The challenge: how to provide the right tools and processes to improve the rapid expansion of composite processing.
Solution: Adopt new processing methods, including dedicated tools and the latest application strategies.
Processed composites are very different from processed metals, and different types of composites are processed differently. Moreover, the types of composite materials are more extensive than metal materials. This can be a daunting task for a plant that is just beginning to make composite parts, and a challenge for plants that already work on composites. Machining composites requires re-evaluation of machining methods, tools and tooling, and in some cases equipment and fixtures. In fact, every new composite material processed at the factory requires a new process.
The cutting process of composite materials is very different from that of metal cutting. The cutting edge produces chips that are not generated by shearing like most metals. Instead, they are broken to remove excess composite material, which is often cut during processing. Resin and broken fiber material.
The general principle of machining composites is to use ultra-sharp cutting edges with sufficient clearance to minimize the friction between the tool and the workpiece while achieving a smooth cutting effect. Small changes in the cutting edge geometry can quickly lead to excessive cutting heat and cracking of the cutting edge. Therefore, tool wear must be minimized. If this problem is not solved, the most important quality requirements will be affected.
Cutting tools require light cutting and minimal thrust, requiring a variety of tool geometries to match the different processing characteristics of different composite materials.
To achieve good performance, high safety and satisfactory results, unique processes need to be established to adapt and optimize the undetermined composite materials and processing methods. Where the material removal rate is important but not the main factor, the most advantageous solution should be found through economic accounting.
For composite processing, the quality of the holes and edges plus the satisfactory hole processing cost and cost per unit of meter have a greater impact on production efficiency. The surface roughness obtained in one operation reduces or eliminates secondary operations and will help extend tool life and reduce equipment downtime.
In the ever-expanding field of composite processing, the selection of special cutting tools for a specific composite material is critical. In addition, it is extremely important to set the correct parameters for the operation at hand and to properly clamp them.
Drilling is one of the most important operations in composite processing, which makes this operation extremely challenging due to the possibility of cracking or even cracking of several layers (layering) at the hole entrance and exit. Therefore, achieving acceptable surface roughness requires extra care to achieve a satisfactory cutting action between the fibrous layer and the substrate. As the impact resistance and heat resistance of composite materials continue to improve, the processing methods must also evolve with them.
Because diamonds withstand the wear of various carbon fibers and laminates (including titanium), specially modified polycrystalline synthetic diamond (PCD) weld tips or diamond coated tips have the longest tool life.
Planar machining of composite parts often has the same high demands as trimming and trimming, requiring the use of suitable indexable inserts and diamond-coated carbide tools combined with innovative machining methods.
Non-standard PCD tools provide a solution for most milling operations. Both textured diamond and welded diamond tools have different groove designs to meet application requirements. The improvement is to apply a special tool geometry to the best method to achieve better surface roughness, and may also require dusting to further reduce the tendency to crack and wear.
For the milling of composite materials, CoroMill 590 face milling cutters are equipped with polycrystalline synthetic diamond (PCD) inserts to meet the high tolerances and surface roughness requirements. It uses high cutting parameters and minimal fiber breakage in dry machining, making it ideal for machining the last step of assembly with a vacuum cleaner (as shown).
For sidewall milling and Sturtz milling of composite materials, especially for high fiber content composites, CoroMill 390 end mills are well equipped with welded diamond blades or diamond coated inserts. For trimming and trimming of composite parts, carbide inserts, diamond inserts or solid carbide inserts can meet high quality requirements.
Composite processing solutions are selected based on the specific application. These options may include the selection of a suitable CoroDrill geometry for the material and processing conditions. Due to the different materials used in the different parts, three groove types have been developed, including the universal CoroDrill 855 drill bit, with an optimized process to ensure the highest drilling quality.
CoroDrill 856 minimizes the tendency to delamination at the entrance and exit of the borehole, especially for resin-rich composites. However, when drilling fiber-rich composites, there is a need for a groove that reduces cracking, such as the new CoroDrill 854 drill bit, which has a trough shape similar to that used for aluminum machining.
Composite material
A composite material is a material having a certain property formed by combining two materials having different characteristics.
Fibers, whiskers, particles or fabrics are dispersed in the matrix to increase its stiffness and strength. The structural composite consists of a layered material or an interlayer. Multilayer composites are glued from laminates and each layer has different strength orientations.
The main matrix materials include organic materials, metals and ceramics, etc., and the reinforcing materials may be continuous or discontinuously distributed carbonaceous materials or some inorganic materials.
Carbon fiber, aramid fiber and carbon aramid fiber reinforced plastic composites are common aircraft fuselage materials. The fibers are bonded together with a base material such as an epoxy resin. The application of composite materials is growing rapidly, so the development of materials is also constantly emerging.
to sum up
In addition to developing cutting tools that improve the processing properties of composite materials, Sandvik Coromant also focuses on the development of the best processes in the field.
A range of new drills and milling tools are improving the processing properties of composites. Sandvik has designed diamond-coated carbide drills and textured PCD drills for a variety of applications. A variety of new drill bit geometries have been developed for high quality hole machining of various carbon fiber reinforced (CFRP) materials. For the milling, trimming and trimming of composite parts, end mills and face milling cutters and coated carbide tools with special diamond inserts offer new advantages. Standard and non-standard products form the processing solution for drilling and milling composite materials today and in the future.
Solution: Adopt new processing methods, including dedicated tools and the latest application strategies.
Processed composites are very different from processed metals, and different types of composites are processed differently. Moreover, the types of composite materials are more extensive than metal materials. This can be a daunting task for a plant that is just beginning to make composite parts, and a challenge for plants that already work on composites. Machining composites requires re-evaluation of machining methods, tools and tooling, and in some cases equipment and fixtures. In fact, every new composite material processed at the factory requires a new process.
The cutting process of composite materials is very different from that of metal cutting. The cutting edge produces chips that are not generated by shearing like most metals. Instead, they are broken to remove excess composite material, which is often cut during processing. Resin and broken fiber material.
The general principle of machining composites is to use ultra-sharp cutting edges with sufficient clearance to minimize the friction between the tool and the workpiece while achieving a smooth cutting effect. Small changes in the cutting edge geometry can quickly lead to excessive cutting heat and cracking of the cutting edge. Therefore, tool wear must be minimized. If this problem is not solved, the most important quality requirements will be affected.
Cutting tools require light cutting and minimal thrust, requiring a variety of tool geometries to match the different processing characteristics of different composite materials.
To achieve good performance, high safety and satisfactory results, unique processes need to be established to adapt and optimize the undetermined composite materials and processing methods. Where the material removal rate is important but not the main factor, the most advantageous solution should be found through economic accounting.
For composite processing, the quality of the holes and edges plus the satisfactory hole processing cost and cost per unit of meter have a greater impact on production efficiency. The surface roughness obtained in one operation reduces or eliminates secondary operations and will help extend tool life and reduce equipment downtime.
In the ever-expanding field of composite processing, the selection of special cutting tools for a specific composite material is critical. In addition, it is extremely important to set the correct parameters for the operation at hand and to properly clamp them.
Drilling is one of the most important operations in composite processing, which makes this operation extremely challenging due to the possibility of cracking or even cracking of several layers (layering) at the hole entrance and exit. Therefore, achieving acceptable surface roughness requires extra care to achieve a satisfactory cutting action between the fibrous layer and the substrate. As the impact resistance and heat resistance of composite materials continue to improve, the processing methods must also evolve with them.
Because diamonds withstand the wear of various carbon fibers and laminates (including titanium), specially modified polycrystalline synthetic diamond (PCD) weld tips or diamond coated tips have the longest tool life.
Planar machining of composite parts often has the same high demands as trimming and trimming, requiring the use of suitable indexable inserts and diamond-coated carbide tools combined with innovative machining methods.
Non-standard PCD tools provide a solution for most milling operations. Both textured diamond and welded diamond tools have different groove designs to meet application requirements. The improvement is to apply a special tool geometry to the best method to achieve better surface roughness, and may also require dusting to further reduce the tendency to crack and wear.
For the milling of composite materials, CoroMill 590 face milling cutters are equipped with polycrystalline synthetic diamond (PCD) inserts to meet the high tolerances and surface roughness requirements. It uses high cutting parameters and minimal fiber breakage in dry machining, making it ideal for machining the last step of assembly with a vacuum cleaner (as shown).
For sidewall milling and Sturtz milling of composite materials, especially for high fiber content composites, CoroMill 390 end mills are well equipped with welded diamond blades or diamond coated inserts. For trimming and trimming of composite parts, carbide inserts, diamond inserts or solid carbide inserts can meet high quality requirements.
Composite processing solutions are selected based on the specific application. These options may include the selection of a suitable CoroDrill geometry for the material and processing conditions. Due to the different materials used in the different parts, three groove types have been developed, including the universal CoroDrill 855 drill bit, with an optimized process to ensure the highest drilling quality.
CoroDrill 856 minimizes the tendency to delamination at the entrance and exit of the borehole, especially for resin-rich composites. However, when drilling fiber-rich composites, there is a need for a groove that reduces cracking, such as the new CoroDrill 854 drill bit, which has a trough shape similar to that used for aluminum machining.
Composite material
A composite material is a material having a certain property formed by combining two materials having different characteristics.
Fibers, whiskers, particles or fabrics are dispersed in the matrix to increase its stiffness and strength. The structural composite consists of a layered material or an interlayer. Multilayer composites are glued from laminates and each layer has different strength orientations.
The main matrix materials include organic materials, metals and ceramics, etc., and the reinforcing materials may be continuous or discontinuously distributed carbonaceous materials or some inorganic materials.
Carbon fiber, aramid fiber and carbon aramid fiber reinforced plastic composites are common aircraft fuselage materials. The fibers are bonded together with a base material such as an epoxy resin. The application of composite materials is growing rapidly, so the development of materials is also constantly emerging.
to sum up
In addition to developing cutting tools that improve the processing properties of composite materials, Sandvik Coromant also focuses on the development of the best processes in the field.
A range of new drills and milling tools are improving the processing properties of composites. Sandvik has designed diamond-coated carbide drills and textured PCD drills for a variety of applications. A variety of new drill bit geometries have been developed for high quality hole machining of various carbon fiber reinforced (CFRP) materials. For the milling, trimming and trimming of composite parts, end mills and face milling cutters and coated carbide tools with special diamond inserts offer new advantages. Standard and non-standard products form the processing solution for drilling and milling composite materials today and in the future.
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