The depth of cut level in the dry
turning process of S45C medium-carbon steel has been proven to directly
correlate with the rates of flank wear and crater wear on carbide tools. This
conclusion stems from experimental research conducted by Abd. Haris Assa Bani,
Achmad Rijanto, and Nuril Ahmad from Universitas Islam Majapahit, Indonesia,
published in 2026. These findings serve as an important foundation for the
manufacturing industry in optimizing cutting parameters to extend tool life
while reducing production costs.
In manufacturing machine
components such as shafts and gears, S45C steel is widely used due to its
balanced combination of strength and wear resistance. However, its hard
material properties generate intense friction and high temperatures at the
cutting zone, rapidly eroding the tool tip. Frequent tool replacement not only
increases capital expenditure but also prolongs machine downtime and reduces
product dimensional accuracy. Precise measurement of cutting parameters is
crucial to minimize these operational losses.
The research team from
Universitas Islam Majapahit tested the dry turning process on S45C steel bars
measuring 95 mm in diameter, varying the depth of cut across three levels: 1
mm, 2 mm, and 3 mm. The experiment kept the feed rate constant at 0.2 mm/rev,
while tool wear was measured using a USB digital microscope to observe flank
wear and crater wear.
Measurement results revealed that
increasing the depth of cut consistently escalated tool wear and cutting
temperature:
- Flank Wear: Increasing the depth of cut from 1 mm to
3 mm increased flank wear from 0.0186011 mm to 0.0325576 mm.
- Crater Wear: Across the same depth range, crater wear
increased from 0.0005118 mm to 0.001432 mm.
- Cutting Temperature: The temperature at the cutting zone rose
from 28.9°C at a 1 mm depth to 30.1°C at a 3 mm depth.
Although all measured wear values
remained well below the 0.3 mm critical threshold specified by the ISO 3685
standard, the upward trend confirms that deeper cuts accelerate physical tool
degradation. The researchers recommend utilizing a 1 mm depth of cut for
precision machining to maximize tool lifespan. However, if production speed or
efficiency is the priority, larger depths of cut can be applied provided they
are paired with cutting fluid or adjusted cutting speeds.
This study provides practical
guidance for machine technicians and workshops in establishing economical lathe
settings. Setting parameters based on experimental data enables manufacturers
to reduce tool damage without compromising final product quality.
Author Profile
- Abd. Haris Assa Bani: Researcher from the Department of
Mechanical Engineering, Universitas Islam Majapahit, Indonesia,
specializing in machining processes and manufacturing materials.
- Achmad Rijanto: Lecturer and researcher at the Department
of Mechanical Engineering, Universitas Islam Majapahit, Indonesia,
focusing on manufacturing technology and machining parameter optimization.
- Nuril Ahmad: Academic at the Department of Mechanical
Engineering, Universitas Islam Majapahit, Indonesia, with expertise in
production engineering and materials testing.
Research Source
- Article Title: Effect of Depth of Cut Variation on
Flank Wear and Crater Wear of Carbide Tools in S45C Steel Turning
- Journal: International Journal of Advanced Technology and Social
Sciences (IJATSS), Vol. 4, No. 8, Year 2026, Pages 973–980
- Authors: Abd. Haris Assa Bani, Achmad Rijanto, & Nuril Ahmad
- DOI: https://doi.org/10.59890/ijatss.v4i8.282
- https://aprmultitechpublisher.my.id/index.php/ijatss
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