Aerospace & Automotive Micro-Drilling of Nickel Alloy (Inconel 718)

🕜 Efficiency - 2x higher | ⚙️ Tool Life - 5x longer
  • Difficulties in Machining
  • HIT Achievements
  • Industry Application
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What makes Nickel Alloy (Inconel 718) difficult to machine?



Nickel alloy (Inconel 718) is corrosion-resistant, heat-resistant, and has high mechanical strength.  However, the low thermal conductivity (difficult for heat dissipation) and work-hardening material properties have made chips with high hardness difficult to evacuate under continuous cutting.  This leads to BUE (Built-Up Edge) on the tool blade, which not only increases tool wear but also damages hole quality of workpiece.

 

☑️ Nickel Alloy (Inconel 718) Micro-Drilling: Machining Information

 
    Nickel Alloy (Inconel 718) : Micro-Drilling: Machining Information
  Material   Nickel Alloy (Inconel 718)
  Feature   Φ0.6 x 6mm_blind holes
  *aspect ratio 10x
  Ultrasonic Machining Process & Parameters   S 16,000rpm_ F 640mm/min_Vc 30m/min_
  G83_Ultrasonic Power Level 100%_
  Q 0.6mm drilling to 0.6mm, and Q 0.3mm drilling to 6mm
  *process time: 26 sec/per hole
  Ultrasonic Tool Holder        HSKE40-R02-06
  Tool Selection   Mikron Crazydrill 2.CD.120060.Type IK
  Φ0.6mm drill


 
HIT HSK-E40 ultrasonic machining module was used on Nickel Alloy Inconel 718 micro-drilling
(Figure 1. HIT HSK-E40 ultrasonic machining module was used on Nickel Alloy Inconel 718 micro-drilling)




 

HIT's Goal in Keyway Side Milling of Nickel Alloy (Inconel 718)


The goal is to achieve higher machining efficiency and longer tool life on micro-drilling of nickel alloy (Inconel 718) with HIT ultrasonic-assisted machining technology.





 

Ultrasonic-Assisted Keyway Side Milling of Nickel Alloy (Inconel 718) Machining Results

 

Nickel Alloy (Inconel 718) Keyway Side Milling: Machining Efficiency

 
  • The solution to micro-drilling Nickel Alloy (Inconel 718) in conventional machining was to decrease feed rate (original feed rate: 320mm/min) and increase cutting speed.  However, continuous cutting under such high temperature, decreasing feed rate would be time-consuming and inefficient; increasing cutting speed would have excessive cutting heat and high cutting force (work-hardened layer), which led to serious tool wear.
  • Introduction of HIT ultrasonic-assisted machining process: the machining mechanism of HIT ultrasonic - the high frequency micro-vibration allowed for easier inflow of cutting fluid - brought better cooling effect and better evacuation of cutting chips.  This helped reduce cutting force.
  • As a result, with HIT ultrasonic, it can enhance 2x of feed rate (optimized feed rate: 640mm/min) while maintaining low cutting speed.  This could not only reduce cutting heat, but also avoid the work-hardened layer on the material.  It resulted in 2x higher machining efficiency, and much longer tool life.


 

Nickel Alloy (Inconel 718) Keyway Side Milling: Tool Life

HIT ultrasonic-assisted micro-drilling of Nickel Alloy Inconel 718, the reduction in cutting heat and cutting force allowed for drilling 64 holes per tool, while the tool breakage happened at 12th hole without ultrasonic
(Figure 2. HIT ultrasonic-assisted micro-drilling of Nickel Alloy Inconel 718, the reduction in cutting heat and cutting force allowed for drilling 64 holes per tool, while the tool breakage happened at 12th hole without ultrasonic)



HIT ultrasonic-assisted micro-drilling of Nickel Alloy Inconel 718 achieved 5x longer tool life
(Figure 3. HIT ultrasonic-assisted micro-drilling of Nickel Alloy Inconel 718 achieved 5x longer tool life)




 

HIT Achievements in Keyway Side Milling of Nickel Alloy (Inconel 718)



🕜 Efficiency - 2x higher
⚙️ Tool Life - 5x longer



 

Nickel Alloy (Inconel 718) : Micro-Drilling: Industry Application



Micro-drilling of Nickel Alloy (Inconel 718) is often applied in the Aerospace industry, especially for aircraft turbine engine components, fasteners, etc.


Nickel alloy (Inconel 718) is corrosion-resistant, heat-resistant, and has high mechanical strength.  It is widely applied in the aerospace industry and used as the material of aircraft turbine engine components, turbine blade, and fasteners.

However, the low thermal conductivity (difficult for heat dissipation) and work-hardening material properties have made chips with high hardness difficult to evacuate under continuous cutting.  This leads to BUE (Built-Up Edge) on the tool blade, which not only increases tool wear but also damages hole quality of workpiece.


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 BUE while trying to shorten the process time.  The machining efficiency and tool life can be greatly enhanced.  HIT assures its clients of not only matching up with their requirements, but also achieving even better outcomes!





💡 Learn more about other HIT Ultrasonic Machining of metal alloys, alloy steel, tool steel, carbide mould cases

💡 Introduction on HIT Ultrasonic Machining on metal alloys, carbide mould, etc.