In the high-stakes world of sealface manufacturing, where precision and reliability are paramount, a groundbreaking study led by Riona Ihsan Media from Politeknik Manufaktur Bandung has shed new light on optimizing critical components in the powder metallurgy process. The research, published in Metal: Jurnal Sistem Mekanik dan Termal, focuses on the redesign of cover lower dies in the ejector compaction tool system, a component that has long been a bottleneck in the production of sealfaces. The findings could be a game-changer for the energy sector, where sealfaces play a crucial role in the efficiency and longevity of equipment.
The study began with a pressing issue: the deformation of cover lower dies after the production of just eleven sealfaces. This failure not only halted production but also raised significant concerns about the reliability and safety of the compaction tools. “We realized that the current design was not up to the task,” explains Riona Ihsan Media. “The existing materials and design parameters were insufficient to withstand the stresses involved in the compaction process.”
To tackle this challenge, the research team employed the Pahl & Beitz design methodology, a rigorous approach that combines theoretical analysis with practical observations. The team conducted extensive discussions with previous researchers, meticulously observed existing tools, and even disassembled current tools to understand their limitations. The culmination of this effort was a series of simulation analyses that delved deep into the static properties of the cover lower dies, focusing on stress, deflection, and safety factor values.
The results were clear: the existing design was not robust enough. The team identified several key areas for improvement, including the material used, the thickness of the cover lower dies, and the number of springs and retained pins. The optimal solution, as outlined in the study, involved changing the material to AISI D2 with a hardness of 62 HRC, increasing the thickness of the cover lower dies by 13mm, and doubling the number of springs and retained pins from 2 to 4 pieces. These modifications were designed to achieve a safety factor exceeding 2.00, ensuring that the redesigned ejector compaction tool system is operationally safe and reliable.
The implications of this research are far-reaching, particularly for the energy sector. Sealfaces are integral to the performance of various energy equipment, and any improvement in their production can lead to more efficient and durable machinery. “This redesign could significantly enhance the reliability and performance of sealfaces, reducing downtime and maintenance costs for energy companies,” says Ihsan Media. The study not only addresses the immediate issue of tool failure but also paves the way for future advancements in the field of powder metallurgy and compaction technology.
As the energy sector continues to evolve, the demand for high-quality, reliable components will only increase. This research, published in Metal: Jurnal Sistem Mekanik dan Termal (Mechanical and Thermal System Journal), offers a roadmap for manufacturers to optimize their production processes, ensuring that the tools they use are up to the task. The future of sealface manufacturing looks promising, with innovations like these driving the industry toward greater efficiency and reliability.
