Efficient machining of difficult-to-machine materials

Difficult-to-machine materials, challenging geometries, and high surface and tightness requirements call for careful process planning and special machining strategies when machining components for the gas and oil sector.

To prevent corrosion and withstand the high pressures that occur, superalloys such as Inconel are used for valve bodies, flanges, manifold blocks, and pump housings. Inconel is a family of nickel-chromium-based superalloys known for their extreme strength, corrosion resistance, and heat resistance.

These materials, which are used in hydraulic fracturing pumps, for example, are among the most difficult to machine, as the alloys have been specially developed for extreme pressures and operating conditions. In order to achieve the required production rates or the customer's manufacturing targets and to increase the service life of the tools, the machining strategy and the coolant used are decisive factors in this application.

Distribution blocks are precision components with numerous passages for control and measuring lines. The many channels with thin-walled structures and complex cavities inside the block often require 5-axis strategies. Due to the tightness requirements, tight tolerances are necessary for fits and sealing surfaces.

High surface quality is critical for the hydraulic efficiency and service life of the component. Machining therefore not only shapes these highly stressed, safety-critical components, but also determines their quality. The combination of high pressures, abrasive media, and aggressive materials makes machining both challenging and economically relevant.

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