Investigation of tool wear and surface roughness when machining AISI 1045 with CIP pressed ceramic cutting tool

Abdul Manap, Muhamad Naim Fahmi (2017) Investigation of tool wear and surface roughness when machining AISI 1045 with CIP pressed ceramic cutting tool. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Ceramic cutting tool is among frequently used cutting tool in machining operation especially in dry condition. The advantages of ceramic including high hot hardness and high refractoriness enable this cutting tool to be applied in machining various hardened steels. This study focuses on the application of cold isostatic press (CIP) to produce alumina based ceramic cutting tool. Spray dried alumina powder was used as a raw material to produce the cutting tool. The powder was pressed using hydraulic press at 8 tons before compressed through CIP at 30000 psi. Green body then was dried and sintered at 1700 °C at 4 hours sintering time. The cutting tools were then tested in turning operation to machine AISI 1045 with different cutting speeds. Flank wear of the cutting tools and surface roughness of the AISI 1045 were analyzed using stereo microscope and surface roughness tester respectively. The results shows that CIP pressed alumina cutting tool obtained the hardness of 83.2 HRA which is considered adequate to machine AISI 1045 steel. The shrinkage of alumina powders recorded about 7% form green compact to sintered body. In terms of flank wear, the alumina cutting tool demonstrated decreased wear rate as the cutting speed increased from 150 m/min to 225 m/min. In term of surface roughness, the trend demonstrated decreased in surface roughness as the cutting speed increased. This study enables the industries to understand how to fabricate their own cutting tool for better feasibility in machining.

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