Analysis of Design Results of Automatic Trimming Press Machine at HPDC Casting Line

Abstract

One of the manufacturing companies is engaged in aluminium casting which produces aluminium casting main products in the form of two-wheeled vehicle parts, four wheels, and several other types of machinery. One of the main products is rail rear grab, rail rear grab is a rear handle for two-wheeled vehicles, which requires high quality with a smooth surface and optimal strength. In the manufacture of rail rear grab, the previous manual trimming process posed various challenges, such as non-valuable manual work on the operator and a high product defect rate, which amounted to 9.89% in the last three months. This research aims to design and implement an automatic trimming press machine to replace the manual trimming process. The methods used include problem identification, design, tool making, testing, and tool performance analysis. The machine is designed using pneumatic and hydraulic systems controlled by a Programmable Logic Controller (PLC), allowing automatic and manual operation to improve efficiency and consistency of trimming results. The implementation results showed a decrease in the product defect rate from 9.89% to 3.34%. This decrease is due to the improvement of the trimming process from manual to automatic using an automatic trimming press machine. In addition, the use of this machine also reduces manual work on the operator, thus increasing the productivity and efficiency of the trimming process. The automatic trimming press machine proved to be an effective solution for making real grab rail.