 250 rpm motor rotation the power needed is 26.5 watt, and at 400 rpm the motor needs power of 43.6 watt while at 600 rpm the motor needs power of 600 watt. The power consumption is also depends on the type of material, the better the mechanical properties of the materials, the higher the power consumption. For cast iron, the 400 rpm motor rotation needs power as high as 569.7 watt. This prototype of gang drilling machine needs power of 350 watt to make five holes on teak wood while ordinary drilling machine needs total power of 1350 watt. Keywords-birdcage, fixtures, gang drill, jig, small business Abstrak-Makalah ini membahas mengenai rekayasa prototipe gang drill dengan jig & fixturenya, untuk mengatasi salah satu permasalahan yang ada di UKM sangkar burung, di dalam proses pembuatan sangkar burung, perlu adanya penerapan teknologi tepat guna yang berupa satu unit mesin gang drill dengan jig & fixturenya yang mampu membuat lubang yang banyak, dengan jarak dan kelurusan yang sama secara cepat, sehingga produksi UKM sangkar burung dapat ditingkatkan. Pengembangan metode perancangan dan modifikasi fixture dengan pendekatan varian pada modular fixture berbasis dowel pin juga bisa memudahkan dalam perancangan fixture. Sofware CAD CAM dapat digunakan sebagai metode sintesis fixture termasuk analisis geometri, perencanaan dan perakitan fixture secara 3 dimensi dengan cepat. Mesin gang drill dengan jig & fixture, hasil rekayasa dapat bekerja dengan baik dan berdasarkan hasil pengujian makin tinggi putaran motor, maka makin besar daya yang dibutuhkan, untuk bahan kayu jati pada putaran 250 rpm, daya yang dibutuhkan sebesar 26,5 W dan pada putaran 600 rpm daya yang dibutuhkan 600 W. Juga kebutuhan daya pada proses drilling, juga tergantung jenis bahan yang akan diporoses, makin tinggi harga sifat mekanik bahan, maka kebutuhan daya untuk proses drilling makin besar. Kebutuhan daya untuk proses drilling pada bahan kayu jati dengan putaran motor 400 rpm sebesar 43,6 W, sedangkan untuk bahan besi tuang dengan putaran motor 400 rpm sebesar 569,7 W. Kebutuhan waktu dan daya dalam pembuatan 5 luban...

Development of a Drilling Machine for an Asymmetric Element with Multiple Holes

“…The functional analysis steps and its tools are given in [3,6] and is shown in fig. 1 The analysis of multispindle drilling machines shows that the most of technical application use the multispindle head [3] or gang drilling machine [2] to solve simultaneously execution of multiple holes. The drilling arrangements discussed above are suitable for symmetric elements where the manufacturing cost is reduced.…”