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The objective of the research was to propose a 90 degree steering mechanism system. The application of this steering system can be implemented on off-road cars, military vehicles, and city cars. The advantage of the systems is its flexibility in movement. Therefore, the vehicle will have high degree of moving in any direction. The mechanism was designed in 2D and 3D model. Subsequently, the components were joined in assembly and the kinematic simulation was done by using CATIA. Clash detection among the components was carried out in assembly workbench of CATIA. The results of this study will help the automotive industries to develop a real 90 degree steering system. All components were completely designed in 3D solid by using CATIA. Furthermore, the clash among the component in the product assembly could be eliminated by part editing. In the final assembly, none of the clash was detected.

The objective of the research is to design truck frame of 120 PS series. The method used in the research is reverse engineering, by re-designing the existing frames and taking its measurements. The measurement results are then used to design a frame in the CATIA V5 software. After the modeling, it will obtain the three-dimensional design in solid form. Static analysis was then performed to see the truck’s frame strength under the static load. The given loads vary from 8, 10, 12, and 16 ton. Based on the load, the maximum Von Mises stress results are 1.37 x 107 N/m2, 1.98 x 107 N/m2, 2.37 x 107 N/m2 and 3.16 x 107 N/m2 respectively. The maximum stress condition is still in the safe category based on comparison with the yield stress of steel material used of 2.5 x 108 N/m2. While the maximum strain that occurred at each loading was 0.025 mm, 0.0832 mm, 0.0999 mm and 0.133 mm, respectively.

Dissimilar welding of aluminum is an innovation used to increase the effectiveness and efficiency in making a product or component. It has been applied on the automotive industry, aerospace, and shipbuilding. Aluminum has low weldability in compared with steel material because of the oxide layer on the surface of aluminum. The welding problems of aluminum can be overcome by using a solid state welding such as friction stir welding (FSW). The objective of this study was to determine the strength of the welding joint and the microstructure of dissimilar welding joint with different series of aluminum. The tensile testing was performed with the weld directions of 0° and 45° to assess the formability, hardness testing, and microstructure of FSW. In this study, welding process was conducted to combine aluminum 1100 series (low strength aluminum) and aluminum 6061-T6 series (high strength aluminum) in the 2 mm thickness of aluminum sheet. The analysis was done by making comparison of the strength between dissimilar and similar aluminum series. The results showed that the dissimilar weld types, both in angle orientation of 0° and of 45° had fracture location on the HAZ area of 1100 aluminum series. The highest results of tensile strength were 78.07 MPa and 75.26 MPa for weld angle orientation of 0° and 45°, respectively. Weld angle orientation had significant effect to the strain where value of the welding direction of 0° was 10.99% and of 45° was 13.8%. Hardness test in the weld zone generated diverse values because the material stirring was not homogenous, whereas the similar welding was more stable in the welding area. Microstructure investigation on the dissimilar aluminum welding found a hook defects in the weld nugget. In the HAZ area, the grain size of 6061-T6 increased while of 1100 material decreased. It might be affected by the temperature and the aluminum characteristic. Meanwhile, in weld nugget, the grain size increased due to the stirring tool joint and heating during the welding process.

The objective of the research is to design the outer rear door of Esemka Rajawali 2 by using reverse engineering method. Esemka car is one of the national cars being developed in Indonesia. Esemka Rajawali 2 has a Sports Utility Vehicle (SUV) model with 1.6L engine version, 1,597 cc inline DOHC. Reverse engineering method is used to obtain geometry data from the existing products and to reconstruct into three-dimensional drawing model. The three-dimensional model is used to design the mold or dies. Dies design is done by using CATIA V5 software. The process of die making plays an important role because it will be produced with a variety of car body components with particular desired shape. Design of a car body consists of various models, shapes, and construction. After the mold designs are completed, static analysis was done to determine the stresses that occur in the mold. This research has succeeded in modeling a three-dimensional model of the rear door using reverse engineering method. The dies design was successfully created using CATIA V5 software. From the static analysis results, by employing a maximum load of 50,000 N, the mold is still in a safe condition based on the yield stress of the used material.

In commercial aerospace development, feasibility accidents design or crashworthiness is a major concern in aviation safety. Fuselage structure plays an important role in absorbing energy during an accident. The research aims are to determine drop test phenomenon on the fuselage, to investigate deformation occurred in the structure of the fuselage, and to know the influence of the airframe falls position to the stress strain which occurred in the structure of the fuselage. This research was conducted by varying the fall angle of the fuselage in a vertical position or 0° and 15°. Fuselage design was modeled by using SolidWorks. Then the model is imported to the Abaqus for drop test simulation. From the simulation results, it can be obtained the phenomenon of deformation on the structure of the fuselage when it comes in contact with the rigid ground. The high deformation occurs shows the structure capabilities in order to absorb the impact. It could be happened because the deformation is influenced by intern...