Hybrid Machining: An Industrial Case-Study Comparing Inconel718 Reaming and Drilling with Abrasive Waterjet Technology

Abstract

Abrasive waterjet technology is one of the fastest growing metal cutting technologies. When used in conjunction with conventional metal cutting methods, abrasive waterjet cutting can be both cost saving and environmentally favorable. This paper shows that when processing hard to cut alloys, abrasive waterjet will be an excellent hybrid alternative. Reaming and drilling have traditionally been used to produce turbine blisks. Reaming is a highly expensive method since it uses very large amounts of cutting tools. Especially when cutting hard materials such as Nickel alloys, tools have to be replaced after only a few minutes of usage. By applying abrasive waterjet cutting to part of the process, the cost for tooling can be almost entirely eliminated. It will also increase the return profit for revert material and greatly reduce environmental emissions. This is because reaming and drilling produce chips while large amounts of cutting fluids are being used. Abrasive waterjet cutting will produce one large metal chunk per cut and uses no cutting fluids. This paper presents a method to combine abrasive waterjet cutting with reaming and drilling.