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Ultrasonic Machining of S45C Medium-Carbon Steel : Deep Hole Drilling with Gun Drill

HIT applied ultrasonic machining technology on the deep hole drilling of S45C Meidum-Carbon Steel with gun drill. With the aspect ratio being 25x, under the same rotation speed, the entire machining efficiency was enhanced 2 times higher than that without ultrasonic. The high frequency micro-vibration of HIT ultrasonic-assisted machining technology allowed for intermittent contact between the tool and workpiece, achieving better chip and cutting heat removal with only 40bar of coolant through spindle (CTS). The size of chips was shrank by 91%, which greatly reduced tool wear.

💡 Watch the full video at Ultrasonic Machining of S45C Medium Carbon Steel : Gun Drill Deep Drilling | Hantop Intelligence Tech.

S45C (Medium-Carbon Steel) is carbon steel that contains between 0.25% to 0.60% carbon. This type of steel provides a good balance between strength and ductility, while being not as hard compared to other metal steels. It will acquire even better mechanical properties after heat treatment, and it also has great mechanical machinability. S45C is not only an ideal material for architecture, but is also used to be made into various mechanical parts, including air compressors, impellers of steam turbines, shafts of heavy machinery, gears and parts with wear-resistant surfaces, such as crankshafts, machine tool spindles, rollers, fitter tools, etc.

Normally, when it comes to deep hole drilling process with gun drills, industrial manufacturers tend to invest in the specialized gun drilling systems. The CTS would have to be over 70-80bar to ensure smooth chip removal during the machining process, which could be a very high energy consumption. The applications of gun drilling products include bone nails and bone screws in the medical industry; pellet dies in the animal feed industry; crankshafts and injection system for diesel engines in the automotive industry.

With HIT ultrasonic-assisted machining technology, the ultrasonic module can be installed onto the current CNC machines, without using specialized gun drilling systems. The high frequency micro-vibration of HIT ultrasonic-assisted machining technology allowed for intermittent contact between the tool and workpiece. This greatly reduced cutting heat produced by constant contact between the tool and workpiece during conventional CNC machining. It also brought easier inflow of the cutting fluid. The machining mechanism also helped with chip breakage. The chips became 91% smaller and broke naturally once it reached to certain volume, under the machining condition of 40bar of CTS. With better chip and cutting heat removal, the tool wear was immensely reduced. Overall, the machining efficiency was enhanced 2 times higher with less energy consumption, which also helps in fulfilling the ESG responsibility.

💡 Read more about Facing the Challenges in Machining of Tungsten Carbide
💡 Read more about How to Drill Titanium: The Aerospace Fever in Titanium Drilling

In addition to S45C, HIT also applies the ultrasonic-assisted machining technology to a wide range of demanding materials, including aluminum oxide ceramic (Al2O3), quartz glass, silicon carbide (SiC), zirconium dioxide ceramic (ZrO2), sapphire, tungsten carbide, mould/tool steel, alloy steel, titanium alloys, and even composites.

💡 Learn more HIT ultrasonic machining application cases


If you are looking for a better way to improve the machining efficiency, workpiece quality, and stability in tool life, please feel free to contact us 📩


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Ultrasonic Machining of Tungsten Carbide : Internal Threading

HIT applied ultrasonic machining technology on the internal threading of Tungsten Carbide. The high frequency micro-vibration of HIT ultrasonic-assisted machining technology allowed for intermittent contact between the tool and workpiece, achieving better chip and cutting heat removal. This greatly reduced tool wear and ensured the complete profile of M2 internal thread under 3 times higher machining efficiency.

💡 Watch the full video at Ultrasonic Machining of Tungsten Carbide : Internal Threading | Hantop Intelligence Tech.

Tungsten Carbide is an alloy of tungsten and carbon. It is a metal-like substance and is approximately 2 to 3 times as rigid and dense as steel. Tungsten Carbide is often referred to as a Hard Metal, for it possesses very high hardness in relation to other metals.

The hardness and resistance to heat of tungsten carbide make it an ideal material for cutting tools and high-performance wear parts to be used in the environments under high temperature and high speed. It has a wide range of application in many industry sectors such as mould & die, metal machining, wear parts for mining, metal forming tools, cutting tips for saw blades, etc.

Generally, EDM (Electrical Discharge Machining) is the most commenly used machining process when it comes to the machining of tungsten carbide. However, it would inevitably create a white layer upon the machining surface, resulting in worse workpiece quality. The followed-up manufacturing steps to remove the white layer were needed and could be extremely time-consuming.

On the other hand, with conventional CNC machining, the strong cutting force and the constant contact between the tool and workpiece would consequently accelerate and intensify the tool wear, especially for a material as hard as tungsten carbide. The major diameter of the M2 internal thread became smaller as the thread went deeper. Eventually, the screw could not be fully locked into the thread, resulting in serious impact on the quality of product.

The high frequency micro-vibration of HIT ultrasonic-assisted machining technology allowed for intermittent contact between the tool and workpiece. This greatly reduced cutting heat produced by constant contact between the tool and workpiece during conventional CNC machining. It also brought easier inflow of the cutting fluid. With better chip and cutting heat removal, the tool wear was immensely reduced. With the fact that less machining processes were needed compared to EDM, the entire machining efficiency was greatly enhanced while achieving the completeness of M2 internal thread on tungsten carbide.

💡 Read more about Facing the Challenges in Machining of Tungsten Carbide

In addition to tungsten carbide, HIT also applies the ultrasonic-assisted machining technology to a wide range of demanding materials, including aluminum oxide ceramic (Al2O3), quartz glass, silicon carbide (SiC), zirconium dioxide ceramic (ZrO2), sapphire, mould/tool steel, alloy steel, titanium alloys, and even composites.

💡 Learn more HIT ultrasonic machining application cases


If you are looking for a better way to improve the machining efficiency, workpiece quality, and stability in tool life, please feel free to contact us 📩


👉 HIT YouTube Channel 👈

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Ultrasonic Machining of Aluminum Oxide (Al₂O₃) : Internal Threading

HIT applied ultrasonic machining technology on the internal threading of 99.7% Aluminum Oxide (Al₂O₃). The high frequency micro-vibration of HIT ultrasonic allowed for intermittent contact between the tool and workpiece, achieving better chip and cutting heat removal. This greatly reduced tool wear and ensured complete profile of M2 internal thread dimension.

💡 Watch the full video at Ultrasonic Machining of Al2O3 Ceramic : Internal Threading | Hantop Intelligence Tech.


Aluminum Oxide (Al2O3) ceramic has excellent chemical resistance and thermal stability, which makes it widely applied in the semiconductor manufacturing processes (including etching and thin film processes), especially being made into the key components (such as ceramic electrostatic chuck) for wafer foundry. The high-density porous ceramic layer of Ceramic Electrostatic Chuck (Ceramic ESC, Ceramic E-chuck) ensures even distribution of absorption forces during the wafer dicing process. The required quality of micro-pores and flatness can be achieved through high-precision machining.

However, the high hardness and brittleness of aluminum oxide have brought great challenges and difficulties for industrial manufacturers, especially for the machining of M2 internal thread dimension. In conventional CNC machining, the strong cutting force and the constant contact between the tool and workpiece would consequently accelerate and intensify the tool wear. The major diameter of the internal thread became smaller as the thread went deeper. Eventually, the screw could not be fully locked into the thread, resulting in serious impact on the quality of product.

The high frequency micro-vibration of HIT ultrasonic-assisted machining technology allowed for intermittent contact between the tool and workpiece. This greatly reduced the cutting heat produced by constant contact between the tool and workpiece during conventional machining. It also brought easier inflow of the cutting fluid. With better chip and cutting heat removal, the tool wear was immensely reduced. This ensured the completeness of the profile of M2 internal thread and successfully enhanced the quality of workpiece.

💡 Read more about how HIT ultrasonic machining conquer the ceramic substrates

In addition to aluminum oxide, HIT also applies the ultrasonic-assisted machining technology to a wide range of demanding materials, including quartz glass, silicon carbide (SiC), zirconium dioxide, sapphire, tungsten carbide, mould/tool steel, alloy steel, titanium alloys, and even composites.

💡 Learn more HIT ultrasonic machining application cases


If you are looking for a better way to improve the machining efficiency, workpiece quality, and stability in tool life, please feel free to contact us 📩


👉 HIT YouTube Channel 👈

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Ultrasonic Machining of Silicon Carbide (SiC) : Micro-Drilling

HIT applied ultrasonic machining on micro-drilling of SiC (Silicon Carbide). HIT's ultrasonic-assisted machining technology greatly enhanced the hole quality. The size of edge-cracks is reduced by 53%, compared to that without ultrasonic.

💡 Watch the full video at Ultrasonic Machining of SiC (Silicon Carbide) : Micro-Drilling | Hantop Intelligence Tech.


Silicon carbide has a Mohs hardness rating of 9, making it an excellent material choice for high-precision mechanical components. The material also bears excellent chemical and mechanical stability with high-temperature and thermal shock resistance, which also makes it an ideal material for semiconductor fabrication commodities, such as substrates and showerheads. Showerheads are used for even distribution in the semiconductor industry. The hole quality and configuration of the concentrated holes on the product are important to maintain high yield rate of wafer foundry.

However, due to the high hardness of silicon carbide, the risk of machining SiC resides in poor hole quality with massive size of edge-cracks. If the thrust force and torque are not well-controlled during the drilling process, both the quality and positional precision of the holes will be severely impacted. HIT ultrasonic-assisted machining technology can help reduce cutting force/heat and allows for an easier chip removal process, resulting in great improvement in workpiece quality.

💡 Read more about Rotary Ultrasonic Machining Great for CVD-SiC Machining

In addition to SiC (Silicon Carbide), HIT can also apply the ultrasonic-assisted machining technology to a wide range of demanding materials, including quartz glass, technical ceramics (Al2O3, ZrO2), tungsten carbide, titanium alloys, and even composites.

💡 Learn more HIT ultrasonic machining application cases


If you are looking for a better way to improve the machining efficiency, workpiece quality, and stability in tool life, please feel free to contact us 📩


👉 HIT YouTube Channel 👈

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Ultrasonic Machining of Titanium Alloy : Side Milling

HIT applies ultrasonic-assisted machining technology on titanium alloy side milling, and achieves higher machining efficiency, better surface quality, and longer tool life.

HIT utilized the ultrasonic machining module for Titanium Alloy (Ti-6Al-4V) side milling.  HIT's ultrasonic-assisted machining technology allowed for 3 times faster of the cutting speed, resulting in the increase in feed rate and machining efficiency.  The high-frequency ultrasonic micro-vibration reduced the cutting force and cutting heat, which ensured better surface quality and improved the tool life.
The ultrasonic machining module offers the highest amount of precision and flexibility when fabricating components that require high quality, high precisional repeatability, and high yield rate.

💡 Watch the full video at Ultrasonic Machining of Titanium Alloy : Side Milling｜Hantop Intelligence Tech.


Titanium alloy (Ti-6Al-4V) offers a combination of lightweight, high strength, low density, good corrosion resistance and ductility.  It is also recognized for their exceptional resistance to a wide range of chemical environments provided by a thin, invisible but extremely protective surface oxide film.

These extraordinary properties make it ideal for numerous kinds of industrial applications, including biomedical industry (titanium bone plate, artificial joint), aerospace and defence industry (turbine blade, aircraft engine components), 3C electronic industry (Apple watch Ultra bezel, smartphone phone case), and electric car industry (underbody of Tesla Model S).

However, titanium alloy has bad thermal conductivity and work-hardening quality.  This would accumulate massive amount of cutting heat during the machining process, resulting in the chips being repeatedly adhesive to both the tool and workpiece.  The adhesive wear of the tool then leads to the breakage on the tool's rake face and worsens the surface roughness of the workpiece.

💡 Read more about how HIT solves the problems in machining titanium alloy

In addition to titanium alloy, HIT also applies the ultrasonic machining technology to a wide range of demanding materials, including technical ceramics, quartz glass, silicon carbide (SiC), tungsten carbide, inconel alloy, and even composites..

💡 Read more about HIT's application cases


If you are looking for a better way to improve the machining efficiency, workpiece quality, and stability in tool life, please feel free to contact us 📩


👉 HIT YouTube Channel 👈

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Ultrasonic Machining of Aluminum Oxide (Al₂O₃) Ceramic : Micro-Drilling

HIT applies ultrasonic-assisted machining technology on Al₂O₃ ceramic micro-driling, and achieves higher efficiency and better quality.