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CFRP Composite machining is NOT difficult: Unlocking Solutions for Three Key Challenges

Difficulties and main problems

Carbon fiber composites have unique difficulties and problems when machined, which cannot be solved by experience in metal processing. Cutting tools, fixtures, and machining parameters for composite machining must be reconsidered. In general, composite machining mainly needs to overcome:

  • Material delamination
  • Splintering
  • Quick tool wear

• First, the quality of the composite machining itself is difficult to assess because:
• Composite machining does not produce chips to judge the machining quality
• Roughness measurement is not obvious
• Lamination after machining may not be visible
• For machining quality, only hole quality and tool condition can be judged
• The use of coolant may cause the drilled hole to shrink
The carbon fiber is removed in a brittle fracture on the machined surface, removing only the heat rarely generated by the machining. So, the cutting-edge temperature of the tool is very high. It results in reduced tool life.
• The composition of synthetic resin is easy to react with the tool surface, resulting in the composition of synthetic resin on the tool surface is easy to respond with the tool surface, resulting in the tool surface wear
• The resin matrix material can be oxidized and degraded at high temperatures, and the carbon fiber can not be cut smoothly, resulting in a poor cutting effect.
• The resin matrix material can be oxidized and degraded at high temperatures, and the carbon fiber can not be cut smoothly, resulting in a poor cutting effect.
• Splintering: Due to the passivation of the tool, the fiber is not entirely cut and remains in the hole
• Delamination: the layers are separated by the interpenetration of the drill
• On unidirectional fiberboards, elliptical holes are produced due to the different bending forces of the fibers

Splintering and Fraying

Delamination

Fraying

Tool wear

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