DefinePK

Abstract

Increasing productivity by applying hard and dry machining concepts is background of study. The concepts have been well implemented by using CBN and ceramic. However, high cost of CBN and ceramic makes metal cutting industry seeking other possible solutions. The alternative solution offered is carbide due to the development of coating materials and coating deposition technologies. In this research, the use of multilayer CVD-coated carbide (TiN/Al2O3/TiCN) when machining hardened steel AISI 1045 (40-45) HRc is studied. Focus of study is on formulating cutting condition and productivity, which represented by metal removal rate (MRR) and volume of material removal (VMR). Turning experiment was carried out by utilizing design of experiment factorial 23 with 4 center points. Wear mode including its evolution, machining time and surface roughness (Ra) were recorded. From the results of study, flank wear was observed as the wear mode of multilayer CVD-coated carbide. Cutting condition that could be resulted by the tool was v (250-350) m/min, f (0.14-0.24) mm/rev, a (1.5-2.5) mm with tool life at VB (0.22-0.24) mm was (2.2-19.5) minutes. Under the cutting condition, MRR (53-210) cm3/min and VMR (462-1059) cm3 were resulted and surface roughness was obtained at medium finish quality or grade N7. Case study was carried out in the related industry and result show that the productivity of sample product made of hardened steel AISI 1045 was successfully increased about (220-420)%. Those 8 cutting edges of multilayer CVD-coated carbide insert give great contribution to increase productivity.