Composite Materials

 

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Composite Materials

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Solutions for Advanced Industries w w w . i s c a r. c o m

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The Global Network g n i r e v Deli y t i l i b Prof it a ISCAR nte Guara sul es Re ts Marketing Support Marketing Support & Production Center A Leader in Metalworking Innovations Innovation at ISCAR clearly begins with its technologically advanced research & development department. Approximately 10% of ISCAR’s total resources are dedicated to R&D. As a result, time and time again the company has developed and contributed to the metalworking industry many original products and cost saving processes to provide bottleneck solutions. ISCAR is constantly upgrading and implementing improvements in computerization, data flow, quality assurance and employee safety. Global Support In order to facilitate machine tool builders, ISCAR has organized product manager groups with dedicated tool designers and field engineers. ISCAR is known for its advanced solutions for the most demanding challenges in the machine tool builders industry. ISCAR offers technical support and several manufacturing facilities around the globe. The Development Stages Each new product begins as an idea in an engineer’s mind. The image is entered into a computer aided design/machining (CAD/CAM) program. A prototype is produced and goes through exhaustive analyses. Repeated refinements, analyses, and testing continue until the exact results are achieved. Only after such an extensive development and testing sequence can the new idea move from the prototype phase to development for manufacturing. 2 Composite Materials

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A Global Metalworking Company In a world of different languages and different mentalities, it is important to have a fully equipped, knowledgeable local supplier to meet your needs. ISCAR knows this. We have subsidiary offices and agents located in 52 major industrial countries. In some of the larger countries, regional offices have been opened to bring ISCAR personnel and facilities as close as possible to customer production sites. Many of our subsidiaries have fully equipped training centers. These centers are dedicated to providing a local location where metalworking personnel can be trained in the latest techniques and products for metal removal. ISCAR has global manufacturing facilities in each of the following countries: In Europe France Germany Italy Spain Switzerland Turkey Hungary Slovenia 3 In the Americas Argentina Brazil United States In Asia South Korea China Israel

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Metal Cutting Leadership The increased popularity of composites in aerospace applications creates new challenges for shops that are used to cutting metal. One of these substances, carbon fiber-reinforced plastic (CFRP), can be especially difficult to drill because instead of executing a clean cut, tools often ‘push’ through the material. At ISCAR we realize that these materials are extremely abrasive and difficult to machine, as a result of the different physical properties of the materials used in the layers that make these composites hard, tough and strong. Due to the harsh cutting environment, tool life can be very short when machining CFRP composites. As the exact formula of what these composites are made from is not known, it can be difficult to design appropriate tools. Much of ISCAR’s R&D resources are spent to solve the problem of machining these complex materials. The machining of materials which are used for advanced types of aircraft demands new processes, as these difficult materials are lightweight, yet very strong. The tooling that shops commonly use for machining CFRP features long-lasting diamond PCD insert drills, vein PCD drills or brazed mandrel tools. When machining composites such as CFRP – there is no chip to speak of. Instead, the material removal mechanism might be better described as shattering. The impact of the cutting edge fractures the hard carbon fibers, instead of shearing material away. This process causes the cutting edge considerable abrasion that can lead to rapid wear. In composite machining, as well as any cutting tool application, tool geometry drives cutting performance. However, in composites, tool material also becomes a driver of performance. Unless the edge material can withstand the abrasion well enough to hold its geometry and stay sharp, the tool can wear so rapidly that the geometry can change rapidly as well. ISCAR’s engineers work closely with advanced aerospace industries in order to understand their new demands for efficient machining of lightweight composites. 4 Composite Materials

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g n i r e v i l e D ty i l i b a t i f o Pr Guara ISCAR ntees Resul ts In order to successfully machine CFRP , ISCAR has developed hard, sharp solid-carbide tools which are coated with hard, long-lasting diamond. 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 large advantage of CVD diamond coatings is that they reduce heat and friction created by the highly abrasive composite. Though the machining operations required for composite parts may be simple (sometimes only drilling and trimming), the fixtures designed to support these parts can be small feats of engineering themselves. Thus, the fixture for machining a composite part can be a considerable engineering investment. Clean cutting without fraying, delamination or otherwise separation of the layers, requires the part to be firmly secured against vibration. Quality Standard ISCAR has been certified by the prestigious Standards Institution, as being in full compliance with quality standards AS 9100, ISO 9001:2000, OHSAS 18001 and ISO 14001. Incoming batches of carbide powders are carefully analyzed to ensure that the raw materials do not deviate from set standards. In addition, completed products are inspected before shipping, to ensure delivery of the finest quality goods. Quality control facilities include the metallurgical laboratory, raw metal testing, an online testing procedure and a machining center for tool performance testing and final product inspection. Only the finest products are packaged for entry into ISCAR’s inventory. 5

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Drilling Composites 1 Drilling PREMIUM LINE Micrograin carbide for CFRP machining. High accuracy with no delamination or burr, providing longer tool life. Vc=60-150 m/min, 200-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 2 1 5 4 3 2 Drilling PREMIUM LINE Micrograin carbide with diamond coating for longer tool life. Lower tangential forces, eliminates delamination. Vc=60-150 m/min, 200-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 3 Drilling PREMIUM LINE Produces holes in CFRP/AL stacked materials. Diamond coating. Achieves elimination of burr, good surface and splinter reduction. Vc=60-150 m/min, 200-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 6 Composite Materials

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Drilling 4 Drill-reamer tools with separate cutting edges for drilling and reaming in one tool. Brazed PCD. Achieves elimination of burr, good surface and splinter reduction. Vc=60-150 m/min, 200-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt Drilling 5 Brazed PCD drill with straight flute. Achieves elimination of burr, good surface and splinter reduction. Vc=60-150 m/min, 200-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 7

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Countersinking Composites 5 1 Countersink Drilling 3 2 4 PREMIUM LINE Countersink drills for drilling and countersinking in one step. Diamond coating. Vc=60-150 m/min, 200-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 1 2 Countersinking and Chamfering Indexable solid carbide head for chamfering and countersinking. Available with diamond coating. Vc=60-150 m/min, 200-500 ft/min Fz=0.03-0.0 5 mm/t, 0.001-0.002 ipt 3 Countersinking PCD tipped countersinks, available with replaceable pilot guide. Vc=80-100 m/min 260-330 ft/min Fz=0.03-0.05 mm/t, 0.001-0.002 ipt 8 Composite Materials

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Drilling and Countersinking 4 Spiral diamond tipped countersink drills, for drilling and countersinking in one step. Vc=100-150 m/min 330-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt Drilling and Countersinking 5 Straight flute diamond tipped countersink drills for drilling and countersinking in one step. Vc=100-150 m/min 330-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 9

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Milling & Orbital Milling 1 Milling Brazed PCD endmill for side and face milling, trimming, rampdown and orbital milling. Vc=150-600 m/min, 490-1970 ft/min Fz=0.015-0.05 mm/t, 0.0006-0.002 ipt 1 1A 1A Milling Solid carbide interchangeable heads for side, facing, trimming, rampdown and orbital milling. Vc=100-150 m/min 330-500 ft/min Fz=0.02-0.06 mm/t, 0.008-0.024 ipt 2 2 3 Milling EPNI Diamond coated carbide endmill. Right and left spiral flute for side milling. Vc=100-120 m/min 330-400 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt 10 Composite Materials

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Milling Slitting Cutters TGSF 3 Cutting saw with indexable Tang-Grip inserts for slotting and parting applications. PCD tips on request. Vc=150 m/min, 500 ft/min Fz=0.05-0.2 mm/t, 0.002-0.008 ipt 3 4 Milling 4 6 EPND Diamond coated drilling and milling tool. Right and left spiral for rough trimming. Vc=100-150 m/min 330-500 ft/min Fz=0.03-0.1 mm/t, 0.001-0.004 ipt 11

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Milling Edging and Trimming 1 Milling High speed endmills for facing. Adjustable endmills for excellent axial runout. ADKW 150508 PDR PCD tipped inserts. Vc=150-600 m/min, 500-1970 ft/min Fz=0.08-0.2 mm/t, 0.003-0.008 ipt 1 2 Milling 2 3 High speed endmills for face and side milling. Adjustable endmills for excellent axial runout. ADKW 150504PDR-14 PCD tipped inserts. Vc=150-600 m/min, 500-1970 ft/min Fz=0.08-0.2 mm/t, 0.003-0.008 ipt Indexable carbide insert AD… 1505-Diamond coated. 3 Milling A unique interchangeable head brazed PCD endmill for side milling, trimming, rampdown and orbital milling. Vc=150-600 m/min, 500-1970 ft/min Fz=0.015-0.05 mm/t, 0.0006-0.002 ipt 12 Composite Materials

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Milling 4 EPNC Diamond coated drilling and milling tool. Right and left spiral for rough trimming. Vc=100-150 m/min 330-500 ft/min Fz=0.03-0.1 mm/t, 0.001-0.004 ipt Milling 5 4 5 6 EPNF Solid carbide right-hand spiral flute for endmill slotting, side and trim milling. Interpolation drilling for roughing and finishing. Vc=100-150 m/min 330-500 ft/min Fz=0.015-0.025 mm/t, 0.0006-0.001 ipt Milling 6 EPX Carbide diamond coated with right and left spiral flute for side finishing milling. Vc=100-150 m/min 330-500 ft/min Fz=0.015-0.05 mm/t, 0.0006-0.002 ipt 13

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Vacuum Brazed Diamond Too 1 BRP… Router with linear grooves for trimming composites. Shanks available in metric or imperial sizes. Available with flat and round end. Diameter range 10 to 40 mm. Grit size-D181 (80/100) to D1001 (18/20). 4 2 BRP… Router with spiral grooves for trimming composites. Shanks available in metric or imperial sizes. Available with flat and round end. Diameter range 10 to 40 mm. Grit size-D181 (80/100) to D1001 (18/20). . 5 3 3 BRBC… Tool for profiling composites in various shapes. Used for chamfering and for a specific R size. Diameter range 60 to 150 mm. Suitable for R 10 – 50 mm. Grit size-D181 (80/100) to D1001 (18/20). 14 Composite Materials

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ols BRH… Large drill, for drilling holes in composite materials. Available in metric or imperial sizes. Diameter range 10 to 150 mm. Available with shanks G1/2” thread or M14 thread. Grit size-D181 (80/100) to D1001 (18/20). Also available in electro-plated. 4 1 2 BRH… Large drill, for drilling holes in composite materials. Available in metric or imperial sizes. Diameter range 10 to 150 mm. Available with shanks G1/2” thread or M14 thread. Grit size-D181 (80/100) to D1001 (18/20). Also available in electro-plated. 6 5 ISCAR offers vacuum brazed tools for machining composite materials in various industries such as aerospace. They are produced using a new method for diamond and C.B.N. tools. Special tools can be manufactured with a low concentration of diamond, which provides longer tool life. The tools are widely used for milling on a machine center. They eliminate the risk of delamination, feature minimal clogging, maintain correct profiles and reach a very homogeneous thickness layer. On request 15

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