Semiconductor Micro-Drilling of AISI-304 Stainless Steel on curved surface

📈 Quality - drilling holes with no burrs | ⚙️ Tool Life - 4x longer
  • Difficulties in Machining
  • HIT Achievements
  • Industry Application
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What makes AISI-304 Stainless Steel difficult to machine?



AISI-304 stainless steel is an austenitic grade stainless steel.  It is said that nearly 70% of commercially produced stainless steel are austenitic, and 304 accounts for more than 50% of stainless steel consumed.

304 stainless steel has excellent corrosion resistance under various kinds of environments.  Its good machinability also allows it to be used across different industries.  Though 304 stainless steel has good machinability in general, it still has machining difficulties due to its material properties, such as work hardening and low thermal conductivity.

The work hardening of 304 stainless steel brings increased cutting forces during the machining process.  Low thermal conductivity also makes it difficult to remove the heat generated during the machining process, along with the long, stringy chips, which can result in poor workpiece quality and serious tool wear.


 

☑️ AISI-304 Stainless Steel Machining Information

 
    AISI-304 Stainless Steel Machining Information     
  Material   AISI-304 Stainless Steel
  *workpiece size Φ8mm solid round rod
  Feature   Φ1 x 5mm (blind holes)
  *aspect ratio 5x
  Process   Micro-drilling  
  Ultrasonic Tool Holder           HSKA63-GEN-06
  Rotating Speed   12,000rpm
  Tool Selection   OSG MRS-GDL Φ1 drill bit  



 
HIT HSK-A63 ultrasonic machining module was used for micro-drilling on curved surface of AISI-304 stainless steel
(Figure 1. HIT HSK-A63 ultrasonic machining module was used for micro-drilling on curved surface of AISI-304 stainless steel)



 

HIT's Goal in Machining AISI-304 Stainless Steel



The goal is to prevent burrs around the drilling holes on a curved surface of 304 stainless steel and to reduce tool wear, by using CNC machining with HIT ultrasonic-assisted machining technology. 


 

Ultrasonic-Assisted Machining AISI-304 Stainless Steel Results

 

AISI-304 Stainless Steel Micro-Driling: Hole Quality


HIT ultrasonic-assisted micro-drilling on curved surface of AISI-304 stainless steel can effectively eliminate burrs around drilling holes, and have better roundness without plunge milling process
(Figure 2. HIT ultrasonic-assisted micro-drilling on curved surface of AISI-304 stainless steel can effectively eliminate burrs around drilling holes, and have better roundness without plunge milling process)

 
  • In conventional CNC machining, high cutting forces caused tool deflection during the micro-drilling on a curved surface.  This resulted in poor roundness in drilling holes, which would require plunge milling before the main micro-drilling process.
  • Under the same machining parameters within this trial, high cutting forces without ultrasonic made it hard to cut off the material, and left massive burrs around the drilling holes.
  • With HIT ultrasonic, high frequency micro-vibration helped reduce cutting forces.  Hole quality can be greatly improved with fine roundness without plunge milling process.  The tool can cut off the material more easily with better chip removal process, resulting in effective elimination of burrs around drilling holes. 



HIT HSK-A63 ultrasonic machining module was used for micro-drilling on curved surface of AISI-304 stainless steel, and achieved zero burrs around drilling holes
(Figure 3. HIT HSK-A63 ultrasonic machining module was used for micro-drilling on curved surface of AISI-304 stainless steel, and achieved zero burrs around drilling holes)




 

AISI-304 Stainless Steel Micro-Drilling: Tool Life


HIT ultrasonic-assisted micro-drilling on curved surface of AISI-304 stainless steel helped reduce cutting forces, and completed 20 drilling holes with no obvious tool wear
(Figure 4. HIT ultrasonic-assisted micro-drilling on curved surface of AISI-304 stainless steel helped reduce cutting forces, and completed 20 drilling holes with no obvious tool wear)

 
  • Without ultrasonic, high cutting forces made the material hard to cut off.  This also resulted in the occurrences of entangled chips.  The long, stringy chips stuck on the tool blade could cause serious blade breakage.
  • With HIT ultrasonic, the reduction in cutting forces not only helped improve hole quality, but also allowed the tool to cut off the material more easily with better chip removal.  This prevented the tool from entangled chips, which greatly reduced tool wear and effectively prolonged 4 times of tool life.



HIT HSK-A63 ultrasonic machining module was used for micro-drilling on curved surface of AISI-304 stainless steel, resulting in 4 times longer tool life compared to that without ultrasonic
(Figure 5. HIT HSK-A63 ultrasonic machining module was used for micro-drilling on curved surface of AISI-304 stainless steel, resulting in 4 times longer tool life compared to that without ultrasonic)



 

HIT Ultrasonic Machining Technology Achievements



📈 Quality -  drilling holes with no burrs
⚙️ Tool Life - 4x longer


 

AISI-304 Stainless Steel Machining in Industry Application



Micro-drilling AISI-304 Stainless Steel is applied in the Semiconductor industry and 3C Electronics industry, especially for vacuum plates used in semiconductor manufacturing process, and electronic spare parts.


AISI-304 stainless steel is an austenitic grade stainless steel.  It is said that nearly 70% of commercially produced stainless steel are austenitic, and 304 accounts for more than 50% of stainless steel consumed.

304 stainless steel has excellent corrosion resistance under various kinds of environments.  Its good machinability also allows it to be used across different industries in the making of cutlery, architectural panelling, tubing, springs, nuts, bolts, screws, sinks, electronic spare parts, semiconductor vacuum plates, food and pharmaceutical production equipment.

Though 304 stainless steel has good machinability in general, it still has machining difficulties due to its material properties, such as work hardening and low thermal conductivity.


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 hole quality and tool life due to high cutting forces and entangled chips.  HIT assures its clients of not only matching up with their requirements, but also achieving even better outcomes!




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