University of Indonesia

Pendahuluan

DEFINISI:

TOOL STEEL (BAJA PERKAKAS)

Dr.-Ing. Ir. Bambang Suharno Dr. Ir. Sri Harjanto
Dept. of Metallurgy and Materials, University of Indonesia 2007

Semua Jenis Baja yang dipergunakan sebagai perkakas (tool) Biasanya dipergunakan untuk CUTTING SHAPING/ FORMING Kondisi selama pemakaian: Beban yang Tinggi dan Tiba-tiba (Very high & rapidly loads) Temperatur Operasi yang (Very high temperature)
Dept. of Metallurgy and Materials FTUI

Part/ Component

Tinggi

University of Indonesia

Pendahuluan
Tool Steel merupakan paduan kompleks yang mengandung sejumlah besar unsur: Carbon (C) Tungsten (W) Molybden (Mo) Vanadium (V) Mangan (Mn) Chrom (Cr) Kebanyakan Tool Steel dibuat: Wrought Product (Rolling) Precision Khusus) Casting (Cor

University of Indonesia

Pembuatan Tool Steel

Pembuatan Tool Steel:

Peleburan pada EAF dengan kapasitas relatif kecil (small tonage EAF) Dimurnikan dengan Argon Oxygen Decarburization (AOD) Pengurangan gas/ kotoran (Degassing) Effisiensi paduan (Alloy Efficiency)

Powder Metallurgy (Serbuk)

Dept. of Metallurgy and Materials FTUI Dept. of Metallurgy and Materials FTUI

University of Indonesia

Sifat-sifat Penting Tool Steel

Harus tahan terhadap softening (pelunakan) material pada Temperatur tinggi (Kemampuan mempertahankan high red hardness atau hot hardness) Harus tahan terhadap wear (keausan), deformation (perubahan bentuk) & perpatahan Harus Tangguh (toughness) untuk menyerap beban yang besar dan tiba-tiba Sifat Mampu Mesin (Machinability)

University of Indonesia

Penggunaan Tool Steel

Cutting :
Mata Bor Mata Potong Mesin Frais

Sifat Yang Diinginkan: Kekerasan Tinggi Kekuatan Tinggi Tahan Aus Ketangguhan Tinggi Tahan Panas (Red Hardness Tinggi)

Shearing :
Punches Blanking Dies

Forming :
Menekan bentuk logam menjadi

seperti bentuk tool nya baik dlm keadaan dingin/ panas (Termasuk Die Casting)

Drawing/ Extrusion Rolling

Dept. of Metallurgy and Materials FTUI Dept. of Metallurgy and Materials FTUI

University of Indonesia

University of Indonesia

Jenis Tool Steel

Mikrostruktur dan Sifat Mekanis : C- STEEL ALLOY STEEL & TOOL STEEL

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Jenis Tool Steel

University of Indonesia

High Speed Steel (HSS)

Baja yang dapat menjaga kekerasan yang tinggi saat digunakan Penggunaan Untuk High Speed Cutting Jenis : Group M (Alloy Molybdenum) Group T (Alloy Tungsten = W) Aplikasi : Cutting Tools Bor Bubut PERGERAKAN DISLOKASI dihindari/ terhalang oleh pengerasan dispersi akibat adanya metal karbida (jumlah banyak, keras, tahan aus)

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

High Speed Steel (M dan T series)

University of Indonesia

Hot Work Tool Steel

Dipergunakan untuk kombinasi:

Heat Pressure Abrasion

Operasi Manufaktur - Shearing, Punching, - Metal forming

Pada Temperatur tinggi Cocok Untuk: Dies untuk Ekstrusi Hot Forging Die Casting Hot Shears

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Hot Work Tool Steel (H10 H42)

University of Indonesia

Hot Work Tool Steel

Sifat Hot Hardness baik
memiliki elemen paduan pembentuk carbida yang stabil dan keras (tahan terhadap softening pada temp tinggi)

Klasifikasi: Hot Work Cr Base (H11-H19) Min 3,25% V,W,Mo,C Cr, sedikit

Total Kandungan Cr, Mo dan W = min. 5 % Chromium Hot Work Tool Steel Digunakan untuk logam dengan TL rendah (Al, Mg) Tungsten & Mo HWTS Untuk TL Tinggi (Brass, Ni, Alloys Steel)

Untuk ekstrusion dies, die casting dies, forging dies Hot Work W Base (H21 H 26) Tahan high temp softening Tahan thd brittleness Untuk extrusion dies for brass, Ni, Steel Hot Work Mo Base (Mo 8%, Cr 4%, sedikit W & V) Tahan heat cracking

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Pengaruh Unsur
Pembentuk Karbida yang meningkatkan Kekerasan, Kekuatan, Keausan Carbide Former (Cr23C6) meningkatkan kekerasan dan ketahanan aus Meningkatkan kekuatan dan kekerasan, meningkatkan hot hardness, weak carbide former Carbide former ( M6C / Fe4Mo2C),High Temperature Strength, toughness, Hot hardness Strong carbide former VC or V4C3, grain refinement (good toughness), hot hardness Strong carbide former, (M6C/ Fe4W2C), abrasion resistant particle, ketahanan hot hardness

University of Indonesia

Aplikasi Hot Work Tool Steel

.

Karbon (C) Khromium Kobalt (Co) Molibdenum (Mo) Vanadium (V) Tungsten (W)

Application Area Application Area

Hot Forging Tool and Dies : Dies

Specific Application Specific Application

Dies for presses and hammer: H20, H21 For severe condition over extended service period : H22H26 Extrusion dies dummy block; : H21 H26 Tool exposed to less heat: H10 - H14, H16

Application Area Application Area

Dies for pierching, punching, and triming; Shear blade

Specific Application Specific Application

For shearing knives : H11, H12 For severe hot shearing application: H21, H25 For Aluminum and lead; : H11, H13 For brass : H21

Shearing Tools :

and Insert; Forging machine

Hot Extrusion and Dies :

Extrusion dies and , mandrel; Dummy block; Valve extrusion tool

Dies Casting and Molding Dies :

Dies : Bending; Forming; Drawing; Deep Drawing Dies and Punches

Cold Forming

Cold-heading die casings : H13

Structural Part for Sever Service Condition

For air craft components (Landing gear, arrester hook, rocket cases) : H11

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

Features

University of Indonesia Applications

1. 2. 3. 4. 5.

Finely distributed spherical carbides Excellent quenching nature Excellent softening resistance under high temperature Excellent heat impact and fatigue resistance Excellent erosion resistance to molten

- Al, Zn, die caster mold - Mold's accessories (Plunger sleeve, chip etc.)

MATERIAL H13 = SKD 61

BOHLER W302 HITACHI DAC NIPPON KOSHUHA KDA-1

University of Indonesia

Tipe Baja dan Kekerasan Pada Komponen Die Casting

K om ponen P a d u a n y a n g d ib u a t Pb, Zn, Sn P 2 0 a t 2 9 0 -3 3 0 H B ( a ) H 1 1 a t 4 5 -5 0 H R C H 1 3 a t 4 6 -5 0 H R C H 1 3 a t 4 6 -5 2 H R C C o re s H 1 3 a t 4 8 -5 2 H R C C o re P in s Al & M g H 1 3 a t 4 2 -4 8 H R C H 1 2 a t 4 2 -4 8 H R C H 1 3 a t 4 4 -4 8 H R C D IN 1 .2 3 6 7 A t 4 2 48HR C D IN 1 .2 3 6 7 P re h a rd e n e d to 3 7 40 HR C H 1 3 a t 4 6 -4 8 H R C D IN 1 .2 3 6 7 a t 4 4 46 HR C H 1 3 a t 4 2 -4 8 H R C H 1 3 a t 4 6 -5 0 H R C (b ) H 1 3 a t 4 2 -4 8 H R C (b ) D IN 1 .2 3 6 7 a t 4 2 48 H R C (b ) 4 1 4 0 p re h a rd e n e d to 300 H B C u & b ra ss D IN 1 .2 3 6 7 a t 3 8 -4 4 HRC H 20, H 21, H 22 at 4 4 -4 8 H R C D IN 1 .2 3 6 7 a t 4 0 -4 6 HRC D IN 1 .2 3 6 7 P re h a rd e n e d to 3 7 40 HR C D IN 1 .2 3 6 7 a t 4 2 -4 6 HRC D H H H H H H D H IN 1 .2 3 6 7 a t 4 0 -4 4 RC 1 3 a t 4 2 -4 8 H R C 1 3 a t 4 6 -5 0 R C (b ) 1 3 a t 4 2 -4 6 R C (b ) IN 1 .2 3 6 7 a t 4 2 -4 6 R C (b )

Equivalent

JIS SKD61

DIN 1.2344

AISI H13

ASSAB 8407

C a v ity in se rts

Composition (%)

C 0.32-0.42

Si 0.80-1.20

Mn max 0.50

Cr 4.50 - 5.50

Mo 1.00 - 1.50

V 0.80 - 1.20

Heat treatment (oC)

Forging 1,100 - 900

Annealing 820 - 870 (Slow cooling)

Hardening 1,000 - 1,050 (Air cooling)

Tempering 550 - 650 (Air cooling)

H 1 3 a t 4 8 -5 2 H R C S p r u e p a r ts N o z z le T y p e 4 2 0 a t 4 0 -4 4 HRC H 1 3 a t 4 6 -5 0 H R C (b ) H 1 3 a t 4 6 -5 0 H R C (b )

Hardness

Annealed 229 HB (20.5 HRC) max.

Tempered 53 HRC max.

E je c to r p in s P lu n g e r s h o t sle e v e H o ld e r b lo c k s

Thermal conductivity (cal/cm.sec.oC)

25 oC 0.0569

100 oC 0.0605

200 oC 0.0702

300 oC 0.0707

400 oC 0.0687

500 oC 0.0624

600 oC 0.0712

700 oC 0.0721

Coefficient of thermal expansion (x10-6/oC)

~100

oC

~200

oC

~300

oC

~400

oC

~500

oC

~600

oC

~700

oC

4140 p re h a rd e n e d to 300 H B

4 1 4 0 p re h a rd e n e d to 300 H B

10.5

11.4

12.1

12.8

13.3

13.7

13.6

( a ) F o r s h o r t - r u n z i n c c a s t i n g o n l y ; ( b ) n i t r id e d . S o u r c e : D i e S t e e l a n d I p r o v e d P r o d u c t i v i t y i n D i e C a s t i n g , p r o d u c t l it e r a t u r f r o m U d d e l h o m N o r t h A m e r i c a

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Perlakuan Panas
: 850 OC , t = 1 jam : preheating 650 OC, t=30 mnt 1010 OC = 1 jam pendinginan udara : 550 - 650 (OC), t = 1 jam pendinginan udara

University of Indonesia

Siklus Perlakuan Panas

SKD 61 - Annealing -Austenisasi -Tempering

Temp (oC)

Annealing 850O C(SKD 61) (60 mnt)

Preheat 650 o C (30 mnt)

Austenisasi 1010o C (60 mnt)

Temper (500,550,600 oC)

Waktu (menit)
Dept. of Metallurgy and Materials FTUI Dept. of Metallurgy and Materials FTUI

University of Indonesia

Cold Work Tool Steel

Tidak Tahan Terhadap Softening pada Temp. Tinggi Temp Operasi < 260 oC Terdapat 3 Kelompok: Group A : Air Hardening Group B : High C, High Cr Steel Goup O : Oil Hardening

University of Indonesia

Cold Work Tool Steel

KELOMPOK D (High C, High Cr) Cr : 11 13.5 % C : 1.4 2.5 % KELOMPOK O (Oil Hardening) Cr : < 0.85 % C : 0.85 1.5%

KELOMPOK A (Air Hardening) Cr: 4.75 5.5 % C: 0.5 1.5 % Selama Hardening tendensi untuk distorsi cracks, Aplikasi : shear knives, punches, blanking, trimming dies

Kebanyakan Air Hardening High Wear Resitant at T rendah Excellent wear resistant, Non Deforming Properties, Good Abrasion Resistance, Minimum dimensional change in hardening Aplikasi : dies for blanking, forming, deep drawing, shear & Slitter knives Poor Resistant to Softening pada T tinggi Aplikasi: Dies, punches for blanking, trimming, drawing & forming

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Cold Work Tool Steel

University of Indonesia

SHOCK RESISTING (S), LOW ALLOY SPECIAL PURPOSE (L), WATER HARDENING (W) STEEL
LOW ALLOYS SPECIALS
Karbon Tinggi (0.45 1%) Sedikit Cr, V, Ni, Mo Oil Hardening Digunakan sbg Machine Part Kombinasi antara good strength & good toughness Untuk Bearing = AISI 52100

SHOCK RESISTING
Paduan Utama Mn, Si, Cr, W & Mo C = 0.5 % Ciri-Ciri Kekuatan Tinggi Toughness Tinggi Wear resistance sedang Aplikasi Digunakan untuk aplikasi yang ketangguhan nya tinggi serta tahan terhadap beban shock

WATER HARDENING TOOL STEEL

Pada dasarnya C Steel (0.6 1.4%) Sedikit Cr: hardenability, tahan wear Sedikit Va: fine Austenite grain size, ketangguhan tinggi Untuk Wood Working Tools

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

TOOL STEEL (S, L, W dan P)

University of Indonesia

Material Cetakan Pada Aplikasi Plastik

P r ose s In je c tio n M o ld in g M a te r ia l T h e r m o p la s t ic J e n is B a ja P 2 0 (a ) P 6 (b ) S7 H13 420 E lm a x S7 A2 D2 E lm a x (c ) A S P 2 3 (d ) S7 420 E lm a x (c ) D2 A S P 2 3 (d ) P 2 0 (a ) 420 420 F P 2 0 (a ) 420 420F 4 1 3 0 /4 1 3 5 ( e ) 420F K ekerasa n y an g d ir e k o m e n d a sik a n (H R C ) 33 54 58 54 58 45 54 50 54 58 60 54 58 58 60 58 60 58 60 60 64 54 58 52 54 58 60 58 60 60 64 3 3 (-3 1 0 ) 45 54 3 7 (-3 4 0 ) 3 3 (-3 1 0 ) 45 54 3 7 (-3 4 0 ) 3 3 (-3 1 0 ) 3 7 (-3 4 0 )

In je c tio n M o ld in g

T h e rm o se t

C o m p re ss io n M o ld in g

T h e rm o se t

B lo w M o ld in g

E k stru s io n

H o ld e r M a te ria l

G e n e ra l th e rm o s e t/th e rm o p l a stic P o ly v in y l c h lo rid e G e n e ra l T h e r m o s e t/t h e r m o p la stic p o ly v in y l c h lo rid e G e n e ra l th e rm o s e t/th e rm o p l a s tic

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Mold Tool Steel (P)

Ciri : C rendah (< 0.4%) Paduan : Cr, Ni, Mo, V Penggunaan: Low temp die casting dies Mold untuk plastic injection Tipe P 21 Ditambah Al (1-1.25%) Precipitation steel HRC 32 -36 Excellent Polishability hardening

University of Indonesia

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI

University of Indonesia

Pemilihan Tool Steel (Resume)

Performance Tool Steel:
Hot Hardness VS Toughness Wear Resistance VS Toughness Nilai 9 Tertinggi, 1 Terendah

University of Indonesia

Guide Pemilihan Tool Steel (Toughness vs Hot Hardness)

Idealnya High Toughness High Hot Hardness High Wear Resitant Sulit, biasanya 2 faktor oke, 1 faktor kompromi
Dept. of Metallurgy and Materials FTUI Dept. of Metallurgy and Materials FTUI

University of Indonesia

Guide Pemilihan Tool Steel (Toughness vs Wear Resistant)

University of Indonesia

Tugas Pembuatan Power Point

MANGANESE STEEL (1, 7) HIGH-CHROMIUM WHITE IRON (2, 8) PEARLITIC CHROME MOLY STEEL (3, 9) HIGH STRENGTH LOW ALLOY STEELS (4, X) QUENCHED & TEMPERED STEELS (5, Y) PEARLITIC IRONS (6, Z) Kumpulkan saat mid test Hari Rabu 29 Oktober 2008, dalam bentuk soft copy.

Dept. of Metallurgy and Materials FTUI

Dept. of Metallurgy and Materials FTUI