Perancangan dan Optimasi Posisi Clamp pada Jig Welding untuk Mengurangi Distorsi Pengelasan Mounting Yamaha Aerox Menggunakan Simulasi CAE

Abstract

Welding process on the Yamaha Aerox mounting component is susceptible to distortion due to uneven heating and cooling, which directly affects dimensional accuracy and final product quality. Without proper control mechanisms, welded components often fail to meet predetermined dimensional specifications, making the design of a welding jig with optimal clamp positions a critical solution. This study aims to design a welding jig and optimize clamp positions to minimize welding distortion on the Yamaha Aerox mounting component. The main contribution of this research lies in the application of CAE simulation that systematically analyzes clamp position sensitivity for a specific motorcycle mounting component geometry, an approach not previously reported in existing literature. The research was conducted systematically, encompassing literature review, CAD-based welding jig design, development of four clamp configuration variants, and CAE/FEM simulation to analyze temperature distribution, Von Mises stress, and maximum deformation values for each variant. The material used was grey iron cast (JIS G5501) with welding parameters kept constant across all simulation variants. Simulation results show that Variant C with six symmetrically distributed clamp points produced the lowest maximum deformation of 0.873 MPa and Von Mises stress of 43 MPa. Variant A recorded the highest deformation at 1.693 MPa, while Variants B and D were intermediate at 1.223 MPa and 1.308 MPa respectively. A convergence rate of 0.388% for Variant C confirms the reliability and stability of the simulation results. Variant C is proven to be the most optimal clamp configuration and is recommended for implementation in the Yamaha Aerox mounting component welding process.