PCD Inserts processing carbon fiber reinforced epoxy resin material: effectively improve surface roughness

06 July 2024
As the manufacturing industry develops towards lightweight and green environmental protection, the application fields of composite materials are becoming more and more extensive.
Common lightweight materials include high-performance steel, lightweight aluminum alloy, high-strength plastic, and fiber-reinforced resin-based composite materials.
Among them, carbon fiber-reinforced epoxy resin composite materials (CFRP) have become important materials in aircraft, rockets, wind turbine blades, automobiles, and other industries due to their high specific strength and lightweight.
Wide application of carbon fiber-reinforced epoxy resin composite materials
CFRP is composed of carbon fiber and resin matrix, with excellent high specific strength and light weight, and is widely used in the following fields:
1. Aerospace: As an important structural component of the aircraft fuselage, wings, doors, etc., it is also used in rocket engine nozzles, combustion chambers, and other parts due to its excellent high-temperature resistance and friction resistance.
2. Wind power generation: The main component material of wind turbine blades.
3. Automobile industry: Gradually replacing traditional materials as key parts such as transmission shafts and structural parts.
4. In the fields of construction, electronics and electrical, rail transportation, industrial machinery, and medical treatment, its application is also being continuously expanded to meet various performance requirements and increase penetration in various industries.
Customer Case: Improving CFRP Surface Roughness
Moresuperhard recently received a request from a Romanian customer. The customer hopes that we can recommend a PCD tool that can meet the surface roughness requirements of his CFRP workpiece (Ra<1) according to his processing parameters.
The tools currently used by the customer are Ceratizit's VCGW160408 FN_A5CTDPS30, VCGW160404FN_A5CTDPS30 and VCGT160402FN_A3 CB1CTDCD10. The best processing effect of the workpiece is Ra1.8. Through Moresuperhard's previous case presentations, customers are very impressed with our technology and ideas.
Through the communication between Moresuperhard engineers and customers, we learned that the current customer processing situation is as follows:
- Workpiece material: 70% carbon fiber and 30% epoxy resin
- Workpiece size: diameter 70-250mm, maximum 2000mm
- Equipment: Dmg mori CTC 2000
- Spindle maximum speed: 2500rpm
- Feed speed: 0.1mm/rev
- Main demand: Improve the surface roughness of the workpiece to Ra<1
Moresuperhard engineers suggested that we first try to change the blade model and reduce the feed speed. The customer agreed with our suggestion and decided to test the DCMT/DCGT model blades and the different chip breaker designs we recommended.
Moresuperhard is very confident that it can help this customer solve the problem and achieve its goals.
PCD Inserts
Advantages of PCD inserts
PCD inserts have extremely high hardness and wear resistance, which are very suitable for cutting CFRP materials. Its advantages include:
- Long-term sharpness: longer tool life, faster cutting speed, and improved production efficiency.
- Surface finish: excellent surface quality and reduced delamination.
If you have better suggestions on improving the surface roughness of CFRP machining with PCD inserts, please feel free to discuss them with us.
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