Compare with metallic cutting photograph, the treatment of composite material posed unique challenge. Abrasion of the fibrous that add pliable but strong makes cutting tool loss of life. Cut bits to differ with the metal, the quantity of heat that plastic matrix takes away is very few, and temperature may make matrix high fused too. Composite material is easy and statified come off, the burr that machines generation and fiber show the brim quality that gets cut hole or milling is very poor. Compare with metallic cutting photograph, the treatment of composite material posed unique challenge. Abrasion of the fibrous that add pliable but strong makes cutting tool loss of life. Cut bits to differ with the metal, the quantity of heat that plastic matrix takes away is very few, and temperature may make matrix high fused too. Composite material is easy and statified come off, the burr that machines generation and fiber show the brim quality that gets cut hole or milling is very poor. Other challenge still includes to be opposite by composite material and titanium alloy (or aluminium alloy) of composition pressure add up to the material that fold a layer to undertake machine and be gettinged cutting. It is particularly difficult that research and development gives the cutting tool that can finish bores of pair of this kind of material that fold a layer to machine. The commonly used strategy that devises cutting tool of composite material cutting includes to use cutting tool of cutting tool of blame coating hard alloy, CVD diamond coating, serve as edge with PCD or of knife head solder cutting tool. Traditional PCD cutting tool is through embedding diamond crystal agglomeration metallic matrix is made, the cutting part of cutting tool is needed into place by cut appearance, solder (or agglomeration) go up in hard alloy knife handle. Traditional PCD cutting tool gets on appearance of cutting tool geometry certain confine, the cutting tool of PCD of integral agglomeration type that nevertheless already a few companies can carry sacrificial vessel to have figure of more intricate geometry now. When design composite material machines cutting tool, need makes cutting force the smallest change, getting especially in cutting treatment, shun stuff statified it is very important to come off. Agree explanation of Karthik Sampath of offer company senior engineer says, "Statified come off when happening in cutting tool to get a work normally, axial thrust will be right now right of next surfaces fold a layer to use force. Statified when coming off easy also generation gets the face on workpiece in cutting tool. " although of material statified come off with axial thrust is concerned, but agree offer company thinks, fibrous position is different and hole of the existence in material also can build composition layer to come off. When processing metallic data, those who cut bits cut and figuration can agree equably, and the treatment of composite material differs somewhat, it needs to cut off fiber, undertake cutting to matrix material even at the same time. To wear away with the smallest cutting tool implementation does not have burr cutting, agree offer company undertook optimizing designing to the geometrical structure of cutting tool. Sampath points out, "Our experiment bright, get the need when cutting composite material to use big helix angle, big hind horn and large tine unoccupied place part, enter work in order to make cutting tool is cut more easily. " the design of the horn after needing to take cutting blade seriously especially. Use 10 ° , 20 ° and the comparative cutting test of the horn after 36 ° respectively in in, as the accretion of the horn after cutting tool, be improved apparently by the quality of treatment aperture. Of cutting tool sharp degree crucial also, "Our test result makes clear, cutting tool has sharp cutting blade before coating (10µm) of ≤ of radius of circular arc of point of a knife, can achieve optimal treatment result " . In side of cutting tool data, agree offer company is recommended use broach of PCD of integral agglomeration type and bit of coating of diamond of low cobaltic steel. According to Introduction Sampath, with not the photograph of hard alloy broach of coating is compared, the life of diamond coating broach can raise 10 times; Below certain circumstance, diamond coating broach can rise than the life of PCD broach 50% . "To acquire best wearability and optimal cutting property, we are recommended use ply to be 12µm diamond coating. Thinner coating may bring about blade of cutting blade collapse, and thicker coating needs to raise additional cost, sexual price is poorer. " agree offer company is treatment composite material, developed B531 and B532 series broach. Stephen Jean of manager of product of Emuge company milling also agrees, the design can make cutting pressure the least the cutting tool that turn. Geometrical appearance to composite material without burr cutting crucial, "Our cutting tool establishing mill has distinctive appearance, establish milling cutter photograph to compare with traditional hard alloy, more resembling is milling cutter of a whorl. This milling cutter includes two detached dentate cutting blade, an edge up cutting, another edge is down cutting. When edge rotates, its effect is similar to scissors cut motion, but material of efficient milling matrix, cut fiber at the same time, can avoid to wear away effect. " Emuge company also stands milling cutter and razor blade to machine composite material to offer PCD, and razor blade of all sorts of hard alloy of CVD diamond coating and establish milling cutter. Laeh Diamond company developed a variety of broach for cutting composite material, establish milling cutter and knife head. This company machines engineer Jason Lindsey to say, this company is produced only use PCD to solder the cutting tool of bit and CVD diamond coating. According to saying, their cutting experiment shows, the life of cutting tool of CVD diamond coating lengthened 20 times above than cutting tool of common hard alloy. "The key depends on cutting tool must having enough large watch area, so that solder PCD razor blade above. Accordingly, be less than the broach of 4mm to the diameter, we are recommended use CVD diamond coating; Be more than the broach of 4mm to the diameter, we are recommended solder PCD getting is pointed. " PCD cutting tool besides have longer life beyond, after still can undertaking weighing grind and be adjustmented to bit, repeat use. The Z composite material that establishing milling cutter is Lach company design machines an example of cutting tool. Design of this milling cutter is used at treatment of periphery thick mill, its characteristic is PCD knife head distributing provide vicissitudinous to cut corner, controallable cutting force. The cutting tool that this company develops includes to insert mill is used and be not insert mill to use cutting tool. Lindsey explanation says, when undertaking circumjacent milling around composite material, this kind of design can make thinner, not stable carbon fiber basic level avoids fast fluctuation vibration. To achieve optimal cutting result, commendatory cutting rate is 914m/min) of ～ of 2200 ～ 3000fpm(670. Lach company still produces other 4 kinds of cutting tool that use at cutting composite material: The M that machines outline of inside and outside with Yu Jingxi establish milling cutter; The P that for circumjacent milling triumphant husband draws Er fiber material and designs before horny double chamfer establishs milling cutter; Establish milling cutter with the C that at periphery half essence mill machines double chamfer; And establish milling cutter with the WA that machines at envelope face plate double chamfer. The fluctuation reciprocating type of WA milling cutter cuts force of OK and quits cutting, reduce cutting pressure, avoid composite material thereby statified come off. Tool supplier is normally composite material treatment cutting tool serves as custom-built product and not be standard catalog product will design. Current, all and complex material of full company of coke of gram of hill spy dimension makes cutting tool of the labour that attack a mouth is custom-built development. This company treatment manages manager Francis Richt to express, on the market nowadays, the element of dominant cutting data includes requirement of workpiece quality, surface, finished cost and material part. The field is created in aviation, use extensively of composite material, the diversity that machines a machine tool, make the cutting condition of composite material slashing, need special and custom-built cutting tool. Mr Richt also agrees, cut treatment to folding a material to undertake those who finish get sex of particularly rich challenge. Recently, the company rolled out Shanteweikekeleman to be used at getting to cut the CorooDrill R854 that processes composite material. This kind of broach is made with fine grained hard alloy, used diamond coating, the design of its geometry structure can reduce axial cutting force. Those who inspect treatment requirement and treatment data is different, this company still can offer hard alloy broach and PCD bit. To carbon fiber composite material (edge preparation and the exterior treatment of CFRP) , nap treatment, this company supplies cutting tool not only, and still offer treatment solution, include all sorts of soldering type may cutting tool of dislocation type milling. Fine of right short for the Yihe River of milling craft and cutting tool solution depends on on degree greatly the type of the machine tool, shunt-wound structure machine tool is used when be being machined namely (machine tool of PKM) , numerical control or robot. AMAMCO company is another custom-built tool supplier that values composite material to develop prospect, the cutting tool that this company designs is the response that enlarges the market increasingly to this. Introduce according to Andrew Gulpin of AMAMCO company director, the composite material broach of this company is had very small get a tip, coarsen gradually advocate diameter. When bradawl awl enters work, produced effect of a kind of disintegrate in composite material actually; When taper getting the needle continues when treatment getting gives this opening, undertook be rectifyinged solely clearing to disintegrate place again. Pass these two kinds of acts, can obtain without statified, do not have disintegrate without burr (bright and clean) aperture. This company earlies childhood to enhance composite material and aluminium alloy by carbon fiber for be being used at getting to cut (or titanium alloy) the cutting tool of the material folding a layer that make. Gulpin thinks, without a kind of cutting tool the design can satisfy the treatment of all type stuff in folding a layer to ask, to assure the treatment quality of aperture, have life of sacrificial cutting tool only. He points out, not coating cutting tool suits treatment pressing to combine the material that fold a layer most normally. Nextpage is current, what AMAMCO company uses is exclusive a kind of coating is the DiaTiger coating that provides by company of Diamond Tool Cutters. Roger Bollier of president of company of Diamond Tool Cutters thinks, the performance when diamond coating is used at composite material to machine is outstanding. Performance of diamond heat conduction is superior, have sex of chemical the Sui Dynasty at the same time, as won't chemical as the colophony happening that uses in composite material response issues in cutting high temperature. In addition, it still has extremely low coefficient of friction. Diamond coating craft uses size normally bigger get together the structure of accept rice diamond with crystal structure and thick 1µm is alternant coating, is not to use onefold diamond coating. This kind of alternant coating can prevent crackle to be faced from coating watch expand inside matrix, and the chief reason that this kind of crackle expands is coating invalidation. Grain is bigger get together the crackle in brilliant coating tends to perpendicular grow at exterior direction, and the crackle in coating of accept rice crystal tends along 45 ° direction outspread. Alternant coating carries the patulous part that changes crackle to go to another from ceaselessly, restrain crackle to expand thereby. The coating of accept rice diamond that carries a layer on the head (grain diameter is only 0. 01µm) can offer slick surface. Bollier introduced to apply at the coating of circular cutting tool and razor blade, yu Hanzuan of its matrix confine measures the hard alloy matrix of 6% . Cutting tool of DiaTiger CVD coating is in happen after wearing away, cannot grind again commonly, although Bollier also pointed out broach,be ground to get pointed example again. Bollier points out, "As aviation manufacturing industry forward the way of large-scale treatment develops composite material industrialization, the application of diamond coating is being accepted by increasing ground. The key that we pay close attention to at present is to shorten coating Hu busyness accumulates time. Deposit now ply needs to cost 20 ～ 60 hours normally for the coating of 12µm, shorten deposit time will make diamond coating has appeal more. " company of Europe person aircraft (the treatment that OSG Tap And Die) also is composite material is custom-built design cutting tool. This company makes the bit that is used at processing composite material, establish head of knife of milling cutter, milling cutter and reamer to wait. Tod Petrik of engineer of this company advanced treatment says, the treatment of composite material of avery kind of may be not same, because this must adjust cutting tool,design in order to obtain optimum behavior. Current, OSG can be offerred not cutting tool of coating hard alloy, PCD solders cutting tool and diamond coating cutting tool. "For the user custom-built cutting tool makes we can adjust cutting tool design to obtain optimum behavior freely. E.g. , when the manufacturing demand of the user produces change, improve the productivity of the user to last, we are in a few short broach the design was revised 3 times inside the month. And the product to standardization, the design should be being modified 3 times inside two months is very difficult. " the horn before getting pointed design, helix angle, radial through control and ply of broach horizontal blade, can realize specific treatment tie, "For example, what issue the exit of exterior aperture to control workpiece is statified come off, we often need to change the helix angle of broach. The aperture that installs fastener with Yu An needs edge normally, because this user does not worry about the quality of the entry point of aperture. Be united in wedlock through designing diagnostic phase with correct physics, in those normally incidental statified the place that come off, we can maintain the thrust of cutting tool to be less than 30N. " Petrik says, "We more value cutting tool of hard alloy of CVD diamond coating, because of craft of CVD of have the aid of, can have coat to appearance of all sorts of complex and changeful cutting tool geometry, compare with the cutting tool posture that sets PCD point of a knife, we can have bigger design to be spent freely. " but he also expresses, if machine need, they also can supply PCD cutting tool. This company more one of reasons of favour CVD coating are OSG has technology of him proprietary CVD. Use technology of coating of this kind of low cost, can undertake recoat layer to tatty cutting tool, is not refuse, namely cutting tool can be ground again and reuse. PCD whether the cutting tool that is used at making to have intricate geometry figure? Scott Horman of manager of products plan of Mega Diamond company points out, the PCD that the conventional means that uses PCD at cutting cutting tool is pair of deposit is compound piece have cut and solder its to go up to cutting tool. This kind of means not only confine the geometrical appearance design of cutting blade, and because solder contact nears the cutting surface with very high temperature, bring about cutting tool invalidation easily. A solution is: Machine the knife base that gives hard alloy milling cutter and bit above all, on knife base form cutting gives intricate geometry appearance or cut a groove, in filling diamond powder these groove next, burn form PCD. Grind through driving groove and blade, can mix material knife base to make a cutting tool that has intricate geometry measure with these. Solder with traditional PCD cutting tool photograph is compared, the solder contact of cutting tool of PCD of type of agglomeration of this kind of whole is far from cutting surface, because this decreased,accept the cutting tool be no longer in force that order be no longer in force and causes because of solder. MegaDiamond company offers the knife semifinished product that passes semifinishing machining cooperative company, undertake by them cutting tool opens groove and blade to grind next, win the final geometry figure of cutting tool. From the point of the angle of the machine tool, cutting composite material has definite advantage. "You can be used than cutting metal (especially titanium alloy) and (going up somehow) steel or cast-iron when get much exterior speed quickly to undertake cutting. When processing composite material, we move with speed of the largest main shaft, can amount to thousands of feet / minutely, compare with the 152m/min) of ～ of 200 ～ 500fpm(61 when machining titanium alloy, six to one. " the treatment manager Mike Sess of MAG Cincinnati company says so. He also thinks, get when cutting composite material, "Get " it is a problem, "Sometimes we add layer of a mat in composite material the reverse side, when composite material by drill through when, can support action to arriving since material " . Suffer to protect cutting tool to avoid wear away to be affected with high temperature, sess is recommended use PCD to solder cutting tool (look the lover) that he is not CVD diamond coating. He thinks, still have the problem that a few need note, "We discover, receive a part in solder of cutting tool drill rod sometimes, the fiber in composite material can be given by get rid of; Or, if move below dry cutting position, sometimes quantity of heat may make weld fused. " after a kind of circumstance falls, use cooling fluid will be helpful. Nevertheless, some composite material may with cooling fluid (especially oil radical cooling fluid) produce reaction and cause pollution to remain, after need user is being machined, perhaps undertake other is operated in order to clean workpiece. Because cross big cutting thrust and attrition,can bring about material statified come off, so whether use different cutting to machine a concept to solve certain problem? The prejudicial pattern that considers to take helix interpolation to move is gotten cut a technology. The prejudicial type that be developed by Swedish Novator company and has patent gets the main shaft that cuts device to have an independence, while it makes broach is circling oneself axes to rotate, return can turn around its center axle. Agree the Sampath of offer company says, this company developed a series of having to have the cutting tool of geometrical appearance design, base material and coating only, the prejudicial type that is Novator is gotten cut device form a complete set. Compare with twist drill photograph, agree the much chamfer design of accept cutting tool can reduce axial pressure. The Sess of MAG Cincinnati company thinks, helix interpolation is machined to composite material is a kind very the cutting that breathe out is politic. "On our Bench Machine Tool, we can raise composite material to machine efficiency actually through helix interpolation motion. But go up in our large machine tool, we are willing to install Novator prejudicial type to get on machine tool main shaft directly more cut unit, we can sorrowful reason arrives this. " link 1: Novator prejudicial type gets the prejudicial pattern that cuts technical Novator company to own patent cut a technology (Orbital Drilling) is to be based on cutting while cutting tool is circling its oneself axes to rotate, still turn around axes of a center, and deflection exists between this center axes and cutting tool axes. Accordingly, cutting tool can make axial already motion undertakes getting cutting or aperture is machined, make aleatoric and transverse motion again at the same time in order to machine mouth or sunken antrum. Through adjusting deflection amount, the cutting tool that can have specific diameter with goes drilling the hole that cuts different diameter, this is meant can reduce cutting tool inventory greatly. At present this product can divide for two series: ① computerized numerical control (CNC) prejudicial type is gotten cut unit, can slant through what process designing set differs accumulate offset; ② but process designing logic is controlled (PLC) prejudicial type is gotten cut unit, can the hand is moved adjust slant willow offset. The prejudicial type that dominates deflection by CNC is gotten cut device to be able to be used all sorts of means decide and optimize auger cut a course, this makes multiform agile can accuse prejudicial auger cut treatment (the hole that if use the straight chamfer of identical diameter and setting,broach getting cuts a complex figure finishs finish machining to operate) become a possibility. Link 2: Broach of PCD of type of agglomeration of whole of broach of PCD of integral agglomeration type won patent 1987 and apply at printed circuit board industry. Since thenceforth, this kind of cutting tool already was in preform of medical treatment, pottery and porcelain, hard alloy, metal radical gets applied extensively in composite material, car and aviation industry. The production of broach of PCD of integral agglomeration type is grind on hard alloy preform piece narrow groove, it is in groove cram diamond is pulverous, undertake agglomeration through PCD agglomeration craft below high temperature high pressure next, its end item is the semifinished product of hard alloy knife that contains striation PCD namely. The aleatoric geometry form that structure of this kind of stripe can be wanted into place of cutting cutting tool by grinding, accordingly, can grind with base of this kind of knife make a cutting tool that has PCD cutting blade. The advantage of broach of PCD of integral agglomeration type depends on can be being formed appearance of horny cutting geometry, also can make small size bit. Common PCD broach is PCD compound piece receive cutter hub to go up through silver-colored solder solder, this kind of cutting tool is not had appearance of horny cutting geometry, and be soldered the border of contact area is made, broach dimension is done impossibly too smally. CNC Milling
CNC Machining