Investigation of tool wear and surface roughness when machining AISI 1045 using alumina ceramic cutting tool

Mokhtar, Muhammad Faiz (2017) Investigation of tool wear and surface roughness when machining AISI 1045 using alumina ceramic cutting tool. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This report presents the evaluation of tool wear and surface roughness when machining AISI 1045 using alumina ceramic cutting tool. The insert for cutting tool was made from dry sprayed alumina powder by using compaction method. The compaction pressures were varied from 6, 7, 8 and 9 ton for each cutting tool. Then, the compacted powder was sintered at temperature of 17000C for 4 hours sintering time. The insert then undergone machining test by CNC lathe turning at dry condition. Their performance were evaluated based on hardness test, tool wear and surface roughness. The workpiece material used was AISI 1045 medium carbon steel which having carbon content range from 0.45 to 0.50% carbon. The test were held at constant cutting speed of 200 m/min, feed rate of 0.05 mm/rev and depth of cut of 1 mm. The results show that the hardness of the cutting tool increased when the compaction pressure of the powder increased. Highest hardness value recorded at 86.1 Hv when the pressure was set at 9 ton. For tool wear, it was found that the wear rate decreased when the compaction pressure of the cutting tool increased. The lowest wear rate was recorded at 0.0025 mm/s when the 9 ton cutting tool was used. The surface roughness evaluation show that 6 ton cutting tool prodcued the highest Ra value which is 3.56 μm. Meanwhile, for 7, 8, and 9 ton compaction pressure, the cutting tool gave average Ra value around 1.24 μm. This project enable the industry to understand the correlation between compaction pressure and hardness of each cutting tool on tool wear and surface roughness when machining AISI 1045.

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