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to blow out, which may lead to quality issues. In an unsup- ported application, we believe there is not an effective way to machine ceramic matrix composites, due to the materials inherent brittleness,” said Win. “But what we have found is that when we apply positive tool ge- ometry with the PCD-veined diamond tooling, you can actually reduce the amount of stress forces that being applied because now you have freer cutting edge and are able to produce the features that are needed with lower thrust force.”


“PCD diamond-veined tools can be applied to almost every type of machining operation,” said Win. “With structural products for the frame, I think it’s a little easier. What I found in drilling carbon fi ber and titanium stacks is that once you clear the carbon material and encounter the titanium material interface, the tita- nium chips will sometimes score the composite material, again potentially causing a quality issue. To alleviate the problem, we’ve adopted a micro-peck technique in the drilling cycle that al- lows the formation of smaller titanium chips to clear. In regards to the ampli- tude of the micro-peck, we are talking on the scale of millimeters. The peck distance is going to be around 0.1–0.2 mm at a frequency of 1.5 to 2.5 micro- pecks in a 360° rotation. What the micro-peck technique does is break up the titanium chips during a drilling cycle and allows for proper evacuation of the smaller more manageable chips. The result is that we’re cutting both materials—the composite and the titanium—with one diamond-veined tool.” Sandvik Coromant is developing a new 88 series geometry PCD-veined tool for CNC applications and a new 86 series for power-feed tools. Due to the wide array of applica- tions, no two CFRP materials are ex-


actly alike. Each composite can take on different character- istics by changing the matrix formulation, fi ber type, content, orientation, build-up, and the method of forming, according to Precorp.


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BOOTH W-2154 15700 S. Waterloo Road | Cleveland, OH 44110-3898 1.877.426.2504 | jergensinc.com/WORKHOLDING | workholding@jergensinc.com


September 2016 | AdvancedManufacturing.org 87


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