Understanding the Differences in Machining Metal versus Composite. SmartManufacturingSeries.com
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1 Understanding the Differences in Machining Metal versus Composite
2 Differences in Machining Composite vs. Metal Lorem ipsum dolor sit amet, consectetur adipiscing elit. Nullam venenatis vel mauris vitae mollis. Etiam interdum nulla sit amet elit lobortis, at malesuada nunc eleifend. Integer finibus orci dictum libero mattis scelerisque. Material Process Modelling Heat Failure Analysis Tool Wear Coolant Strategy Milling Strategy
3 Differences in Machining Composite vs. Metal MAPAL Process, Program, People Material Process Modelling Heat Failure Analysis Shape of Waste Tool Wear Coolant Strategy Milling Strategy
4
5 AT YOUR SIDE WORLDWIDE IN 43 COUNTRIES Seattle Port Huron Fountain Inn Subsidiaries with regional production, sales and service in 21 countries 4000 employees worldwide, approx. 2,000 are in Germany Technical and sales representatives in 25 countries
6 AT YOUR SIDE WORLDWIDE AEROSPACE CUSTOMERS
7 GENERAL PRODUCT PROGRAM PART MACHINING SPM Tools HPC for aluminium Solid Carbide Tools Honey comp ISO Indexable tool for Wind blade root machining Solid Carbide tools for composites Indexable Trochoidal Milling Indexable Indexable Adapter Setting fixtures End mill Steel / Tiatnium Face mill Helical mill HSK X
8 GENERAL PRODUCT PROGRAM AIRCRAFT ASSEMBLY Solid Carbide & PCD Drills Green tools Solid carbide tools HSSE tools 1 shot H8 stack drilling Hand held applications Hand held applications Replaceable Replaceable head tools for Taper Lock Tools Threated adapter drill heads 2 shot drilling and reaming heat shrink
9 Differences Metal vers. Composite Material 2. Zulässige Grenztemperatur
![Differences in Machining Metal versus Composite Materialkennwerte im Vergleich 80 70 60 50 40 30 20 10 [Km] density Aramid](/docs-images/75/71522020/images/10-0.jpg "(Kevlar) = 256 KM tensile strength Carbon Fiber = 250 KM breaking length = Tensile = strength / density (specific tear")
10 Differences in Machining Metal versus Composite Materialkennwerte im Vergleich [Km] density Aramid (Kevlar) = 256 KM tensile strength Carbon Fiber = 250 KM breaking length = Tensile = strength / density (specific tear strength)
11 Composite Material Structure Fiber Orientation Fiber transverse direction: Et up to N/mm. Longitudinal fiber direction. E up to N/mm. weak Van der Waal bonding, SP2 covalent bond, electron pair bond, SP3 Ehrenstein, G.W.: Faserverbund Kunststoffe: Werkstoffe, Verarbeitung, Eigenschaften. Hanser Verlag, 2006
12 Composite Material Structure Carbonfaser Herstellung und produktion Carbon fraction > 95% T = C T = 1300 C The mechanical properties of carbon fibers are critically dependent on the stretching of the PAN Precursor and the thereby existing temperature
13 Differences Metal vers. Composite Failure Analysis Vergleich Bearbeitung von Metall zu Composite
14 Machining Metal vers. Composite Physical Description Physikalisches Versagenskriterium
15 Machining Metal vers. Composite Process Model Physikalisches Versagenskriterium
16 Machining Metal vers. Composite Process Heat 6. Woher kommt die Wärme bei der CFK Bearbeitung
17 Machining Metal vers. Composite Process Heat 6. Woher kommt die Wärme bei der CFK Bearbeitung Heat Generation Heat Transfer Diamond Coating Fibre Matrix Q Friction Q Q stress crack v f v c Metal Composite Q
18 Machining Metal vers. Composite Reversibility 12. Wirtschaftliches Fräsen von Composites
19 Machining Metal vers. Composite Tool Wear 8. Verschleiß bei Metall bzw. Composite Bearbeitung
20 Machining Metal vers. Composite Tool Wear Function of? 8. Verschleiß bei Metall bzw. Composite Bearbeitung Cutting temperature? Cutting speed, relative velocity? Contact length?
21 Machining Metal vers. Composite Tool Wear Function of? 8. Verschleiß bei Metall bzw. Composite Bearbeitung Cutting temperature? Cutting speed, relative velocity? Contact length? Tool wear machining Composite: proportional / Linear correlation Easy calculable
22 Machining Metal vers. Composite Tool Wear Trimming Composite Half Circumference (perimeter or Tool Diameter ) H feasible number of rev s = Longevity *of the cutting edge /Half Circumference Feasible Feed Rate number = feasible number of rev s * feed rate * To be determined as a function of fiber and Matrix, tool coating etc. and must verified experimentally
23 Machining Metal vers. Composite Tool Wear Drilling Composite Circumference (perimeter or Tool Diameter ) C 2 feasible number of rev s = Longevity *of the cutting edge /Circumference Feasible Feed Rate number = feasible number of rev s * feed rate * To be determined as a function of fiber and Matrix, tool coating etc. and must verified experimentally
24 Machining Metal vers. Composite Shape of Waste Gestalt der Werkzeuge für die CFK Bearbeitung
25 Shape of Waste Carbon Fiber Dust Gestalt der Werkzeuge für die CFK Bearbeitung Verification of the process model rectangular fracture No critical length/with fracture a p V c Granualt removal Fibre Matrix Fiber cutting Angle = C Q Q v f Dust particles similar to broken spaghettis
26 Shape of Waste Carbon Fiber Dust Gestalt der Werkzeuge für die CFK Bearbeitung Verification of the process model rectangular fracture No critical length/with fracture V c Fibre Matrix Q Q v f Dust particles similar to broken spaghettis Fiber cutting Angle = 90
27 Shape of Waste Metal Chips by the use of Micro Peck Gestalt der Werkzeuge für die CFK Bearbeitung
28 Machining Metal vers. Composite Shape of Waste Gestalt der Werkzeuge für die CFK Bearbeitung
29 Machining Metal vers. Composite Coolant Strategy 7. Welche Kühlung ist sinnvoll
30 Machining Metal vers. Composite Prea- and Post Machining 10. Schruppen und Schlichten bei Metall bzw. Composite Bearbeitung
31 Machining Metal vers. Composite Process Heat 6. Woher kommt die Wärme bei der CFK Bearbeitung Heat Generation Heat Transfer Diamond Coating Fibre Matrix Q Friction Q Q stress crack v f v c Metal Composite Q
32 Machining Metal vers. Composite Milling / Trimming Strategy 13. Frässtrategie bei Metall bzw. Composite Bearbeitung
33 Machining Metal vers. Composite Trimming with different feed rate
34
35 Machining Metal vers. Composite Trimming with different feed rate
36 Trimming with different Strategies Counter Clock / Clock wise feed Cut off
37 Trimming with different Strategies Counter Clock / Clock wise
38 Trimming with different Strategies Counter Clock / Clock wise High pressure due to overloaded dust removal capability
39 Trimming with different Strategies Counter Clock / Clock wise Thermal infusion of the boundary layer
40 Trimming with different Strategies Counter Clock / Clock wise For feed lover then 1m/min the use of climb milling is recommended Climb milling for larger tool life Conventional milling for high chip removal rate
41 Trimming with different Strategies Counter Clock / Clock wise
42 Summary Difference in 13. Frässtrategie bei Metall bzw. Composite Bearbeitung
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