The research aims to develop insert dies utilising waste-bearing material and assess their quality for circular blanking applications. Through the study, the viability of waste bearing as a material for insert dies will be evaluated, focusing on its effectiveness in the blanking process. The goal is to contribute to sustainable manufacturing practices by repurposing waste materials and optimising their performance in metalworking applications.The design methods used in this study are VDI (Verein Deutscher Inginieuer) 2222 and ISO 14006. The research encompasses composition testing, material characterisation, and the fabrication of test equipment using dies made from waste bearings. The methods are employed to evaluate product quality, focusing on cutting performance and service life.The experiments demonstrated that waste-bearing material exhibits properties like SKD 11, making it a viable alternative for insert dies. The cutting process yielded minimal burrs, indicating its effectiveness. Additionally, implementing waste bearing resulted in a substantial cost savings of 57.7%. The findings suggest that waste bearing holds promise as a sustainable and cost-effective material for insert dies in metalworking applications.One limitation of this study is the requirement of two waste bearings to produce the same output as SKD 11 before requiring grinding. Therefore, future research should focus on optimising the durability and lifespan of waste-bearing insert dies through improved design and maintenance strategies. Developing tools and methodologies to streamline the maintenance process of dies will be crucial for maximising the efficiency and effectiveness of using waste-bearing material in industrial applications.The production of almost the same cutting quality from the use of bearing waste and SKD 11 opens opportunities for small business enterprises in Indonesia in the tool-making and mould and dies fields to use this material as an alternative material. It is due to uncertain market conditions, which cause the price of SKD 11 to increase yearly.The paper presents the original finding that waste-bearing material can serve as a viable alternative for insert dies in metalworking applications. The observation reveals that the burr height generated by waste bearing is comparable to that of SKD 11, despite SKD 11 still outperforming waste bearing in terms of lifetime durability. The value of the paper lies in its contribution to sustainable manufacturing practices by identifying waste bearing as a potential material for insert dies, thus offering cost-saving and environmental benefits to industries involved in metalworking processes. Additionally, it highlights the need for further research to enhance the longevity of waste-bearing insert dies, thereby expanding their applicability in industrial settings.
