I. Made Londen Batan

Three Wheel Bike as Physical Therapy Equipment for Post-Stroke Patient

Three wheel bike as a physical therapy equipment for post-stroke patients was designed with length of 1937 mm, 1010 mm in width and height of 905 mm. The bike is designd ergonomic and can be driven by rider foot or hand simultaneously. By using CATIA software the strength of material bike frame was analyst to support 100 kg of load. The design is realized into a prototype. The performance of bike prototype is tested, and the result sows that the function of bike mechanisme is fulfilled. By 10 respondents, who have a standard body mass index, the pedal test was conducted, and the result indicates that, the higher the speed of the pedal, the higher the energy consumption to pedaling. Leg tension muscles is measured by leg-dynamometer before and after pedaling, and the result shows the tension muscle is proportional to the increase of pedal speed. In order to evaluate the ergonomic aspect of bike design, the risk angle of extrem position of body during cycling are measured by goneo-set. By RULA method the risk of injury value of rider body is calculated while pedaling, and the result showed that 70% of respondents have a value of risk injury 2, while 30% had a value of 3. It means that, the bike design is ergonomic and comfortable to ride. In oder to evaluate the benefits of disigned bike, the pedal test is conducted by 4 post-stroke patients for 30 days periodical once every 3 days. The result shows that during 1 month exercise, the average number of cycling to pedal increase up to 100%. This means that the ability of post-stroke patients to pedal the bike increase significantly. That result showed that the bike design is useful as a tool for physical therapy post-stroke patients.

Simulation of Semi-Active the Blank Holder Force Control to Prevent Wrinkling and Cracking in Deep Drawing Process

This paper presents simulation of drawing force and thickness deformation in deep drawing which employs semi-active blank holder force system, to solve the problem of cracking and wrinkling. The method of slab with feed back control failure criteria, was employed to make the modeling system and the semi-active blank holder to prevent wrinkling and cracking in forming low carbon steel sheet, without lubrication (μ=0.4). In this study, the mechanical properties of the material were chosen since that they equivalent to those of low carbon steel with its thickness of 0.2 mm, k = 572 N/mm2, UTS = 391 N/mm2, yield stress = 309 N/mm2 and n = 0.2. The diameter and the depth of the cylindrical cup-shaped product were 40 mm and 10 mm, respectively. Results from simulation have shown that the semi-active blank holder system can control very responsive against changing of deformation condition. The optimum of initial blank holder force is approximately 3000 N up to 4000 N. In the early stages (initial stroke), blank holder force system could be responsive to prevent cracking, and at the end of the punch stroke, it is very effective to prevent wrinkling. Simulation of semi-active blank holder force control system is excellent in model formation to prevent cracking and wrinkling.

Ironing force modeling analysis on aluminum cup using CATIA V5

Wall-ironing is a metal forming process to reduce the wall thickness and increase the cup length. Ironing is a bulk forming process where the deformation force (tensile force) must be absorbed by the cup wall which is deformed. In the ironing process, the thickness reduction ratio or TRR is an important factor. If TRR is low to achieve the desired thickness, the process should be carried out several times. The greater the TRR, the more increased tensile force resulting in a larger stress. If the stress in the formed cup wall exceeds the tensile strength of the cup material, the base is torn off. This stress must be between the yield and the ultimate stress of the material. The die angle also affects the ironing force. This research is using CATIA software in order to get the die angle, TRR, and ironing force relationship.In this study, the products used are deep-drawn aluminum cup 37 mm of outer-diameter, 32 mm inner-diameter, 20 mm height, and 2.5 mm wall thickness. Outer wall thickness is reduced with varying TRR of 30%, 20% and 10%. Reducing process is done through ironing force on punch (punch force) inside the cup, whereas outer wall of cup is reduced through die ring with various die angle 5°, 10°, 15°, 20°, 25°, and 30°. By using CATIA modeling and stress analysis simulation, we can obtain stress (Von Misses stress) that occur on cup wall.The results of varying ironing force modeling simulation with 30%, 20%, 10% of TRR and 5°, 10°, 15°, 20°, 25°, 30° of die angle, can be obtained the occuring Von Misses stress. Based on this stress, the most optimal condition can be selected i.e. 30° of die angle for 30% of TRR, 15° of die angle for 20% of TRR, and 10° of die angle for 10% of TRR. Furthermore, this method can be used to analyze the research related to the press tool design on metal forming, especially the ironing with different methods.Wall-ironing is a metal forming process to reduce the wall thickness and increase the cup length. Ironing is a bulk forming process where the deformation force (tensile force) must be absorbed by the cup wall which is deformed. In the ironing process, the thickness reduction ratio or TRR is an important factor. If TRR is low to achieve the desired thickness, the process should be carried out several times. The greater the TRR, the more increased tensile force resulting in a larger stress. If the stress in the formed cup wall exceeds the tensile strength of the cup material, the base is torn off. This stress must be between the yield and the ultimate stress of the material. The die angle also affects the ironing force. This research is using CATIA software in order to get the die angle, TRR, and ironing force relationship.In this study, the products used are deep-drawn aluminum cup 37 mm of outer-diameter, 32 mm inner-diameter, 20 mm height, and 2.5 mm wall thickness. Outer wall thickness is reduced with v...

The effect of biocomposite variation composition on thermal characteristic and cross-sectional structure as alternative material plastic product

Recently, plastic product becomes an integral parts of humans daily life. Its use also varies, from vehicle parts material, electrical appliances, household appliances to medical equipment. Plastic is part of polymer which is easy processed and can be combined with another material into new composite material called Polymer Matrix Composites (PMC). Currently, PMC is made by synthetic fiber material which is less environmental friendly and very expensive. Therefore, it is necessary to find a solution to resolve the issue.

Simulation of Ironing Process for Bullet Case to Get Minimum Forming Force with Variation of Die Angle and Reduction Wall Thickness

This study described how the ironing process to manufacture 20 mm caliber bullet case. For this purpose, the first step is analyzing the process parameters, and then calculates the forces needed to make the formation of bullet case. Through the analysis of the process it is known, that the ironing process parameters most influential to the magnitude of forming force are the die angle α and the reduction of the wall thickness. In this study a simulation is conducted to determine a minimum required of forming force until the process successful. That means the required bullet case accordance with the determined specifications and geometry. The material used for bullet case caliber 20 mm is brass Cu30% Zn 70% early-shaped cup with 33.5 mm outer diameter, 3 mm thick and 37 mm high. Based on material strength calculation, the ironing force is determined with value of 50.01 kN. By using this value the maximum allowable wall reduction thickness in the ironing process is 26.7%. The simulation is carried out using finite element method on a variety of die angle such as α = 5°, 10°, 15°, 20° and 25° respectively. The simulation results show that the shell cannot through the die on each angle die. Similarly, in variation of reduction by 5%, 10%, 15%, 20% and 25%, the ironing process is also unsuccessful. However, by load of 138 kN, in the 26.7% reduction and at die angle α=5°, the ironing process to produce cylinder is successfully. Similarly by the same of wall thickness reduction, with force of 148 kN and the die angle of 10°, the ironing process is also successfully to fulfill the bullet case with a specified geometry.

A Review Paper on Product Surface Defect Detection of Ironing Process

The quality of product of manufacturing industries depends on dimension accurately and surface roughness quality. There are many types of surface defects and levels of surface roughness quality. Ironing process is one type of metal forming process, which aims to reduce the wall thickness of the cup-shaped or pipes products, thus increasing the height of the wall. Manually surface inspection procedures are very inadequate to ensure the surface in guaranteed quality. To ensure strict requirements of customers, the surface defect inspection based on image processing techniques has been found to be very effective and popular over the last two decades. The paper has been reviewed some papers based on image processing for defect detection. It has been tried to find some alternatives of useful methods for product surface defect detection of ironing process.

Image Processing Implementation in Measurement of Cross-Flow Water Turbine Geometry

Recently, many studies have been done to look for renewable energy sources such as kinetic energy from marine or fluvial currents. In its utilization, water turbine plays an important role for taking energy from water current. One of the water turbine types is Cross Flow Water Turbine (CFWT). The performance of the CFWT depends on its geometry. Unfortunately, its geometry is very difficult to be measured using conventional measurement because it has complex geometry. Hence, a non-conventional measurement system based on image processing is proposed in this study to deal with the measurement difficulty of the CFWT geometry.

Design of Multi Gender Bicycle - As an Alternative Bike Design to Fulfill Appropriate Requirement for Urban Society in Indonesia

In the present work, a multi-gender bike, which can be used by men and women, was designed. The integrated design method is used to develop a bicycle frame. As a human transportation the frame is must be light, strong, and comfortable for rider. The frame of bicycle is built with the material of aluminum alloy T-6061 and is produced as prototype for a multi gender purpose. With 100 kg load the strength of material is calculated, and the result shows that the frame critical strength is smaller than material ultimate strength. The prototype was tested by 5 respondents who have an average weight of 68.2 kg, and height 169.4 cm. Pedal test is conducted with 5 level of speed such as 6, 8, 10, 12, and 14 mph in 6 minutes of cycling respectively. The paddle energy during cycling was determined. The results show that the paddle energy increase and follow the increasing of speed. However since 10 mph of speed the paddle energy tends to be fixed with average value of 40 kcal. Therefore the tension leg muscles before and after cycling is going together by increasing the speed. The RULA method is used for determining the ergonomic of multi-gender bicycle, and the result shows that the value of risk injury is 3, that mean the developed bike is ergonomic.

The Effect of Seat Tube Angle (STA) on Muscle Tension Leg Riders

Bicycle becomes famous transportation as efforts cut greenhouse gas emission. Comfortable, less injured, and less energy are the requirement of bicycle that urban communities wanted. Seat tube angle (STA) is an angle formed between seat tube and chain stay, which has influences on the above requirement. The objective of this study is to investigate the effect of varying seat tube angle (STA) on the muscle tension leg riders during cycling. This study used changeable frame bicycle into several STA. A total five cycling trials with body mass index 21-25, were conducted at seventeen STA’s position (form 62° until 78°). Muscle tension leg was measured before and after cycling by using leg dynamometer. Oxygen consumption (VO2) and heart rate (HR) data were also collected during cycling at 6 minutes and will be converted to paddle energy. Through this study was found that muscle tension leg rider decreasing with the increasing STA. However, after STA of 66°, the muscle leg tension increasing respecively. The smallest muscle tension leg was 21,4 Kg at 66° STA. At the same position, pedal energy showed 7.148 Kcal which was the smallest result as well. From these study found, that 66° STA also had less muscle tension leg and paddle energy during cycling.

Experimental Study and Analysis of the Influence of Drawbead against Restriction and Deep Drawing Force of Rectangular Cup-Cans with Tin Plate Material

Drawbead are often used to control the flow of material, stress and deep drawing force in the flange area. This paper discussed the drawbead (fully, not fully and without drawbead) that combined with variations in the blank holder force against restriction of material flow and drawbead restriction force of deep drawing with palm oil lubrication. In this paper, analytical and experiments are used to predict the drawbead restraining and deep drawing force. The tin steel sheet with a thickness of 0.2 mm is used as speciment. The results obtained, that the application fully drawbead be very effective in controlling the flow of materials in the flange, as compared to not fully and without drawbead. In the beginning of the process (punch stroke < 4 mm), the magnitude of restraining force and deep drawing force can be increased. And, the magnitude of Radial Stress increases, conversely the magnitude of tangential stress decreased. This can prevent the occurrence optimum blank holder force is recommended in range 4394-8788 N. Comparisons of results between the analysis and experiments show the phenomenon is similar.