Buku Teknik Produksi Mesin Industri Jilid 3 Kelas 12 SMK

Materi Teknik Produksi Mesin Industri Jilid 3

KATA SAMBUTAN ...................................................................... iii
KATA PENGANTAR ................................................................... iv
DAFTAR ISI ................................................................................. v
PETA KOMPETENSI ................................................................... xii

JILID 1
BAB I M EMAHAMI DAS AR -DASAR KEJURUAN
1 . Statika dan Tegangan .............................................................................. 1
1.1 Statika ................................................................................................. 1
1.2 Tegangan ............................................................................................ 9
2. Mengenal Komponen/Elemen Mesin ................................................ 1 4
2.1 Poros ................................................................................................ 1 4
3. Mengenal Material dan Mineral .......................................................... 2 0
3.1 Berbagai Macam Sifat Logam ...................................................... 2 0
3.2 Mineral ............................................................................................. 2 1
3.3 Berbagai Jenis Sumber Daya Mineral ........................................ 2 2
3.4 Pemurnian Mineral ......................................................................... 2 2
4 . Rangkuman ............................................................................................. 2 5

BAB II MEM AHAMI PROSES-PROSES DASAR KEJURUAN .... 29
1. Menge nal Proses Pengecoran Logam ............................................. 2 9
1.1 Pengertian ....................................................................................... 2 9
1.2 Pembuatan Cetakan Manual ........................................................ 3 0
1.3 Pengolahan pas ir Cetak ................................................................ 3 2
1.4 Pengecoran Cetakan Ekspandable
(Ekspandable Mold Casting)..................................................... 3 2
1.5 Pengecoran dengan Gips ............................................................. 3 3
1.6 Pengecoran dengan Pasir ( Sand Casting) ................................ 3 3
1.7 Pengecoran dengan Gips ( Plaster Casting) ................................ 3 4
1.8 Pengecoran dengan Gips, Beton, atau Plastik Resin............................................................................................... 3 5
1.9 Pengecoran Sentrifugal ( Centrifugal Casting)............................. 3 5
1.10 Die Casting ........................................................................................ 3 6
1.11 Kecepatan Pendinginan .................................................................. 3 8
2. Mengenal Proses Pembentukan Logam ......................................... 3 9
2.1 Pengolahan Logam ( Metal Working) .......................................... 3 9
3. Mengenal Proses Mesin Konversi Energi ....................................... 4 3
3.1 Pengertian Energi ........................................................................... 4 3
3.2 Macam -Macam Energi .................................................................. 4 4
3.3 Klasifikasi Mesin Konversi Energi ................................................ 4 7
4 . Rangkuman ............................................................................................... 5 1
5. Tes Formatif .............................................................................................. 5 1

BAB III MEREALISASIKAN KERJA AMAN BAGI MANUSIA, ALAT
DAN LINGKUNGAN
1 . Mengenal Regulasi K3 ......................................................................... 5 5
1.1 Pengertian ......................................................................................... 5 5
1.2 Sasaran Undang- Undang............................................................... 5 5
1.3 Tugas dan T anggung Jawab Perusahaan ................................... 5 6
1.4 Tugas dan Tanggung Jawab Pegawai ......................................... 5 6
1.5 Komite Keselamatan dan Kesehatan Kerja ................................. 5 7
2. Menguasai Prosedur Penerapan K3 ................................................... 5 7
2.1 Simbol Keselamatan Kerja .............................................................. 5 7
3. Menerapkan Prosedur K3 Secara Tepat dan Benar ....................... 6 0
3.1 Tanggungjawab Perusahaan pada Lingkungan Kerja................................................................................................ 6 0
3.2 Rehabilitasi ........................................................................................ 6 1
4 . Rangkuman ............................................................................................... 6 2

BAB I V GAMBAR TEKNIK
1 . Mengenal Alat Menggambar Teknik .................................................. 6 5 1.1 Kertas Gambar ............................................................................. 6 5
1.2 P e n s il Gambar ................................................................................ 6 6
1.3 Rapido .............................................................................................. 6 7
1.4 Penggaris ........................................................................\
................. 6 8
1.5 Jangka ........................................................................\
...................... 6 9
1.6 Penghapus dan alat Pelindung Penghapus ............................... 7 0
1.7 Alat-alat Penunjang Lainnya ........................................................ 7 1
1.8 Meja Gambar ........................................................................\
.......... 7 2
1.9 Mesin Gambar ........................................................................\
........ 7 3
2. Lembar Kerja ........................................................................\
.................... 7 4
2.1 Alat ........................................................................\
............................ 7 4
2.2 Bahan ........................................................................\
....................... 7 4
2.3 Kesehatan d an Ke selamatan Kerja............................................... 7 4
2.4 Langkah Kerja ........................................................................\
........... 7 4
3. Membaca Gambar Teknik ....................................................................... 7 5
3.1 Proyeksi Piktorial ........................................................................\
.... 7 5
3.2 Proyeksi Isometris ........................................................................\
.. 7 5
3.3 Proyeksi Dimentris ........................................................................\
.. 7 8
3.4 Proyeksi Miring (Sejajar) ............................................................... 7 9
3.5 Gambar Perspektif ........................................................................\
. 7 9
3.6 Macam -macam Pandangan ............................................................ 8 1
3.7 Bidang -B idang Proyeksi.................................................................. 8 1
3.8 Simbol Proyeksi dan Anak Panah ................................................. 8 6
3.9 Penentuan Pandangan .................................................................... 8 7
3.10 Gambar Potongan ........................................................................\
.... 9 2
3.11 Garis Arsiran ........................................................................\
........... 1 0 2
3.12 Ukuran pada Gambar Kerja .......................................................... 1 0 5
3.13 Penulisan Angka Ukuran ............................................................... 1 0 8
3.14 Pengukuran Ketebalan .................................................................. 1 1 3
3.15 Toleransi ........................................................................\
.................. 1 2 3
3.16 Suaian ........................................................................\
...................... 1 2 8
4 . Rangkuman ........................................................................\
....................... 1 3 0
5. Soal Latihan (tes formatif) ..................................................................... 1 3 5

BAB V PROSES PRODUKSI DENGAN PE
RKAKAS TANGAN
1. Kerja Bangku........................................................................\
.................. 1 3 7
1.1 Mengikir ........................................................................\
................. 1 3 7
1.2 Melukis ........................................................................\
................... 1 5 0
1.3 Mengebor ........................................................................\
.............. 1 6 9
1.4 Mereamer ........................................................................\
............... 1 7 7
1.5 Menggergaji ........................................................................\
.......... 1 7 9
1.6 Memahat ........................................................................\
................. 1 8 4
1.7 Menyetempel ........................................................................\
........ 1 9 0
1.8 Mengetap dan Menyenei ............................................................ 1 9 2
1.9 Menyekerap ........................................................................\
........... 1 9 7
1.10 Menggerinda ........................................................................\
......... 1 9 9
2. Kerja Pelat ........................................................................\
........................ 2 0 8
2.1 Membengkok, melipat, dan menekuk........................................ 2 0 8
2.2 Menyambung ........................................................................\
........ 2 1 1
3. Lembar Pekerjaan ........................................................................\
........... 2 1 5
3.1 Alas penindih kertas .................................................................... 2 1 5
3.2 Mal mata bor........................................................................\
.......... 2 1 6
3.3 Pengepasan Persegi .................................................................... 2 1 7
3.4 Pengepasan Ekor Burung ............................................................. 2 1 8
3.5 Kotak ........................................................................\
........................ 2 1 9
3.6 Pengasahan penitik,penggores,pahat tangan dan mata bor..220
4 . Rangkuman ........................................................................\
....................... 2 2 2
5. Tes Formatif ........................................................................\
.................... 2 2 4
5.1 Soal-soal ........................................................................\
................. 2 2 4
5.2 Kunci Jawaban ........................................................................\
....... 2 2 4

JILID 2
BAB VI PROSES PRODUKSI DENGAN MESIN
KONVENSIONAL
1. Mesin Bubut Konvensional ................................................................... 2 2 7
1.1 Pengertian Mesin Bubut Konvensional .................................... 2 2 7
1.2 Fungsi Mesin Bubut Konvensional ............................................ 2 2 7
1.3 Jenis - jenis Mesin Bubut Konvensional ..................................... 2 2 9
1.4 Bagian - bagian Utama Mesin Bubut
Konvensional (Biasa) ................................................................... 2 3 8
1.5 Dimensi Utama Mesin Bubut ....................................................... 2 4 6
1.6 Perbedaan Mesin Bubut Konvensional dengan C N C ........................................................................\
.......................... 2 4 7
1.7 Alat Kelengkapan Mesin Bubut .................................................... 2 4 7
1.8 Alat potong ........................................................................\
.............. 2 5 3
1.9 Kecepatan Potong (Cutting Speed ) ............................................ 2 6 0
1.10 Waktu Pengerjaan ........................................................................\
. 2 6 2
1.11 Cara Membubut ........................................................................\
...... 2 6 5
1.12 Tes Formatif........................................................................\
............ 2 7 6
2 . Mesin Frais Konvensional ...................................................................... 2 7 8 2.1 Pengertian ........................................................................\
............. 2 7 8
2.2 Jenis - jenis Mesin Frais ................................................................ 2 8 0
2.3 Alat-alat Potong (cutter) Mesin Frais ........................................ 2 8 6
2.4 Jenis - jenis Bahan Pisau ............................................................... 2 9 4
2.5 Perlengkapan Mesin Frais .......................................................... 2 9 5
2.6 Penggunaan Kepala Pembagi (Dividing Head) ....................... 3 0 0
2.7 Penggunaan Rotary Table ......................................................... 3 0 1
2.8 Kecepatan Potong (Cutting Speed ) ........................................... 3 0 1
2.9 Waktu Pengerjaan ....................................................................... 3 0 3
2.10 Langkah- langkah pengoperasian Mesin Frais ........................ 3 0 5
2.11 Jenis - jenis Pemotongan/pemakanan pada Mesin Frais .......... 3 0 6
2.12 Pisau Roda Gigi ( Gear Cutters)................................................... 3 2 0
3. Teknik Pengukuran pada Proses Produksi ...................................... 3 3 1
3.1 Jenis Pengukuran ........................................................................\
3 3 1
3.2 Metode Pengukuran .................................................................... 3 3 1
3.3 Alat Ukur Mistar Geser (Vernier Caliper) dan Mikrometer Luar
(Outside Micrometer) .................................................................. 3 3 2
4. Pembacaan Toleransi pada Gambar Kerja ......................................... 3 3 7
4.1 Pengkodean Toleransi .................................................................. 3 3 7
5. Keselamatan Kerja Pada Saat Proses Produksi ................................ 3 4 5
5.1 Peralatan Keselamatan Kerja pada Proses P r o d u k s i........................................................................\
................... 3 4 5
5.2 Resiko-resiko dalam mengoperasikan mesin perkakas dan cara menghindarinya ........................................................................\
...... 3 4 6
6 . Rangkuman ........................................................................\
......................... 3 5 0

BAB VII PRO SES PRODUKSI BERBASIS KOMPUTER
1.Computer Aided Design (CAD)............................................................ 3 5 3
1.1 Pengertian CAD ........................................................................\
..... 3 4 9
1.2 Cara Kerja ........................................................................\
............... 3 5 4
1.3 Sistem Koordinat Absolut, Relatif, Polar .................................... 3 5 4
1.4 Perintah Menggambar Pada AutoCAD ...................................... 3 5 6
1.5 Membuat Gambar Solid 3D dengan AutoCAD .......................... 3 8 6
2. Computer Numerically Controlled ( CNC).......................................... 4 0 2
2.1 Sejarah Mesin CNC ....................................................................... 4 0 2
2.2 Dasar-dasar Pemrograman Mesin CNC .................................... 4 0 5
2.3 Gerakan Sumbu Utama pada Mesin CNC ................................. 4 0 9
2.4 Standarisasi Pemrograman Mesin Perkakas
C N C ........................................................................\
.......................... 4 0 9
2.5 Siklus Pemrograman ..................................................................... 4 2 1
2.6 Menentukan titik koordinat benda Kerja ..................................... 4 2 8
2.7 Kecepatan Potong dan Kecepatan Asutan ................................ 4 3 3
2.8 Mengoperasikan mesin CNC EMCO TU 2A .............................. 4 3 4
2.9 Membuat Benda Kerja Menggunakan mesin C N C ........................................................................\
.......................... 4 3 6
2.10 Membuat Benda Kerja Berbasis Software
AutoCAD ........................................................................\
.................. 4 4 2
2.11 Soal Formatif ........................................................................\
........... 4 4 3
3. EDM ( Electrical Discharge Machining) .............................................. 4 6 5
3.1 EDM Konvensional ...................................................................... 3 6 6
3.2 Pembuatan alat cetak logam (coinage de making) ........................................................................\
.................. 4 6 6
3.3 Drilling EDM ........................................................................\
............ 4 6 7
3.4 Kabel EDM (Wire Cut EDM) ......................................................... 4 6 7
4 . Rangkuman ........................................................................\
....................... 4 6 8
ix

JILID 3
BAB VIII SISTEM PNEUMATIK DAN HYDROLIK
1 . P e ngertian Pneumatik .......................................................................\
.... 4 6 9
2. Karakteristik Udara Kempa .................................................................. 4 6 9
3. Aplikasi Penggunaan Pneumatik ....................................................... 4 6 9
4 . Efektifitas Pneumatik ........................................................................\
.... 4 7 0
5. Keuntungan dan Kerugian Pe nggunaan Udara Kempa ............... 4 7 1
5.1 Keuntungan ........................................................................\
........... 4 7 1
5.2 Kerugian/Kelemahan Pneumatik ............................................... 4 7 2
6. Klasifikasi Sistim Pneumatik ............................................................... 4 7 3
7. Peralatan Sistem Pneumatik ............................................................... 4 7 4
7.1 Kompressor (Pembangkit Udara Kempa) ................................ 4 7 4
7.2 Unit Pengolahan Udara Bertekanan ( Air Service
Unit ) ........................................................................\
........................ 4 8 0
7.3 Pemeriksaan Udara Kempa dan Peralatan ............................. 4 8 4
7.4 Konduktor dan Konektor ............................................................. 4 8 5
7.5 Katup-Katup Pneum atik .............................................................. 4 8 7
7.6 Unit Penggerak (Working Element = Aktuator ) ....................... 4 9 3
7.7 Air Motor ( Motor Pneumatik) ...................................................... 4 9 6
7.8 Jenis -J enis Katup Pneumatik ..................................................... 4 9 7
7.9 Model Pengikat ( Type if Mounting)........................................... 5 0 9
8 . Sistem Kontrol Pneumatik ................................................................... 5 1 0
8.1 Pengertia n Sistem Kontrol P neumatik ...................................... 5 1 0
9. Dasar Perhitungan Pneumatik ............................................................ 5 1 1
9.1 Tekanan Udara ........................................................................\
..... 5 1 3
9.2 Analisa Aliran Fluida (V) ............................................................. 5 1 4
9.3 Kecepatan Torak ........................................................................\
.. 5 1 4
9.4 Gaya Torak (F) ........................................................................\
..... 5 1 5
9.5 Udara yang Diperlukan ............................................................... 5 1 5
9.6 Perhitungan Daya Kompressor ................................................. 5 1 6
9.7 Pengubahan Te kanan ................................................................. 5 1 6
10. Analisis Kerja Sis tem Pneumatik ....................................................... 5 1 7
10.1 Pengendalian L angsung Silinder Sederhana .......................... 5 1 7
10.2 Pengendalian Tak Langsung Silinder Penggerak
Ganda ........................................................................\
.................... 5 1 8
10.3 Pengendalian Gerak Otomatis Silinder Penggerak Ganda........................................................................\
.................... 5 2 0
11. Aplikasi Pneum atik dalam Pro ses Produksi ................................... 5 2 1
11.1 Pintu Bus ........................................................................\
................ 5 2 1
11.2 Penahan/Penjepit Benda (ragum) .............................................. 5 3 5
11.3 Pemotong Plat ........................................................................\
..... 5 3 5
11.4 Membuat Profil Plat ..................................................................... 5 3 5
11.5 Pengangkat dan Penggeser Benda .......................................... 5 3 6
12. Pengangkat dan Penggeser Material Full Pneumatik ................... 5 3 7
12.1 Cara Kerja ........................................................................\
............... 5 3 7
13. Tes Formatif ........................................................................\
..................... 5 3 8
13.1 Soal-soal ........................................................................\
................ 5 3 8
13.2 Kunci Jawaban ........................................................................\
..... 5 3 8
14. System Hidrolik ........................................................................\
................. 5 4 1
14.1 Cairan Hidrolik ........................................................................\
........ 5 4 1
14.2 Komponen Hidrolik ........................................................................\
. 5 5 1
15. Pengendalian Hidrolik ........................................................................\
..... 5 5 5
15.1 Klasifikasi Pengendalian Hidrolik ................................................ 5 5 5
15.2 Katup Pengatur Tekanan ..............................................................
5 5 6
x
16. Dasar-Dasar Perhitungan Hydrolik .................................................... 5 5 6
1 6 .1 Prinsip Hukum Pascal ................................................................. 5 5 6
16.2 Perhitungan Kecepatan Torak ................................................... 5 5 8
16.3 Pemeliharaan Cairan Hydrolik ................................................... 5 5 9
1 6 .4 Pompa Rod a Gigi dalam Tipe Crescent ................................... 5 6 1
16.5 Pompa Roda Gigi dalam Tipe Geretor ..................................... 5 6 1
16.6 Balanced Vane (Pompa Kipas Balanced) ................................ 5 6 2
16.7 Pompa Torak Radial ( Radial Piston Pump) ............................. 5 6 3
16.8 Bent Axis Piston (Pompa Torak dengan Poros
Tekuk) ........................................................................\
.................... 5 6 3
16.9 Instalasi Pompa Hidrolik ............................................................. 5 6 4
16.10 Pengetes an Efesiensi Pompa Hidrolik ...................................... 5 6 6
16.11 Unit Pengatur ( Control Element) ............................................... 5 6 7
17. Soal Formatif ........................................................................\
..................... 5 6 8
17.1 Soal-soal ........................................................................\
.................. 5 6 8
17.2 Kunci jawaban ........................................................................\
........ 5 6 8
1 8 . Rangkuman ........................................................................\
........................ 5 7 0
BAB IX PROSES PRODUKSI INDUST RI MODERN
1. Sejarah Perkembangan Otomasi Industri ........................................ 5 7 3
2. Otomasi Teknik Produksi ..................................................................... 5 7 5
3. PLC ( Progr ammable Logic Controller ) ............................................ 5 7 7
3.1 Sejarah PLC ........................................................................\
.......... 5 7 7
3.2 Pengenalan Dasar PLC .............................................................. 5 7 8
3.3 Ins truksi-instruksi Dasar PLC ..................................................... 5 8 0
3.4 Device Masukan ........................................................................\
... 5 8 5
3.5 Modul Masukan ........................................................................\
.... 5 8 6
3.6 Device Masukan Program .......................................................... 5 8 7
3.7 Device Keluaran ........................................................................\
... 5 8 8
3.8 Modul Keluaran ........................................................................\
.... 5 8 9
3.9 Perangkat Lunak PLC ................................................................. 5 8 9
3.10 Perangkat Keras PLC .................................................................. 5 8 9
3.11 Ladder Logic ........................................................................\
......... 5 9 0
3.12 Hubungan Input/Output (I/O) dengan Perangkat
Lunak ........................................................................\
...................... 5 9 0
3.13 Processor ........................................................................\
.............. 5 9 1
3.14 Data dan Memory PLC ................................................................ 5 9 3
3.15 Program m an Dasar PLC OMRON dengan Komputer........................................................................\
................ 5 9 6
3.16 Cara pengoperasian SYSWIN ................................................... 5 9 6
3.17 Penggunaan Fungsi Bit Kontrol ................................................. 6 0 2
3.18 Contoh Aplikasi dan Pembuatan Diagram Ladder
Menggunakan Syswin ................................................................... 6 0 5
4 . Rangkuman ........................................................................\
....................... 6 1 6
BAB X TEKNOLOGI ROBOT
1. Pengenalan Robot ........................................................................\
......... 6 1 9
1.1 Istilah Robot ........................................................................\
.......... 6 2 0
1.2 Komponen Dasar ........................................................................\
. 6 2 1
1.3 Gerakan Robot ........................................................................\
..... 6 2 5
1.4 Tingkatan Teknologi .................................................................... 6 2 7
2. Operasi dan Fitur Manipulator ........................................................... 6 2 9
2.1 Sistem Koordinat Lengan Robot (Arm Geometry) ........................................................................\
.... 6 2 9
xi
2 .2 Rotasi Wrist ........................................................................\
........... 6 3 4
2.3 Sistem Penggerak Manipulator ................................................. 6 3 4
2.4 Jangkauan Kerja ........................................................................\
.. 6 3 5
3. Aplikasi Robot ........................................................................\
................ 6 3 7
3.1 Penanganan Material .................................................................. 6 3 8
3.2 Perakita n ........................................................................\
............... 6 4 0
3.3 Pengecatan ........................................................................\
........... 6 4 0
3.4 Pengelasan ........................................................................\
........... 6 4 2
4 . Efektor ........................................................................\
.............................. 6 4 3 4.1 Gripper ........................................................................\
................... 6 4 3
4.2 Klasifikasi Gripper........................................................................\
6 4 4
4.3 Jenis Gripper ........................................................................\
........ 6 4 4
4.4 Sensor dan Tranduser ................................................................ 6 4 7
4.5 Sensor Kontak .......................................................................\
....... 6 4 8
4.6 Sensor Non -Kontak ..................................................................... 6 4 8
4.7 Sensor Gaya dan Momen ........................................................... 6 5 1
4.8 Sensor Temperatur ...................................................................... 6 5 2
4.9 Sensor Cair dan Gas ................................................................... 6 5 5
4.10 Sensor Jarak dan Sudut ............................................................. 6 5 7
4.11 Linear Position .............................................................................. 6 5 8
4.12 Sensor Kimia ................................................................................ 6 5 9
5. Ak tuator .................................................................................................... 6 6 0
5.1 Selenoids ....................................................................................... 6 6 0
5.2 Katup .............................................................................................. 6 6 1
5.3 Silinders ......................................................................................... 6 6 1
5.4 Motor Listrik .................................................................................. 6 6 2
6. Tes Formatif .............................................................................................. 6 6 6
7 . Rangkuman ............................................................................................... 6 6 9

BAB XI PENUTUP
1. Kesim pulan............................................................................................. 6 7 1
2. Saran ......................................................................................................... 6 7 4

LAMPIRAN A. DAFTAR PUSTAKA
LAMPIRAN B. DAFTAR TABEL
LAMPIRAN C. DAFTAR GAMBAR
LAMPIRAN D. GLOSARIUM
LAMPIRAN E. INDEX