Composite materials processing differs fundamentally from metal processing. Unlike metal processing, where the machined material is softer than the cutting tool and forms continuous or serrated chips, composite materials experience a brittle fracture process. The cutting edge impacts hard fibers during machining, shattering them into powder or brush-like debris.
Challenges in Machining Composite Materials
Composite materials are widely recognized as difficult to machine due to tearing, burring, delamination, and thermal damage. These challenges place exceptionally high demands on cutting tools in terms of sharpness, wear resistance, and stability. To address these issues, diamond-coated and PCD tools are commonly used to machine composite materials.
Key Features of Diamond-Coated Multi-Flute Endmills
Diamond-coated multi-flute endmills are specifically designed to tackle the challenges of machining composite materials. Their advanced features include:
- Optimized Carbide Matrix: High hardness ensures a durable tool matrix.
- Submicron WC Particles: Provides exceptional wear resistance for extended tool life.
- Left/Right Cross Edge Design: Enhances tool sharpness, effectively reducing delamination and burr formation.
- Strong Close-Tooth Design: Improves machining efficiency and accuracy.
- Sharp Positive Rake Angle: Minimizes cutting force and heat, preventing defects like tearing and burrs.
- Nano-Diamond Coating: Slows tool wear, doubling tool life and maintaining consistent performance.
Case Study: Machining CFRP Composites
Workpiece Material: CFRP composite (T700, T800 grades)
Machine: Vertical machining center
Tool Holder: HSK63A heat-shrink shank
Cutting Method: Dry cutting
Tool Specification: D8*25*L78*SD8*Z8 (Diamond-coated)
Processing Parameters:
- Cutting speed: Vc=200m/min
- Feed: F=800mm/min
- Cutting width: ae=8mm
- Cutting depth: ap=5mm
Processing Results:
- Achieved a machining length of 30 meters without burrs, tears, or delamination.
- Surface finish measured at less than Ra=1.6.
This demonstrates the reliability and effectiveness of diamond-coated multi-flute endmills in producing high-quality machined surfaces for CFRP composites.
Comprehensive Solutions for Composite Material Machining
Moresuperhard has invested heavily in R&D to develop a series of high-performance tools to meet diverse machining requirements for composite materials. These include:
- Carbide Milling Tools and Drills: Ideal for precision machining applications.
- PCD Milling Tools and Drills: Offering superior wear resistance and surface quality.
- PCD Countersink Drills: For specialized machining needs.
- Custom Non-Standard Tools: Tailored solutions for unique challenges in composite processing.
These tools effectively address common defects like delamination, burrs, and tearing in composite machining, enhancing surface quality while extending tool life.
Conclusion
Diamond-coated multi-flute endmills represent a breakthrough in the machining of composite materials. With advanced features and proven performance, they provide an ideal solution for overcoming the challenges of processing composites like CFRP. Coupled with Moresuperhard's comprehensive tool lineup, these innovations ensure superior machining quality and efficiency, meeting the stringent demands of modern manufacturing industries.
