Variations in The Levels of Dromus and Pressure in Mist Cooling of The Lathe

Process Against Surfaces Roughness.

Mazdaril Arif, Advisor: 1Sunomo, 2Imam Sudjono

Mechanical Engineering Department, Engineering Faculty Universitas Negeri Malang, 5,
Semarang Str.,65145 Malang, East Java, Indonesia

Mist cooling (MC) is one of the cooling method that has not developed further, it
has a beneficial potency for metal-cutting industry, it uses less cooling liquid than other
method. MC requires high-pressure of air from the compressor to push oil and compress
the air at the tip of the nozzle to produce liquid in the form of mist. The mist is easier to
enter the cutting area, so that lubrication and cooling work more effectively. This
research aims to determine the surface roughness value of S45C steel resulting from the
turning process using the mist cooling method with variation in the ratio of dromus and
water are 1:20, 1:30, and 1:40 and the MC pressure are 3 bars, 4 bars, and 5 bars. The
surface of the turning specimen was measured by a surface roughness tester Mitutoyo
SJ-301. The data was collected at the Mechanical Engineering Workshop Universitas
Negeri Malang. This research is classified as an experimental research uses the
analytical technique as descriptive statistics. The results obtained from each treatment
variant will be compared with other treatment variants so that the comparison of the
results of each treatment variant will be obtained using a graph that can be explained
descriptively. The ratio of dromus and water were 1:20, 1:30, and 1:40 than the mist
cooling pressure were 3 bars, 4 bars and 5 bars. The result of the research had shown
that variations in the levels of dromus were 1:20, 1:30, and 1:40 in mist cooling of the
lathe process had an influence on surface roughness, the highest level of dromus in
cooling liquid was produced the lowest roughness of specimen. the variation of
pressure, 3 bars, 4 bars, and 5 bars, on the lathe mist cooling process has an influence on
surface roughness, the higher the pressure exerted on the mist cooling process, the
surface roughness (Ra) value decreases. The lowest surface roughness value is produced
from a pressure of 5 bar and a mixture of dromus content of 1:20 with a surface
roughness value of 2.9 μm, while the highest surface roughness value is produced from
a pressure of 3 bar and a mixture of dromus content of 1:40 with a surface roughness
value of 4.22 μm. According to ISO standards, the value of surface roughness produced
in this study is included in the N8 level, with a range of values between 2.4 μm-4.8 μm.

Keywords: levels of dromus, mist cooling pressure, S45C, surfaces roughness.

1. INTRODUCTION

Roughness value is one of the important factors in the metal processing industry, this
can determine the long life or age of the component can be used, because the high level
of roughness is easier to change in structure when subjected to a direct treatment. In
addition to the main parameters in the turning process, the proper cooling method can
reduce the friction that occurs due to the cutting process which causes heat in the cutting
area so that it can cause tool wear which greatly affects the roughness value of the
product being worked on.
 Mist cooling (MC) is one of the cooling method that has not developed further, it has
a beneficial potency for metal-cutting industry, it uses less cooling liquid than other
method. MC requires high-pressure of air from the compressor to push oil and compress
the air at the tip of the nozzle to produce liquid in the form of mist. The mist is easier to
enter the cutting area, so that lubrication and cooling work more effectively.

2. MATERIALS AND METHODS

This research is classified as an experimental research uses the analytical
technique as descriptive statistics. The results obtained from each treatment variant will
be compared with other treatment variants so that the comparison of the results of each
treatment variant will be obtained using a graph that can be explained descriptively. The
ratio of dromus and water were 1:20, 1:30, and 1:40 than the mist cooling pressure were
3 bars, 4 bars and 5 bars.
The material used in this research is ASTM A36 low carbon steel plate with a thickness
of 4.8 mm. Before bending, the specimen is cut to size 20 mm x 50 mm by 90 pieces.
Specimens with bending treatment amounted to 81 specimen, with a bending angle of 60 o, 90o
and 120o, so that each bend angle was 27 specimens with three replications. The remaining
plates are without bending treatment which amounts to 9 specimen.
This research focuses on stress corrosion, but in the bending process there are parts of
the plate that are affected by stress, and some are not affected by stress. The part that is affected
by the stress is the center of the plate with a size of 25 mm x 20 mm, while the part that is not
affected by the stress is the two ends of the plate with a size of 12,5 x 20 mm, the part has the
same dimensions or can be called ½ the part that is affected by stress.
So that the results of corrosion testing carried out purely by stress corrosion require a
plate without bending treatment which is then the weight of ½ plate of the corrosion rate test
results are used to reduce the weight of ½ plate by bending treatment. The weight reduction is
carried out at the initial weighing, and at the end of the specimen. Weighing the specimens in
this study using a digital scale with a precision of 0,001 gr. The corrosion rate testing standard
used in this study is ASTM G31-72 Standard Practice for Laboratory Immersion Corrosion
Testing of Metals.
Following is an illustration of the bending process with the part of the plate being
affected and not affected by stress.

Figure 1. Plate Section

Corrosion media used are PDAM Malang City water, Malang City rainwater, and
Sendang Biru Regency Malang sea water. Rainwater media, and PDAM water are taken directly
with each volume of 19L, specifically for sea water media taken at a distance of about 1 km
from the beach so that the sea water used is not contaminated with fresh water. The volume of
the corrosion media can be calculated using the formula based on the following ASTM G31-72
standard.

Liquid volume = (Minimum ratio) x (Surface area)

Information:
Minimum ratio = 0,20 - 0,40 (ml/mm2)
Surface area = 2 x (p x l + p x t + l x t) (mm2)

So the minimum volume of fluid that can be used is

Liquid volume = 0,20 x [2 x (50 x 20 + 50 x 4.8 + 20 x 4.8)]
= 0,20 x 2672
= 534 ml

Corrosion rate testing method used is a weight loss method, this method is often used because
the equipment used is simple, and the test results are accurate. Corrosion time variations used in
this study were 24 hours, 48 hours and 72 hours. Based on ASTM G31-72 the minimum time to
check corrosion rate is 48 hours, but because the material used is classified as susceptible to
corrosion, the lowest variation used is 24 hours.

The formula used to calculate the corrosion rate is as follows.

Information:
K = Constants in mmpy (8.76 x 104)
W = Weight loss (mg)
𝞺 = Density (mg/mm3)
A = Surface area (mm2)
T = Corrosion time (hours)

3. RESULT AND DISCUSSIONS

Corrosion rate testing is carried out for the part that is affected by the stress that is the
middle part of the plate with a size of 20 mm x 25 mm x 4.8 mm. The results of this study are
the corrosion rate values of each treatment. Treatments with time variations (A), bending
angles (B), and corrosion media (C). The following is the presentation of the data of ASTM
A36 steel plate corrosion test results.
Table 1. Corrosion Rate Value (mmpy)
Corrosion Media
No Time Angle Rain Sea
PDAM
water water
1 60 1,444 2,406 0,962
24 90 1,444 2,085 0,962
120 1,444 1,764 0,962
48 60 1,444 1,604 1,845
 90 1,444 1,444 1,845
120 1,764 1,283 1,363
60 1,39 1,497 1,978
72 90 1,497 1,176 1,23
120 1,176 0,749 1,123
60 1,123 1,764 1,283
24 90 0,481 0,802 1,283
120 0,481 1,123 1,283
60 1,764 1,283 2,326
2 48 90 1,764 1,604 1,684
120 1,604 1,604 1,524
60 1,176 1,925 1,764
72 90 1,069 1,497 1,337
120 1,069 1,283 0,802
60 0,802 0,481 1,283
24 90 0,481 0,16 0,962
120 0,16 0,16 0,962
60 1,123 2,567 1,845
3 48 90 0,802 1,764 1,845
120 0,642 1,123 1,845
60 1,497 1,283 1,551
72 90 0,642 1,069 1,337
120 0,856 0,856 0,588

A. Characteristics of Corrosion Rate Due to Bending 60o

Stresses that occur due to bending 60 o, 90o and 120o are certainly different, this is
evidenced by using Autodesk Inventor 2017 software, this simulation is in the form of stress
analysis in order to determine the stress distribution caused by the bending process. In this
simulation each is given the same load that is 100N on bending 60o, 90o, dan 120o.

Figure 2. Stress Distribution Bending 60o

The stress that occurs in bending 60 o is the biggest compared to the others. The part
that is affected by the maximum stress is red area, and the neutral stress is blue area. The
maximum stress that occurs is 6.683 MPa. As a result of this bending treatment the thickness of
the plate in the middle is reduced by 0.7 mm.
 Figure 3. Corrosion Rate Chart Bending 60o

The characteristics of ASTM A36 steel plate corrosion rate due to bending 60 o can be
seen in the figure 3. At 24 hours the rainwater media was the most corrosive, but at 48 hours
the sea water media became the most corrosive. The lowest corrosion rate value is at A 1C1
treatment (24 hour time, and PDAM water media), the highest corrosion rate value is at A 2C3
treatment (48 hour time, and seawater media). The quality of the corrosion resistance is
classified as poor.
B. Characteristics of Corrosion Rate Due to Bending 90o
Maximum stress that occurs due to bending 90 o is in the middle of the plate with a
value of 5.742 MPa, while the part that is not affected by the stress is the blue area. For more
details, the stress distribution can be seen in Figure 4 below.

Figure 4. Stress Distribution Bending 90o

As a result of bending 90o plate thickness is reduced by 0.4 mm in the middle. Just like
the previous stress analysis simulation using Autodesk Inventor 2017 software, with a load of
100N.
The characteristics of ASTM A36 steel plate corrosion rate due to bending 90 o lower
than with bending 60o that is because the stress that occurs is smaller. The greater the bending
angle, the smaller the stress that occurs. The characteristics of the corrosion rate due to bending
90o can be seen in Figure 5 below.
 Figure 5. Corrosion Rate Chart Bending 90o
Corrosion rate tends to increase at 48 hours, then decrease at 72 hours. The most
corrosive media are sea water with a pH of 7.3, then rainwater with a pH of 6.4, and PDAM
water with a pH of 6.2. The highest corrosion rate is in the A 2C3 treatment (48 hours, and
seawater media) with poor corrosion resistance. Corrosion rate with the lowest value is at A 1C1
treatment (24 hours, and PDAM water media) with fair corrosion resistance.
C. Characteristics of Corrosion Rate Due to Bending 120o
The stress that occurs due to bending 120 o is the smallest compared to other angular
variations. The maximum stress that occurs is in the red area, which is in the middle of the
plate with a value of 4.453 MPa. The part that is blue is the part of the plate that is not affected
by stress.

Figure 6. Stress Distribution Bending 120o

In the stress analysis simulation the same as before, namely by using a load of 100N.
The bending treatment with an angle of 120 o causes the thickness of the center of the plate to
be reduced by 0.2 mm, so that the thickness of the plate becomes 4.6 mm.
Corrosion rate characteristic of 120 o bending is the best corrosion resistance compared
to other angular variations, it is because the stress (corrosion trigger) at 120 o bending is
relatively low. The greater bending angle that is formed, the smaller the stress that occurs.
Here is Figure 7 on the chart of ASTM A36 steel plate corrosion rate due to bending 120 o.
 Figure 7. Corrosion Rate Chart Bending 120o
Corrosion rate with the greatest value is in the A 2C3 treatment (48 hours, and seawater
media) with poor corrosion resistance. Corrosion rate with the lowest value is at A 1C1 treatment
(24 hour time, and PDAM water media) with fair corrosion resistance. Classification of the
corrosion rate is based on ASTM G31-72 standard, where if the corrosion rate value of 1-5
mmpy is classified as poor, and 0.5-1 mmpy is classified as fair.
From the whole test it is proven that the bending angle with the best corrosion
resistance is 120o, and the bending angle with the worst corrosion resistance is 60 o. This is due
to the stresses that occur due to bending, the greater the stresses resulting in rapid corrosion
rates. The results of hypothesis testing also stated that there was a significant effect of
variations in bending angle, corrosion media, and corrosion time on the corrosion rate values.

4. CONCLUSION
The results of ASTM A36 steel plate corrosion rate due to bending with variations in
angle, corrosion media, and corrosion time prove that there is an influence of the three
variations on the value of corrosion rate. The smaller of bending angle can causes the faster
corrosion rate, it is because the small bending angle causes a large stress in the bending
process.
Sea water corrosion media is the most corrosive, it is due to the large pH of sea water.
The pH of sea water is 7.3, while the pH of rainwater is 6.4, and the pH of PDAM water is 6.2.
This research proves that the greater the pH value of the corrosion media, the higher the
corrosion rate can be.
Corrosion time also affects the corrosion rate value, the corrosion time with the highest
corrosion rate value of all tests is 48 hours, and the corrosion time with the lowest corrosion
rate value is 24 hours. The results of hypothesis testing also state that there is a significant
effect of variations in bending angle, corrosion media, and corrosion time on the corrosion rate
values.

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