Aerospace & Automotive AISI-1045 Carbon Steel Machining : Deep Hole Drilling with Gun Drill

🕜 Efficiency - enhanced 2x | 📈 Quality - well-maintained | ⚙️ Chip Size - 91% smaller and shorter

What makes AISI-1045 Carbon Steel difficult to machine?



AISI-1045 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.  AISI-1045 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 specialized gun drilling systems. The CTS would have to be over 70-80bar to ensure smooth chip removal during the machining process, which could result in very high energy consumption.


 

☑️ AISI-1045 Carbon Steel Machining Information

 
   AISI-1045 Carbon Steel Machining Information 
  Material   AISI-1045 Carbon Steel
  Feature   Φ6.13 x 154mm (through holes)
   *aspect ratio 25x
  Process   Deep hole drilling  
  Ultrasonic Tool Holder       HSKA63-GEN-10
  Rotating Speed   4,000 ~ 5,000 rpm
  Tool Selection   Φ6.1 x 250mm - gun drill



 
HSK-A63 ultrasonic toolholder was used on AISI-1045 carbon steel deep hole drilling with gun drill
(Figure 1. HSK-A63 ultrasonic toolholder was used on AISI-1045 carbon steel deep hole drilling with gun drill)



AISI-1045 carbon steel workpiece and HSK-A63 ultrasonic toolholder during the deep hole drilling process
(Figure 2. AISI-1045 carbon steel workpiece and HSK-A63 ultrasonic toolholder during the deep hole drilling process)


 

HIT's Goal in Machining AISI-1045 Carbon Steel


The goal is to enhance the machining efficiency and see the improvement in the stability of tool life, while maintaining acceptable workpiece quality.


 

Ultrasonic-Assisted Machining AISI-1045 Carbon Steel Results

 

AISI-1045 Carbon Steel Deep Hole Drilling with Gun Drill : Machining Efficiency


the machining efficiency was enhanced 2 times higher with HIT Ultrasonic on deep hole drilling of AISI-1045 carbon steel
(Figure 3. the machining efficiency was enhanced 2 times higher with HIT Ultrasonic on deep hole drilling of AISI-1045 carbon steel)

 
  • With HIT Ultrasonic, the feed rate can be enhanced 2 times higher than the one suggested by the tooling supplier (under the same rotation speed of 4,600rpm).
  • Feed can also be enhanced 2 times higher than the original one with just 40bar of high-pressured Coolant Through Spindle (CTS).
  • The entire machining efficiency was enhanced 2 times higher than that without ultrasonic.


 

AISI-1045 Carbon Steel Deep Hole Drilling with Gun Drill : Workpiece Quality

 
  • With HIT Ultrasonic, it helps reduce cutting force.  The tool contacts with the workpiece intermittently during the machining process, which allows for a great reduction in cutting heat.
  • The surface roughness (Ra) of the hole wall was well-maintained after feed rate being enhanced 2 times higher than the one suggested by the tooling supplier.


 

AISI-1045 Carbon Steel Deep Hole Drilling with Gun Drill : Chip Shape & Chip Size


the comparison of chip removal process between HIT Ultrasonic and Without Ultrasonic on deep hole drilling of AISI-1045 carbon steel workpiece
(Figure 4. the comparison of chip removal process between HIT Ultrasonic and Without Ultrasonic on deep hole drilling of AISI-1045 carbon steel workpiece)


 
  • Without ultrasonic, there would be accumulated chips, which were long and hard to remove under 40bar of CTS.
  • The feed rate was enhanced 2 times higher with only 40bar of CTS with HIT Ultrasonic.  The high-speed micro-vibration helps chips to break naturally once it reached certain volume.




the comparison of chip size and chip shape between HIT Ultrasonic and Without Ultrasonic on deep hole drilling of AISI-1045 carbon steel
(Figure 5. the comparison of chip size and chip shape between HIT Ultrasonic and Without Ultrasonic on deep hole drilling of AISI-1045 carbon steel)


 
  • The chips became shorter, and the chip size was 91% smaller than that without ultrasonic (from an average of 70mm to 6mm).





the chip size was 91% smaller and shorter with HIT Ultrasonic on deep hole drilling of AISI-1045 carbon steel
(Figure 6. the chip size was 91% smaller and shorter with HIT Ultrasonic on deep hole drilling of AISI-1045 carbon steel)



 

HIT Ultrasonic Machining Technology Achievements


🕜 Efficiency - enhanced 2x
📈 Quality - well-maintained
⚙️ Chip Size - 91% smaller and shorter



 

AISI-1045 Carbon Steel Machining in Industry Application



Deep hole drilling of AISI-1045 Carbon Steel with gun drill is often applied in the Automotive industry, Animal Feed industry, and Medical industry, especially for the crankshafts, injection system for diesel engines, pellet dies, bone nails, and bone screws, etc.


AISI-1045 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.  AISI-1045 carbon steel 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 specialized gun drilling systems. The CTS would have to be over 70-80bar to ensure smooth chip removal during the machining process, which could result in 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.

That was when HIT's Ultrasonic Machining Module came to help!  HIT offers a comprehensive solution in machining advanced materials.  With the assistance of HIT's Ultrasonic Machining Technology, clients stopped worrying about poor tool life due to serious tool wear caused by accumulated chips while trying to shorten the processing time.  The machining efficiency can be greatly enhanced while improving the stability in tool life.  HIT assures its clients of not only matching up with their requirements, but also achieving even better outcomes!




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