Corresponding Author: Ajeng
Tyas Damayanti
E-mail: [email protected]
INTRODUCTION
Usage goods made from
base plastic such as drink
bottles, cutlery, and so on the more many used. Waste plastic
is a type of waste that is difficult to decompose, so it will take hundreds of years to decompose (Karuniastuti, 2013). This causes
a number of piles of plastic waste
that could pollute the environment. Based on
data from the Ministry of Environment Life and Forestry,
the amount of rubbish in Indonesia
reached 68 million tons in 2019 (Purwaningrum, 2016). The contributor's most extensive
second waste plastic
in the ocean is Indonesia,
with a total of 187.2 million tons (Jambeck et al., 2015). Not only polluting
the environment but also processing plastic waste by burning
can endanger human health through
pollution of the air generated.
In maintenance transportation, train fire naturally needed means nor railway
infrastructure. Railway facilities are vehicles
that can move on railroads, such as locomotives,
trains, carriages, and special equipment (Rosyani & Susilo, 2011). For the facility to operate, it is necessary to infrastructure the railway, which consists
of track train fire, station
train fire, and facility train fire. Track train fire uses Street
rail with constituent components, namely rails,
bearings, ballast, sub-reply, and fasteners
(Munawwarah & Herijanto, 2020).
Bearing is a component composer railroad that
serves as a rail pedestal (Jaya, 2017). Their bearing consists of various materials, including wood,
steel, and concrete. Therefore, the
bearing must have the strength to withhold burden on. Most railway lines in
Indonesia use bearing concrete to replace bearing wood because
material wood is less, and the concrete cushion has a much longer service life than wooden
bearings.���
However, bearing concrete
is considered less elastic heavy weight, so that troublesome in process
installation, �possibility occurs damage on process transfer
or rapture. No one could dampen vibrations and noise (Purwono et al., 2017).
From the problem, the so writer researches
bearing replacement concrete with ingredient composite
made from plastic base waste. (Ramadhani, 2021) has done a study that discusses making
prototype railroad sleepers made of waste plastic HDPE (High-Density Polyethylene) and epoxy resin. This composite bearing prototype was made with the hot press molding method, which is heated at a temperature of
180oC, _ then in press with tools press hydraulic capacity 1 ton. However, after testing bending,
the prototype bearing This composite has a bending strength of 62.64 Mpa and has not met the bearing requirements composite
with standard JIS E 1203:2007, 70 MPa.
Bearings work tie rail use fastener
and receive the load from
the means that move above rail (Karim, 2013). The material used on bearing, among others wood, concrete, and steel. Wood is the material first time used on bearing
because have characteristics which suitable for withholding
burden dynamics (Zulkifli, 2021). Bearing which moment this used
that is bearing concrete.
Based on Regulation Minister
No. 60 the Year 2012 (Number, 60 CE) that bearing
concrete with wide track rail 1067 m has
technical specification dimensions as follows:
Table 1. Specification of Rail Width Bearing Dimension 1067 mm
|
Long
|
2000 mm
|
|
Maximum width
|
265 mm
|
|
Tall maximum
|
220 mm
|
Composites are objects or materials formed by combining two or more materials with different elements, and no reaction
occurs by a chemical in the mixing. A blend of composite
materials such as matrices and amplifier
or filler determines
the nature of a composite
material (Tjahjanti, 2018).
METHOD
Test several specimen tests will be carried out at the State Polytechnic of
Malang, and the types of testing conducted
that is test pull by
standard ASTM D638 and test bending with JIS
E 1203:2007 standard. In research Tasks Recently,
the manufacture of a prototype of railroad sleepers fire made from base waste plastic
HDPE use method compression
molding. Compression
molding is a method by pressing a mixture of test
specimen materials that have been heated to a temperature of 220 o C in print with a tool press hydraulic 1-ton capacity until the size desired (Mawardi, 2019). Specimen test for testing
bending made with scale
reduction standard JIS E 1203:2007 which have
size long 1400 mmm, wide 200 mmm, and tall 140 mm Becomes
1:4 that is with long 350 mmm, wide 50 mm and tall 35 mm.
Tools and materials used in this research include recycled HDPE, epoxy resin + catalyst, lubricant print or mold releases,
fiber nylon, print, tool heating
or oven electricity, glass measuring digital scales, and hydraulic
press tools. The manufacturing steps are explained in more detail as follows:
1.
Prepare tools and ingredients which will be used in the process of making specimens test.
2.
Coating or
applying for mold release on print makes
it easy to release specimen
tests on print.
3.
Prepare to recycle HDPE, nylon fiber, and resin epoxy following
calculation composition, which
has been determined.
4.
Put recycled HDPE and epoxy resin into a bowl
and mix thoroughly.
5.
Insert mixture
recycle HDPE and epoxy
resin into print.
6.
Insert nylon fiber
with a size of 350 mm into the print.
7.
Reinsert HDPE
recycle mix and resin Epoxy for
coat fiber entered the print.
8.
Give pressure
on print with use tool hydraulic press.
9.
Key Closing
print so that pressure
in print no experience change.
10.
Heat the mold
using a tool heating at 220 o C
for 1 hour to speed up the process of drying and element
the composer can be tied with perfectly.
11.
Wait for specimen until cold.
12.
Let go specimen
test from print.
The method of analyzing the data for this research is to make
several specimen tests made from base HDPE plastic
waste, nylon fiber, and epoxy resin with
the use method of compression molding. Comparison of the composition
used on study this which is equal to: recycle HDPE
60% + 5% nylon fiber + 35% epoxy and recycle HDPE
60% + fiber nylon 10% + epoxy 30%.
After the specimen is made, it will be tested with several specimens by each tester. The test used is a tensile test with standard ASTM D638 and test bending with JIS
E 1203:2007 standard to find out the natural mechanics of the specimen. After testing
several specimens, results averaged and analyzed
according to the standards used will be obtained. So that obtained
results best which following standard and could replace concrete pads.
RESULTS AND DISCUSSION
1.
Composite
Bearing Specimen Manufacturing
Composite bearing test specimens are fabricated with the use
method of compression molding. The compression
molding method used in This
research includes the composition, which consists of recycled waste plastic HDPE, fiber
nylon, and resin epoxy
in print which is
then pressed using a press tool hydraulics. After in
press,
print the heated at 220o C for one hour
so that composition could be perfect
and speed up the drying specimen
test-bearing composite
process. The following is the
process of making test specimens for composite railroad sleepers made from recycled waste plastic HDPE, fiber nylon,
and resin epoxy.
Calculation of composition (volume fraction) in making specimen test bearing composite
rail the train is the first
step that must be done to produce test specimens that desired.
On study this use 2 variation comparison composition that is recycle HDPE 60% + nylon fiber 5% + epoxy 35% and recycle HDPE
60% + fiber nylon 10% + epoxy 30%.
The following composition will be used to manufacture
railroad-bearing specimens composite,
as seen in table 4.
Table
2. Specification of Rail Width Bearing Dimensions 1067 mm
|
Composition
|
HDPE 60% + nylon fiber 5% + epoxy 35%
|
HDPE 60% + 10% nylon fiber + epoxy 30%
|
|
Recycle
HDPE
|
357.2 grams
|
357.2 grams
|
|
Fiber
|
35.5 grams
|
71.05 grams
|
|
resin
|
214.4 ml
|
183.75 ml
|
If data calculation composition has been obtained, then the process of making
specimens is carried out with steps as follows:
1.
Prepare tools and ingredients which will be used in the process of making specimens test.
2.
Coating or smear mold is released equally with the use
kit as a lubricant on print and closed
print to make it easy to release specimen
tests from the mold.
3.
Prepare to recycle HDPE
with a composition of 60 % on every variation composition of 357.2 grams.
4.
I am weighing
a nylon fiber with a length of 35 cm which is
well used as mixture bearing
composite with variation
fiber 5% and 10%, respectively, which is 35.5
grams and 71.05 grams.
5.
It is mixing epoxy resin with a hardener with a comparison 1:1 with a variation composition of 35% resin epoxy and 30% resin epoxy
in a row equal to 214.4 ml and
183.75 ml.
6.
Mixing HDPE recycles and resin Epoxy
in the receptacle, stir it up to mix equally.
7.
After recycling
HDPE and resin epoxy mixed equally,
following that enters the mixture recycle HDPE
and resin epoxy
into print.
8.
Inserts 350
mm nylon fiber into the mold with the
appropriate longitudinal direction with
variations in the composition of HDPE 60% + fiber nylon 5% + epoxy 35%
and HDPE 60% +
fiber nylon 10% + epoxy 30% in a row that is
as big as 35.5 grams and
71.05 grams.
9.
Add return mixture recycle HDPE and epoxy resin for fiber coating nylon.
10.
Close and give pressure
on print with use tool press hydraulic.
11.
Key Closing
print so that pressure
in print no experience change.
12.
Insert the
mold into the heater, then heat
at a temperature of 220 o C.
During 1 hour for
speed up process drying, its constituent elements can be
bound to perfect.
13.
Wait for the specimen until cold; then remove the test specimen from print.
2.
Composite
Bearing Specimen Test Results
After making specimen
bearing composite with a
scale of 1:4, next carried out material testing with a
bending test and tensile test, which
aims to determine the mechanical properties of the composite bearings that have
been made (Budiyanto, 2020). The following are the
bending test result and testing
pull.
Test bending done with method three
points bending. Following
data chart which obtained
from the results of the bending test of 2 variations the composition is HDPE 60% + nylon fiber 5% + epoxy
35% and HDPE 60% + nylon fiber 10% + epoxy 30% with use each 3
specimens in each variation.
Table 3. Chart Test Bending Prototype Bearing
Rail Train
|
Test Bending
|
HDPE 60% + fiber 5% nylon + epoxy 35%
|
HDPE 60% + fiber nylon 10% + epoxy 30%
|
|
Specimen 1
|
|
|
|
Specimen 2
|
|
|
|
S
specimen 3
|
|
|
Based on chart results testing
bending with the fulcrum distance
of 280 mm above, the load maximum on every specimen
listed in the table
follows:
Table 4. Score Peakload Test
Bending
|
|
Burden maximum (Peakload)
|
|
Test bending
|
HDPE 60% +
fiber nylon 5% + epoxy 35%
|
HDPE 60% +
fiber nylon 10% + 30% epoxy
|
|
Specimen 1
|
184.20 kg
|
1,806 N
|
263.60 kg
|
2,585 N
|
|
Specimen 2
|
228.60 kg
|
2,242 N
|
265,80 kg
|
2607 N
|
|
Specimen 3
|
207,40 kg
|
2.034 N
|
239.60 kg
|
2.350 N
|
From data in on next conducted calculation three-point bending on all specimen
for knowing voltage
bending each specimen
on two variation composition. Here are the results of the bending
test. After it is done, process calculation with the use of equality three-point bending with two composition variations:
Table 5. Bending Strength 2
Composition Variations
|
Strength Bending
(Mpa)
|
|
Test bending
|
HDPE 60% +
nylon fiber 5% + epoxy
35%
|
HDPE 60% +
nylon fiber 10% + epoxy
30%
|
|
Specimen 1
|
12.38 Mpa
|
17.73 MPa
|
|
Specimen 2
|
15.37 Mpa
|
17.87 MPa
|
|
Specimen 3
|
13.94 MPa
|
16.11 MPa
|
|
Flat -
flat
|
13.89 Mpa
|
17.21 Mpa
|
Bending test results after processing calculation using the equation three-point bending with
two variation composition, specimen
bearing composite have different
strength bending. Variation
composition HDPE 60% + fiber nylon 5% + epoxy 35%
obtained strong bending
average as big as 13.89 MPa. Strong
bending The
highest was obtained in specimen 2, which was
15.37 Mpa, and the lowest bending strength obtained on specimen
1 was 12.38 MPa.
Based on data strength
bending of two variation
composition in on. In
addition, the percentage of nylon
fiber affects the strength bending (Dantes, 2021). This is because
fiber nylon works as enhancer
strength (reinforcement) from prototype
bearings. In addition, as much as 5% proven fiber nylon could add strength to bending from prototype railroad sleepers and bending strength in variations composition HDPE 60% + nylon fiber 10% +
Epoxy 30% experience enhancement strength
from previous studies with a bending strength of 15.66 MPa.
However, on the variation, this does
not yet Fulfill JIS E 1203:2007 composite bearing
standards are 17.5 MPa. Less Bending Strength
from standard produce
prototype bearing the character brittle
or have flexible solid which is not enough. Strength bending bearing prototype rail train fire made
from base waste HDPE plastic,
nylon fiber, and epoxy resin with compression
molding method with a temperature of 220oC
not yet Fulfill standard. This is
because at temperature 220oC, fiber nylon experience depreciation and charred, so HDPE and resin
Epoxy predominates.
Figure 1. Comparison of Clear Strength
Test pull conducted
with the manufacture of
tensile test specimens referring to ASTM
D638 standard with dimensions of 13 mm wide,
thick seven mmm, and long beginning
57 mm. After a tensile test
is carried out to obtain maximum load data and increase
long from testing
pull with use 2 variation
composition i.e.
HDPE 60% + nylon fiber 5% + epoxy 35% and i.e. 60% HDPE + 10% nylon fiber + 30%
epoxy as follows:
Table 6. Maximum Load and
Length Gain
|
Test Pull
|
HDPE 60% + fiber nylon
5% + epoxy 35%
|
HDPE 60% + fiber nylon 10% + 30%
epoxy
|
|
|
Burden
|
L
|
Burden
|
L
|
|
Specimen 1
|
65,40 kg
|
4.17 mm
|
86 kg
|
4.18 mm
|
|
Specimen 2
|
51,20 kg
|
2.41 mm
|
80,20 kg
|
3.74 mm
|
|
Specimen 3
|
57 kg
|
3.29 mm
|
74.20 kg
|
4.17 mm
|
After obtaining the data burden maximum, Next, the tensile strength is calculated. Strain and modulus of elasticity. Here is
an example calculation of tensile
strength, strain, and modulus elasticity specimen one on variation composition HDPE 60% + fiber nylon
5%+ Epoxy 35%.
From the calculation of tensile strength, strain, and modulus elasticity obtained nature mechanic
material after tensile testing at two
variations of composition HDPE 60% + nylon fiber 5% + epoxy
35% And HDPE 60% + nylon fiber 10% + epoxy 30%
yang seen in the table following:
Table 7. Mechanical Properties
of Tensile Test Materials
|
Variation
|
Specimen
|
️ (%)
|
Modulus elasticity
(Mpa)
|
Strong pull
(Mpa)
|
|
|
1
|
7.32
|
97.26
|
7.05
|
|
1
|
2
|
4.22
|
130.1
|
5.52
|
|
|
3
|
5.77
|
106.4
|
6.14
|
|
|
1
|
7.33
|
126.4
|
9.27
|
|
2
|
2
|
6.56
|
131.8
|
8.65
|
|
|
3
|
7.31
|
109.2
|
7.99
|
Based on data calculation of two variations, the
composition of the above railroad sleeper prototype obtained different tensile strengths at every specimen. On variation composition HDPE 60% + 5% nylon
fiber + 35% Epoxy obtained strength. The greatest tensile strength in
specimens 1 and 3 is 7.05 Mpa and 6.14 MPa, whereas
strong pull, the lowest, was obtained in specimen two
at 5.52 MPa. On variation, this
obtained strength pull flat- an average of 6.24 Mpa. Here is a graph stress-strain on HDPE composition 60% + 5% nylon fiber + 35% epoxy.
Figure 2.
Stress-Strain Variation 1
On variations in the composition of HDPE 60% + fiber nylon 10% + Epoxy, 30% obtained tensile
strength the largest in specimens 1
and 2, equal to 9.27 Mpa and 8.65
Mpa, while the lowest tensile strength obtained
in specimen 3 of 7.99 Mpa. On variation,
this obtained strength
pull average as big as
8.64 MPa. Following
is chart voltage
strain at 60% HDPE + nylon fiber composition 10% + epoxy 30%.
Picture 3. Stress-Strain Variation 2
Of the two variations of the composition of the railroad sleeper
prototype, the composition of 60% HDPE + nylon fiber 10% + 30% epoxy has an
average tensile strength bigger than 8.64 Mpa compared to the composition of 60% HDPE + 5% nylon
fiber + 35% epoxy, i.e., as big as 6.24 MPa. Strength
pull on two compositions this
experience enhancement from a study previously by (Purwono et al., 2017) about technological
innovation of railroad sleepers made from raw
plastic waste that has tensile strength as
considerable as 0.5041 MPa.
Figure
4. Comparison Strong Pull
Based on the tensile strength data of the two composition variations above. The addition
of percentage fiber nylon
takes effect on strength
pull. This is based
on fiber nylon reinforcement of
the prototype bearings. In addition, as much as 5% proven
fiber nylon could add strength pull from
prototype bearing rail train fire. Strength pull is materially influenced by power tie fiber with a matrix, even laying fibers and fiber length. While in the tensile test specimen prototype
bearing rail train fire, this has spread
fiber which no equally, so that
obtained strong pull which very low or less
than optimal.
CONCLUSION
������������� Prototype bearing
rail train fire composite made to a 1:4 scale of the original size, which
refers to on standard
JIS E 1203:2007. Manufacturing
of railroad bearing specimens use 2 variation composition that is HDPE 60% + fiber nylon 5% + epoxy 35%
and composition HDPE 60% +
nylon fiber 10% + epoxy 30%. Method making used in a study is compression molding with recycled
HDPE, nylon fiber, and resin epoxy in print. Next conducted, the process pressing with a hydraulic tool press and heated
at a temperature of 220oC using the oven electricity.
������������� Prototype bearing
rail train fire conducted material testing using bending and tensile
tests. Results testing pull obtained strong pull highest at 60% HDPE + fiber
composition nylon 10% + epoxy 30%, which is 8.64 MPa. It was bending test
results with the highest bending
strength obtained at composition HDPE
60% + nylon fiber 10% + Epoxy 30% that is
as big as 17.21 MPa.
This variation does not meet bearing standards. JIS E 1203:2007 composite is 17.5 MPa.
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