Exit-Side Drill Penetration Without Delamination
Slow-motion video shows the effect of a micograin tool coating in drilling CFRP.
Cutting tool maker OSG says a patented coating process keeps the micrograin structure of its diamond coating to less than 1 micron. Coating typically rounds the edge of a tool, but the smaller micrograins produce a coated tool that is sharper. The result, says OSG, is less tradeoff between the tool life of diamond and the delamination that can result from a duller tools. This video shows this. The sharp edge of the small-micrograin diamond-coated tool lets this tool exit the hole much more cleanly.
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.
Though it won’t replace high speed machining, Boeing sees “low speed machining” as a viable supplement to higher-rpm machines. Using new tools and techniques, a shop’s lower-rpm machining centers can realize much more of their potential productivity in milling aluminum aircraft parts.
In carbon fiber reinforced plastic (CFRP), the material removal mechanism is shattering instead of shearing. This makes it different from other machining applications.