BAB III
METODELOGI
Research methodology describes steps undertaken to conduct testing of induction, hardness and
micro-structure of the specimen.
3.1. Diagram Alir Penelitian
Flowchart of this research can be seen in Figure 3.1 below
3.2. Pengujian Komposisi Kimia
Material chemical composition tests performed to compare the chemical composition on
the chemical composition of the specimen certificate test. Testing chemical composition
done in the laboratory of Material PT. Prime metal stage, Tegal. The instrument used is
the engine of Optical Emission Spectroscopy Switzerland QTD-127. Principle of the test
the chemical composition of this work by utilizing radiation beam or electromagnetic
waves of specimens described being the wavelength and measured intensitasnya. From
this it can be concluded the wavelength of the chemical composition of the framers of the
specimen. The result of this test in the form of the composition of the elements contained
in the specimen in size weight%.
3.3. Persiapan Spesimen Camshaft
Specimens obtained from the BPPT camshaft was a cylinder-shaped profile of the
camshaft are elongated. In order to be put to the test the specimen needs to be cut to
resemble its original size with a thickness of 15 mm then perforated in the core to be
gripped and rotated. Specimen cutting done in the Environment Industry work (LIK)
Semarang using wire cutting method. Photos and pictures of technique specimens before
and after the cut can be seen in Figure 3.2 and 3.3.
3.4. Penentuan Parameter Pengujian
Before doing the testing on specimens conducted initial testing of rotary, against 4
of the specimen in order to get the proper testing parameters. The testing performed,
among others, the election of koil, quenchan election and selection of parameters of
heating. on the selection of koil, emilihan done early the number of coils coil 2. This is
done to cover the surface of the cam so that the warming was obtained. On the selection
of quenchan, specimens that have been heated in quench-use water and oil. From the
results of using the air quench cracking occurs on one of the specimens, while oil is not
going to crack on two specimens tested. Images of specimens that are having the crack
can be seen in Figure 3.4.
While at the selection of parameters of heating is done testing with temperature
parameter. From the results of heating with temperature parameter obtained different
warming time on four specimens. This is caused by the akuratnya not readable by
thermocouples temperature, so as to achieve a temperature difference can occur the same
time warming up. In addition, there is 1 initial testing on specimens that have a thickness
which is approaching the criteria, i.e. warming up for 15 seconds
Therefore it was decided to select the oli as quenchan and time as parameters of
heating. In addition it was decided to select a variation of the 2nd and 3rd coil coil as
well as the warming time 15, 20 and 25 seconds.
3.5. Pengujian Pengerasan Induksi Metode Rotary
The tools used in the study, induction hardening, testing procedures and testing of
tempering is discussed as follows:
3.5.1. Peralatan utama
There are induction hardening on testing the main equipment required to operate
the engine induction heaters. These appliances are then assembled to facilitate the
process of testing. Picture a series of induction hardening testing tool rotary
method can be seen in Figure 3.5.
In addition, on this test used three types of coil, i.e. coil coil coil coil of two,
three, and coil tempering. Coil used in this test is made from a copper pipe with a
diameter of 5 mm and a thickness of 1 mm. coil coil Picture two, three, and a coil
coil coil tempering can be seen in Figure 3.6.
3.5.2. Peralatan penunjang
a. Thermocouple dan thermodisplay
Used to measure the temperature of the oil and measure the temperature of
the specimen on the process of tempering. Thermocouple and
thermodisplay can be seen in Figure 3.7
b. Multimeter
Used to measure frequency induction heating machine. A multimeter can
be seen in Figure 3.8.
c. Tachometer
Used to measure the speed turn the specimen. Tachometer can be seen in
Figure 3.9.
3.5.3. Prosedur pengujian induksi
In this study, steps that need to be done in conducting the testing of induction as
follows:
1. Do set up a tool like Figure 3.5 uses two coils coil without putting up on
the tools pencekam specimens specimens
2. Plug the power cord of one phase, 220 V 50/60 Hz on the terminals as a
source of electrical power.
3. Turn on the water pump for the circulation of the cooling system on a coil,
transformer, and inverter.
4. Attach the specimen on the tools pencekam specimens, with pencekam on
the bottom.
5. Position the coil in the middle of the tool pencekam specimens, so that the
specimen is mounted inside the coil.
6. Install pencekam the bottom then tighten, so the specimen perfect
tercekam
7. Adjust the height of the coil by means of turning the handle on the table
buffer height specimens like to induced.
8. make sure that specimens are right in the middle of the coil, so that the
specimens do not come into contact with the coil.
9. set the speed dial using the voltage regulator, and then validate the speed
dial using a tachometer.
10. set the output current of 575 A, and then start the induction by pressing the
green button on the engine induction heaters.
11. check the working frequency induction heating machine using a
multimeter.
12. during the induction heater burning engine note the round motor so as not
to decrease due to the influence of the magnetic field.
13. After reaching the desired warming time, turn off the motor and the engine
induction heaters and do quenching.
14. wait for the temperature of the oil until it reaches room temperature. After
that, lift the specimens of quenchan tubs and then release the specimen
from the specimen pencekam tool.
15. repeat start steps 4 to 14 for testing with the number of coils of the same
coil. For a number of different coil coil, turn off the pump and then replace
with the desired coil. Next do the third step to finish
3.5.4. Prosedur pengujian tempering
Tempering is done in testing steps are as follows:
1. Do set up a tool like Figure 3.5 without tools pencekam specimens. On
testing this use coil tempering.
2. Plug the power cord of one phase, 220 V 50/60 Hz on the terminals as a
source of electrical power.
3. replace tool pencekam specimens with specimens laid the table for
tempering.
4. Adjust the height of the coil by means of turning the handle on the table
buffer height specimens.
5. make sure that specimens are right in the middle of the coil and not in
contact with the coil.
6. set the current of 125 A, and then start tempering with the green button on
the engine induction heaters.
7. check the working frequency induction heating machine using a
multimeter.
8. check the temperature at the edge of the specimen using thermocouples
and then turn off the engine after the induction heater mecapai temperature
of the detention.
9. Do the detention on the temperature variation of the time. When the
temperature of the detentions comes down too much before the detention
time is complete, restart the engine until it reaches the temperature of the
induction heater detention.
10. allow the specimen at room temperature.
11. Do steps 4 through 9 for tempering the specimens with different detention
time
3.5.5. Parameter pengujian hardening dan tempering
On the research of hardening is done using 2 types of coil with 3 time warming up
on each coil. While in the process of tempering is done with temperature variation
2 3 detention time at each temperature. The parameters of the test specimen of the
camshaft can be seen in Table 3.1.
3.6. Pengujian Kekerasan
Testing using the Rockwell method is performed to find out the value of the
macro as well as the violence spread to the depth of hardening on specimen induction
from the edge to the middle. testing conducted in the laboratory of materials, Training
Centre, the University of Diponegoro.
3.6.1 Peralatan pengujian
As for the equipment used for testing the hardness, among others:
1. Brooks Rockwell Hardness Tester
Is a tool that is used to measure the surface roughness by using method of
Rockwell.
2. the Indenter
Indenter used either a diamond cone indenter. Equipment used in testing the
hardness can be seen in Figure 3.10.
3.6.2 Prosedur pengujian
This is a test process phases of violence:
1. make sure the imposition of used 150 kgf.
2. Clean the surface of the sandpaper and the specimen so that both
the parallel and smooth surface.
3. attach the specimen at his position (anvil) then tighten by turning
the handwheel clockwise until the specimen touches the
indenterdan needle on the dial indicator is located on the black
lines.
4. Pull the handle to the main load to perform imposition.
5. After 30 seconds, push the handle to remove the main imposition
of loading (loading and releases the handle pressing the load
slowly and carefully).
6. Do the reading on the indicator of violence and make the test
results of violence.
7. turn the handwheel to lower the specimen. Test specimens in the
next appropriate steps 2 to 6.
[Link] Mikrografi
Microstructure observation conducted to see changes in microstructure of
specimens before and after induced. The observations carried out in the laboratory of
Physical Metallurgy, mechanical engineering, Diponegoro University.
3.7.1 equipment and materials
Tools used include:
1. Machine polisher
2. Beaker
3. Microscope
4. Laptop
5. Camera
While the materials used include:
1. Specimens.
2. Velvet cloth, sandpaper, and wipes.
3. Autosol
4. Nital (for pengetsaan).
Microstructure observation process can be seen in Figure 3.12.
3.7.2 etching Process
Etching function in pengkaratan in the mikronya structure for specimens can be
seen.
Tools and materials:
beaker.
Eyedropper.
Wipes.
clean water to rinse.
1-10 ml of HNO3.
90-99 ml Methanol.
Process:
A comparison of the above can be simplified into a 5-7 drops of nitric acid
and 10 ml of methanol and mixed in the beaker. Specimens are dipped in
the reactants for 1-5 minutes, then rinsed with running water and then
dried.
3.7.3 test procedure
The test steps can be explained as follows:
1. Specimens coded to ease the process of observation.
2. the Surface will be observed should be flat, clean, dry, shiny and has
undergone a process of polishing (polishing) using autosol bludru and
cloth.
3. Do etching using nital on the surface of the specimen to clean the
remnants of the polisher polishing at the time. In addition, the grain
boundary to bring up the surface of the specimens that will be observed.
After undergoing the process of etching, surface specimens cleaned by
water flows.
4. Do your observations on the surface of the specimen which has undergone
the process of etching using a microscope.
5. Do the observations with magnification 100 x, 200 x, 500 x and then save
the observations obtained.
6. Do steps 1 to 5 for the next specimen.
7. Microstructure observation of flow diagrams can be seen in Figure 3.13.
