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COMPOSITES MACHINING


engines pose special machining challenges,” said Linn Win, industry specialist composites, Sandvik Coromant (Fair Lawn, NJ). “The ceramic matrix composite material is extremely abrasive and very brittle. Adding to the diffi culty in machining is the required lightweighting. When you factor in the practical machining for light-weighting applica- tions, it’s very diffi cult to get the cost savings benefi ts from the light-weighting components because of the more expensive tooling that is required for complex components like blades and blisks,” said Win.


Polycrystalline diamond-veined tooling is a technology that has proven to be very effective for machining composites. “PCD is great for its wear resistance properties in composite machin- ing applications, which may lead to longer tool life, but in order to gain the full potential of PCD, the tool will need to have positive cutting geometries,” said Win.


Sandvik Precorp 88 Series veined PCD geometry.


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888 %"3&9 $0. ] See us at Y Booth #W-2180 & #N-7209 86 AdvancedManufacturing.org | September 2016


“Conventional brazed tooling, which involves brazing a PCD wafer into a pocket, at best allows for minute positive formations, not the optimum for machining composites. PCD-veined tooling produced by Precorp, a subsidiary of Sandvik Coromant, enables PCD cutting tools to be manu- factured with the high rake angles and helix angles required to effectively machine composites. Here’s how Precorp’s PCD-veined tooling is produced. A carbide blank is slotted and fi lled with diamond powder. The carbide blank is inserted into one of Precorp’s high- pressure, high-temperature presses and subjected to 270°F (132.2°C) and 876,000 psi (60,398 bar). In this process the diamond powder is compressed and the diamond crystals are bonded to each other and to the carbide blank. The PCD nib is then brazed to a solid-carbide shank. The braze is located suffi ciently far away from the tip of the tool to avoid any potential thermal damage. This allows the use of a high- temperature high-strength braze joint between the nib and the carbide shank. The drill geometry is ground to produce the fi nished PCD tool. This patented process allows for many tool geometries that are impractical and/or impossible using conventional PCD insert processes. “We have found that in drilling applications in ceramic matrix composites, we do not encounter too many issues when entering the material; the problems occur when we exit the material. On the exit surface, we fi nd that the breakout can be quite poor, due to the high axial pressures that are being applied to the workpiece upon the tools exit. The back side of the material in an unsupported environment tends


Photo courtesy Sandvik Coromant


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