Composite materials are increasingly being used in all aspects of our daily life, such as in sports equipment, cars, motorcycles, consumer goods and health care products. An example of use within the medical field is the new method used for the reconstruction of large or complex-formed cranial bone defects. In this area, pre-fabricated, computer-generated, individual CFRP medical grade implants are now used.
It is vitally important for the world’s manufacturers and technologists, involved in almost every industry, to be prepared for the new requirements of the market and be flexible enough to find new applications for CFRP and composite materials.
As one of the leading producers of cutting tools for the metalworking industry, ISCAR boasts a wide range of high-performing, precision-engineered polycrystalline diamond (PCD)- and cubic boron nitride (CBN)-tipped tools. ISCAR also has a variety of advanced diamond-coated solid carbide tools with a range of geometries to meet the most exacting demands of today's metal, wood, CFRP and composite material industries. These products include inserts, countersinks, ball mills and mills, profile cutters and combined drills, step reamers and a drill with countersinks. Also, our highly experienced engineering team welcomes requests for "special" tools for the machining of any kind of material.
PCDs are in increasing demand for more efficient machining of modern materials, such as nonferrous metals, plastics, composite material (graphite) and other hard-to-cut or abrasive materials. CBN tools are required to machine hardened steels above HRC 45, cast iron, super alloys and other specific metals. High-quality tools increase productivity and save production costs. ISCAR's R&D resources are committed to helping solve the problem of machining these complex materials, and a significant amount of money is continually being spent on developing an even wider range of solutions.
The machining of materials which are currently used for advanced types of aircraft demands new processes as these difficult materials are lightweight, yet very strong. The tooling commonly used for machining CFRP features long-lasting diamond PCD inserts, vein PCD milling tools or brazed mandrel tools.
When machining composites such as CFRP, there are virtually no chips created. Instead, the material removal mechanism might be better described as ‘shattering.’ The impact of the cutting edge fractures the hard carbon fibers, rather than shearing material away. This process causes considerable abrasion to the tool’s cutting edge, leading to rapid wear. In composite machining, as well as any other cutting tool application, tool geometry drives cutting performance. However, in the area of composites, tool material also becomes a major driver of performance. Unless the tool’s edge material is able to withstand high levels of abrasion well enough to hold its geometry and stay sharp, the tool can wear so quickly that the geometry can change rapidly. In order to successfully machine CFRP, ISCAR has developed hard, sharp solid-carbide tools which are coated with long-lasting diamonds.
The diamond coating used is commonly a polycrystalline diamond (PCD) coating. However, a diamond coating applied by the chemical vapor deposition (CVD) process is the only coating that utilizes 100% real diamond crystals. A major advantage of CVD diamond coating is that it reduces the heat and friction created by the highly abrasive composite material.
Although the machining operations required for composite parts may be simple (sometimes only drilling and trimming), the fixtures designed to support these often complex parts can represent small feats of engineering in themselves. Thus, the fixture for machining a composite part can be a considerable engineering investment. Clean cutting without fraying, delamination or otherwise separation of material layers requires the part to be firmly secured against vibration.
ISCAR’s high-quality, precise PCD- and CBN-tipped and diamond-coated tools reduce users’ production costs and improve the quality of manufactured products. Considerably improved performance on CFRP and composite materials is guaranteed when compared to the use of comparative tungsten carbide tools. Also, higher precision and excellent surface finish characteristics are achieved.
ISCAR is known throughout the industrialized world for excellent customer service, quality of products and cost-effective price, not just in the area of metal machining, but also in the field of CFRP and composite working.
Previously Featured on Iscar In The News.
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