Pengerasan Permukaan Induksi PDF

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V V III Kata Pengantar Puji syukur kami panjatkan ke hadirat Allah SWT yang telah melimpahkan rahmat, taufik, hidayah, dan inayah-Nya sehingga penulisan Buku yang berjudul “Pengerasan Permukaan Induksi” guna memenuhi Tugas mata kuliah Penulisan Teknik & Presentasi ini dapat terselesaikan dengan ...

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V

V

III

Kata Pengantar

Puji syukur kami panjatkan ke hadirat Allah SWT yang telah melimpahkan rahmat, taufik, hidayah, dan inayah-Nya sehingga penulisan Buku yang berjudul “Pengerasan Permukaan Induksi” guna memenuhi Tugas mata kuliah Penulisan Teknik & Presentasi ini dapat terselesaikan dengan baik. Buku ini disusun sebagai persyaratan mata kuliah Penulisan Teknik & Presentasi, Jurusan Teknik Mesin, Fakultas Teknik, Universitas Diponegoro. Buku ini dapat diselesaikan berkat bimbingan, saran, dan bantuan dari berbagai pihak. Untuk itu kami sampaikan terima kasih kepada : 1. 2. 3.

Dr. Rifky Ismail, MT, selaku Dosen Pengampu mata kuliah Penulisan Teknik & Presentasi. Teman-teman satu kelompok Tugas Perancangan Semua pihak yang telah memberikan dorongan dan dukungan baik berupa material maupun spiritual serta membantu kelancaran dalam penyusunan buku ini.

Penulis menyadari bahwa buku ini masih terdapat kekurangan baik dalam isi maupun dalam penyajiannya. Untuk itu kritik dan saran dari pembaca penulis harapkan. Semoga buku yang telah penulis buat ini dapat menambah pengetahuan dan bermanfaat bagi semua pihak.

Semarang, 7 April 2017

Penulis

IV

V

Daftar Isi

Kata Pengantar Daftar Isi Daftar Gambar Daftar Tabel Abstrak

II IV XI XVII XIX

1.

Pendahuluan 1 1.1. Latar Belakang ..................................................................................................... 1 1.2. Tujuan Penulisan ................................................................................................. 2 1.3. Aplikasi dari Induction Hardenig ......................................................................... 2 1.4. Aplikasi Induction Hardening di Finishing Baja .................................................. 3 1.5. Aplikasi Induction Hardening di Industri Kaca .................................................... 4 1.6. Metode Penulisan .................................................................................................. 5 1.7. Sistematika Penulisan ........................................................................................... 5 Daftar Pustaka ................................................................................................................. 7

2.

Dasar Teori 9 2.1. Pengerasan Permukaan dengan Pemanas Induksi ................................................ 9 2.2. Prinsip Pemanasan Induksi ................................................................................. 10 2.3. Penggunaan Pemanas Induksi ............................................................................. 18 2.3.1. Aplikasi pemanas induksi pada roda gigi ................................................ 18 2.3.1.1 Tinjauan umum tentang roda gigi .............................................. 19 2.3.1.2 Heat treatment pada roda gigi .................................................. 19 2.3.2. Aplikasi pemanas induksi pada silinder pejal .......................................... 22 2.3.2.1 Tinjauan umum tentang silinder pejal ........................................ 27 2.3.2.2 Heat treatment pada silinder pejal ............................................. 29 2.3.3. Aplikasi pemanas induksi pada pisau hammer mill ................................. 30 2.3.3.1 Tinjauan umumtentang pisau hammer mill ................................ 33 2.3.3.2 Heat treatment pada pisau hammer mill .................................... 35 2.3.4. Aplikasi pemanas induksi pada pin kereta api ......................................... 36 2.3.4.1 Tinjauan umum tentang pin kereta api....................................... 38 2.3.4.2 Heat treatment pada pin kereta api ............................................ 40

VI

2.3.5. Aplikasi pemanas induksi pada Camshaft ............................................... 46 2.3.5.1 Tinjauan umum tentang Camshaft ............................................. 47 2.3.5.2 Heat treatment pada Camshaft ................................................... 49 Daftar Pustaka ............................................................................................................. 51 3.

Induksi Silinder Pejal 53 3.1. Alat dan Bahan .................................................................................................... 53 3.1.1 Alat .......................................................................................................... 53 3.1.1.1 Peralatan utama dalam pengujian .............................................. 53 3.1.1.2 Perelatan pencatat data saat pengujian ....................................... 54 3.1.1.3 Peralatan pendukun dalam pengujian ........................................ 54 3.1.2 Bahan ................................................................................................... 55 3.2. Metodologi Penelitian ......................................................................................... 56 3.2.1. Diagram alir pengujian surface hardening .............................................. 56 3.2.2. Tahapan pengujian kekerasan .................................................................. 59 3.2.2.1 Peralatan pengujian .................................................................... 59 3.2.2.2 Prosedur pengujian .................................................................... 60 3.2.2.3 Diagram alir pengujian kekerasan ............................................. 61 3.3. Hasil dan Pembahasan ........................................................................................ 63 3.3.1. Pengujian ke-1 ......................................................................................... 63 3.3.2. Pengujian ke-2 ......................................................................................... 64 3.3.3. Pengujian ke-3 ......................................................................................... 66 3.3.4. Pengujian ke-4 ......................................................................................... 68 3.3.5. Pengujian ke-5 ......................................................................................... 70 Kesimpulan ................................................................................................................. 74 Daftar Pustaka ............................................................................................................. 75

4.

Induksi Gear 77 4.1. Material Gear ...................................................................................................... 77 4.2. Dimensi Benda Uji .............................................................................................. 78 4.3. Metodologi Penelitian ......................................................................................... 79 4.3.1. Diagram alir proses penelitian ................................................................. 80 4.3.2. Pembuatan spesimen ................................................................................ 82 4.3.2.1 Dimensi benda uji ...................................................................... 82 4.3.2.2 Pembuatan spesimen .................................................................. 83 4.3.3. Diagram blok pengujian pemanas induksi ............................................... 85 4.3.4. Pengujian pemanas induksi ...................................................................... 86 4.3.4.1 Peralata utama dalam pengujian ................................................ 86 4.3.4.2 Peralatan pendukung dalam pengujian ...................................... 87 4.3.4.3 Peralatan pencatat data saat pengujian ....................................... 88 4.3.5. Foto proses pengujian .............................................................................. 91

VII

4.3.5.1 Pengujian kekerasan .................................................................. 93 4.3.5.2 Peralatan pengujian .................................................................... 93 4.3.6. Prosedur pengujian .................................................................................. 94 4.3.7. Pengujian mikro vickers .......................................................................... 96 4.3.8. Pengujian mikrografi ............................................................................... 97 4.3.8.1 Peralatan dan bahan ................................................................... 97 4.3.8.2 Prosedur pengujian .................................................................... 98 4.3.9. Proses etsa ................................................................................................ 98 4.3.10. Pengujian komposisi kimia .................................................................... 100 4.4. Hasil dan Pembahasan ...................................................................................... 101 4.4.1 Komposisi bahan ................................................................................... 101 4.4.1.1 Hasil pengujian ........................................................................ 101 4.4.1.2 Pembahasan ............................................................................. 102 4.4.2 Persebaran Kekerasan ............................................................................ 103 4.4.3 Hasil pengujian setelah quenching......................................................... 103 4.4.4 Analisa ................................................................................................. 105 4.4.5 Analisa hasil uji mikro vickers .............................................................. 107 4.4.6 Foto makro ............................................................................................. 111 4.4.7 Struktur mikro ........................................................................................ 114 4.4.8 Validasi nilai kekerasanvarian ST 60 dan AISI4140 ............................. 120 Kesimpulan ............................................................................................................... 121 Daftar Pustaka ........................................................................................................... 122 5.

Induksi Pin Kereta Api 123 5.1. Alat dan Bahan .................................................................................................. 123 5.1.1 Alat ........................................................................................................ 123 5.1.1.1 Peralatan utama dalam pengujian ............................................ 123 5.1.1.2 Peralatan pendukung dalam pengujian .................................... 126 5.1.1.3 Pelalatan pencatat data saat pengujian ..................................... 126 5.1.2 Bahan ..................................................................................................... 128 5.2. Metodologi Penelitian ....................................................................................... 128 5.2.1. Pengujian pemanas induksi .................................................................... 108 5.2.2. Pengujian kekerasan .............................................................................. 129 5.2.2.1 Prosedur pengujian kekerasan ................................................. 130 5.2.2.2 Diagram alir pengujian kekerasan ........................................... 131 5.2.3. Pengujian mikrografi ............................................................................. 132 5.2.3.1 Prosedur pengujia mikrografi .................................................. 132 5.2.3.2 Diagram alir pengujian mikrografi .......................................... 133 5.3. Hasil dan Pembahasan ...................................................................................... 133 5.3.1. Komposisi bahan ................................................................................... 134 5.3.1.1 Hasil pengujian ........................................................................ 134

VIII

5.3.1.2 Pembahasan ............................................................................. 134 5.3.2. Persebaran kekerasan ............................................................................. 136 5.3.2.1 Hasil pengujian setelah quenching........................................... 136 5.3.2.2 Hasil pengujian setelah tempering ........................................... 137 5.3.3. Analisa ................................................................................................... 137 5.3.4. Foto makro ............................................................................................. 139 5.3.5. Struktur mikro ........................................................................................ 143 5.3.6. Validasi nilai kekerasan varian ST 60 / AISI 1045 ................................ 147 Kesimpulan ................................................................................................................ 148 Daftar Pustaka ........................................................................................................... 150 6.

Induksi Pisau Hammer mill 153 6.1. Alat dan bahan .................................................................................................. 153 6.1.1 Klasifikasi baja karbon .......................................................................... 154 6.1.2 Diagram Fe3C ........................................................................................ 155 6.2. Metodologi Penelitian ....................................................................................... 156 6.2.1. Diagram alir penelitian .......................................................................... 156 6.2.2. Pembuatan spesimen pengujian ............................................................. 158 6.2.2.1 Dimensi benda uji .................................................................... 158 6.2.2.2 Pembuatan spesimen ................................................................ 159 6.2.2.3 Pengujian pemanas induksi ...................................................... 160 6.2.2.4 Peralatan utama dalam pengujian ............................................ 160 6.2.2.5 Peralatan pendukung dalam pengujian .................................... 162 6.2.2.6 Peralatan pencatat data saat pengujian ....................................... 163 6.2.2.7 Prosedur pengujian .................................................................. 165 6.2.3. Pengujian kekerasan .............................................................................. 166 6.2.3.1 Peralatan pengujian .................................................................. 166 6.2.3.2 Prosedur pengujian .................................................................. 166 6.2.4. Pengujian mikrografi ............................................................................. 167 6.2.4.1 Peralatan dan bahan ................................................................. 167 6.2.4.2 Prosedur pengujian .................................................................. 168 6.2.4.3 Proses etsa................................................................................ 169 6.3. Hasil dan Pembahasan ...................................................................................... 169 6.3.1. Komposisi bahan ................................................................................... 169 6.3.1.1 Hasil pengujian ........................................................................ 169 6.3.1.2 Pembahasan ............................................................................. 171 6.3.2. Persebaran kekerasan ............................................................................. 171 6.3.2.1 Hasil pengujian kekerasan makro pisau hammer mill.............. 172 6.3.2.2 Hasil pengujian kekerasan makro plat baja (raw material) ..... 172 6.3.2.3 Hasil pengujian kekerasan makro plat baja dengan perlakuan quenching ................................................................ 174

IX

6.3.2.4 Analisa plat baja ...................................................................... 180 6.3.3. Pengaruh frekuensi terhadap nilai kekerasan spesimen induksi ............ 181 6.3.4. Struktur mikro ........................................................................................ 181 6.3.4.1 Raw material (AISI 1019) ....................................................... 182 6.3.4.2 Pisau Hammer mill .................................................................. 182 6.3.4.3 AISI 1019 dengan elemen pemanas induksi 1 lilitan pendingin air ............................................................................ 182 6.3.4.4 AISI 1019 dengan elemen pemanas induksi 2 lilitan pendingin air ............................................................................ 183 6.3.4.5 AISI 1019 dengan elemen pemanas induksi 3 lilitan pendingin air ............................................................................ 184 6.3.4.6 AISI 1019 dengan elemen pemanas induksi 1 lilitan pendingin oli ............................................................................ 185 6.3.4.7 AISI 1019 dengan elemen pemanas induksi 2 lilitan pendingin air ............................................................................ 185 6.3.4.8 AISI 1019 dengan elemen pemanas induksi 3 lilitan pendingin oli ............................................................................ 186 Kesimpulan ............................................................................................................... 187 Daftar Pustaka ............................................................................................................. 188 7.

Induksi Camshaft 181 7.1. Alat dan bahan .................................................................................................. 191 7.1.1 Aalt ........................................................................................................ 191 7.1.1.1 Alat pengujian pengerasan induksi metode rotary ................... 191 7.1.1.2 Alat pengujian kekerasan ......................................................... 193 7.1.1.3 Alat pengujian mikrografi ........................................................ 194 7.1.2 Bahan ..................................................................................................... 194 7.2. Metodologi Penelitian ....................................................................................... 196 7.2.1. Diagram alir penelitian .......................................................................... 196 7.2.2. Pengujian komposisi kimia .................................................................... 198 7.2.3. Persiapan specimen Camshaft ............................................................... 199 7.2.4. Penentuan perameter pengujian ............................................................. 200 7.2.5. Pengujian pengerasan induksi metode rotary ........................................ 201 7.2.5.1 Peralatan utama ........................................................................ 202 7.2.5.2 Peralatan penunjang ................................................................. 203 7.2.5.3 Prosedur pengujian induksi ..................................................... 204 7.2.5.4 Prosedur Pengujian tempering ................................................. 204 7.2.5.5 Parameter pengujian hardening dan tempering ........................ 205 7.2.6. Pengujian kekerasan .............................................................................. 206 7.2.6.1 Peralatan pengujian .................................................................. 206 7.2.6.2 Prosedur pengujian .................................................................. 207

X

7.2.7. Pengujian mikrografi ............................................................................. 208 7.2.7.1 Peralatan dan bahan ................................................................. 209 7.2.7.2 Proses etsa................................................................................ 210 7.2.7.3 Prosedur pengujian .................................................................. 210 7.3. Hasil dan Pembahasan ..............................