Precision Mould AISI-4140 Alloy Steel Machining : Side Milling

🕜 Efficiency - the fine grinding process can be eliminated | 📈 Quality - milling sides are measured to be parallel | ⚙️ Tool Life is stable to prevent inclined surfaces on the milling sides
  • Difficulties in Machining
  • HIT Achievements
  • Industry Application
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What makes AISI-4140/42CrMo4 Alloy Steel difficult to machine?


AISI-4140/42CrMo4 alloy steel is rated approximately 62HRC for its hardness.  Its high strength and toughness allow it to be widely used in high toughness alloy structural steel.  The material has great machining performance under high temperature and nice appearance after machining.  It also has excellent performace in impact absorption that the hammer may bounce back and has hardly any damage caused on impact.

However, due to its high hardness and toughness, it is hard to increase the machining efficiency while maintaining acceptable workpiece quality.  Let alone the stability in tool life.

 
 

☑️ AISI-4140/42CrMo4 Alloy Steel Machining Information

 
    AISI-4140/42CrMo4 Alloy Steel Machining 
  Information          
  Material   AISI-4140/42CrMo4 Alloy steel
  Feature   Ap 6mm, Ae 0.03mm
  Process   Side milling  
  Ultrasonic Tool Holder        BT40-R02-10
  Rotating Speed   5,000 ~ 7,000 rpm
  Machine Tool Type   3-axis vertical machining center


 

ultrasonic-assisted side milling on AISI-4140/42CrMo4 alloy steel workpiece
(Figure 1. ultrasonic-assisted side milling on AISI-4140/42CrMo4 alloy steel workpiece)


the original AISI-4140/42CrMo4 alloy steel workpiece
(Figure 2. the original AISI-4140/42CrMo4 alloy steel workpiece)


 

HIT's Goal in Machining AISI-4140/42CrMo4 Alloy Steel


The goal is to enhance machining efficiency while maintaining high surface quality, and potentially improve and prolong the stability in tool life.


 

Ultrasonic-Assisted Machining AISI-4140/42CrMo4 Alloy Steel Results

 

AISI-4140/42CrMo4 Alloy Steel Side Milling : Machining Efficiency

In conventional machining, the fine grinding process was required to make sure the two milling sides are parallel.

With HIT Ultrasonic, the fine grinding process can be eliminated, and it only took one cut of side milling to complete the machining process.  It allowed to save up more time from fewer setups and less manufacturing steps.


 

AISI-4140/42CrMo4 Alloy Steel Side Milling : Workpiece Quality

​​​the schematic diagram of AISI-4140/42CrMo4 alloy steel milling sides of the workpiece
(Figure 3. the schematic diagram of AISI-4140/42CrMo4 alloy steel milling sides of the workpiece)


The inclined surfaces occurred without the assistance of ultrasonic machining (upper: 10.10mm; lower: 10.15mm).

With HIT Ultrasonic, both the upper and lower parts of the milling sides were measured 10.10mm in compliance of the normal size required by the client.


 

AISI-4140/42CrMo4 Alloy Steel Side Milling : Tool Life

The improvement in the stability of tool life could be seen from the workpiece quality.  The inclined surface on the workpiece usually happened when there was serious tool wear, which made the tool too blunt to maintain the cutting depth.



 

HIT Ultrasonic Machining Technology Achievements


🕜 Efficiency - the fine grinding process can be eliminated
📈 Quality - milling sides are measured to be parallel, no inclined surface
⚙️ Tool Life is stable to prevent inclined surfaces on the milling sides


 

AISI-4140/42CrMo4 Alloy Steel Machining in Industry Application



Side milling AISI-4140/42CrMo4 Alloy Steel is often applied in the Precision Machinery industry, especially for the connecting part of drivien tool holder.


AISI-4140/42CrMo4 alloy steel is rated approximately 62HRC for its hardness.  Its high strength and toughness allow it to be widely used in high toughness alloy structural steel.  The material has great machining performance under high temperature and nice appearance after machining.  It also has excellent performace in impact absorption that the hammer may bounce back and has hardly any damage caused on impact.

However, due to its high hardness and toughness, it is hard to increase the machining efficiency while maintaining acceptable workpiece quality.  Let alone the stability in tool life.

HIT's Ultrasonic Machining Module offers a comprehensive solution in machining these difficult-to-cut materials.  With the assistance of HIT's Ultrasonic Machining Technology, clients stopped worrying about poor surface quality and tool life.  Not only the surface quality and tool life can be improved, but the machining efficiency can also be greatly enhanced.  HIT assures its clients of matching up with their requirements and achieving even better outcomes!




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