End Mill Comparisons in CFRP, Part 2 - Diamond-Coated Tool
Video shows the performance of coated carbide, diamond-coated, PCD and veined PCD tools in carbon fiber reinforced plastic. Part two in a four-part series.
#compositesmachining
Share
Smith MegaDiamond Inc. and Star Cutter Company compared the performance of various end mills in carbon fiber reinforced plastic (CFRP). The tools tested included a coated carbide end mill, a diamond-coated end mill, a conventional PCD end mill with straight flutes, and a “veined” PCD end mll featuring a vein of PCD within a helical slot in a carbide tool body.
The table below summarizes the test parameters. Shown here is the video of a 10-degree helical diamond-coated tool. Jeff Michael, engineering manager for Star Cutter, comments, “Again, the sound is pretty good with this cutter, but uncut fibers appear immediately. This is because a tool’s coating tends to give it a more rounded cutting edge, making it more difficulty to cut the fibers cleanly off.”
Featured Content
To see the next video in this testing, click here.
|
|
Tool Type |
|||
|
Ø .500 in. |
Solid Carbide |
CVD Diamond |
PCD |
Veined PCD |
|
Flute angle |
30° helical |
10° helical |
7° skew |
30° helical |
|
Spindle speed (rpm) |
3,000 |
4,600 |
12,000 |
18,000 |
|
Chip load (in./tooth) |
0.0035 |
0.0035 |
0.001 |
0.0065 |
|
Machine advance (in./min.) |
42 |
64 |
36 |
470 |
|
Radial depth (in.) |
.050 |
.050 |
.050 |
.050 |
Cutting speeds and feed rates were recommended parameters from each tool’s manufacturer.
Editor’s note: To read the next part in the series, click here.
RELATED CONTENT
-
How To Machine Composites, Part 4 -- Drilling Composites
Achieving acceptable tool life and hole quality in a material such as CFRP demands a drill designed with composites in mind.
-
The Anatomy Of An End Mill For Aluminum
By using specialized cutter geometry and incorporating smooth finishes with tough coatings, Toolmex Corp., created an end mill well suited to cut aluminum aggressively. This tool called the "Mako" is part of the SharC line of specialized tools from the same company.
-
The 400° Difference
Cryogenic machining achieves dramatic tool life gains not by flooding the cut, but by refrigerating the tool.
