SANDVIK FRP TOOL SUMMARY c-2920-30

USER’S GUIDE
Machining carbon fibre materials

Content
GENERAL COMPOSITE AREA INFO 3

MATERIAL AND COMPONENTS INFO 8
Sandvik Coromant - Precorp co-branded solutions for
the machining of composites are aimed at giving a wide
HOLE AND SURFACE QUALITY 23
variation of competitive products and high technical service
to our customers.
MACHINING STRATEGIES AND MACHINES 28 Sandvik Coromant - Precorp product solutions include
carbide and PCD vein technology drills, countersink tools,
APPLICATIONS 37 milling cutters and reamers found in this userguide.

PRODUCT OFFER (GEOMETRY SELECTION) 49
Holemaking 52
Milling 55
Grades 57
SOLUTION/PROBLEM SOLVING 60
SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 2

GENERAL COMPOSITE AREA INFO

Composites
with a focus on carbon reinforced plastic (CFRP)
• Carbon fibre is being utilized at a greater

scale which is increasing the demands on
automated production to improve productivity.
• Carbon fiber can be made to become

- stronger than steel
- lighter than aluminium and as stiff as titanium
• Carbon fibre is commonly used to reduce

the weight of the structural components on
aircraft and thereby improving fuel economy,
reducing emmisions and increasing carrying
load.
• As the material develops it gets more difficult

to machine:
- Increasing demand on cutting tool function and tool
performance
- High demands on hole and edge quality

Business environment
- carbon fibre
Clean
Wind power
energy
• Composites and especially carbon
fibre are being utilized at a greater Global
extent due to its benefitial properties. warming
Energy Aerospace
• Driving forces taking advantage of saving

Automotive
composite material properties are
Oil price
cost, environmental and technology inflation
benefits. Various industries are now
using composites at a greater extent, New Energy
especially in the aerospace industry. energy
High
performance
needs
Material Electronics
benefits

Composites in modern aircrafts
Materials used in 787 body • Benefits from composite materials are
especially important where weight control
Fiberglass is critical: Aerospace industry (main focus)
Aluminum - New aeroplane models: >50% in weight from
composites!
Carbon laminate composite
Carbon sandwich composite
• Materials depending on application.
• Structural application
- High-Medium Temperature Epoxy
• Interiors
- Phenolics, HS carbon fibres, Glass fibres,
Aramid (Kevlar)
• Non-structural applications:
Total materials used - Low resistance resins: polyesters, vinylesters
Other
Steel
By weight 10%
5%
Composites
Titanium 50%
15%
By comparison, the 777 uses 12

Aluminum percent composites and 50 percent
20% aluminum.
MATERIAL AND COMPONENTS INFO

What is composite
material?
Definition: engineered materials made from two or more
constituent materials with significantly different physical or
chemical properties which remain separate and distinct on a
macroscopic level within the finished structure
• Polymer Matrix Composites (PMC’s) -The most common. Also known as FRP
- Fibre Reinforced Polymers - these materials use a polymer-based resin as
the matrix, and a variety of fibres such as glass, carbon and aramid as the
reinforcement.
• Metal Matrix Composites (MMC’s) - Increasingly found in the automotive industry,

the matrix is a metal such as aluminium, the reinforcement fibres such as silicon
carbide.
• Ceramic Matrix Composites (CMC’s) - Used in very high temperature environ-

ments, these materials use a ceramic as the matrix and reinforce it with short
fibres, or whiskers such as silicon carbide and boron nitride.

Fibre properties
• Carbon fibres are characterised by:
- High strength difficult to cut
- High elastic modulus abrasive
• Can be in unidirectional tapes (UD) or woven fabrics
Typical Cost of ~300g/m2 Woven Fabric (£/m2)

2500 IM Carbon 50
45
HS Carbon
2000 40
Tensile Stress (MPa)
S-Glass 35
1500 30
25
Aramid
1000 E-Glass 20
15
500 10
5
0 1 2 3 4 E-Glass E-Glass S-Glass Aramid HM HS IM

Roving Yarn 7781 Yarn 6781 Style 900 Carbon Carbon
Tensile Strain (%)

Composition: matrices (resins)
• Epoxy The high-quality standard
• Phenolic Fire resistant
• BMI, cyanate High temperature
• Polyester, Vinylester Low cost
• Thermoplastic (PEEK, PEKK) High impact resistance

Fiber Orientation and Structure
• Unidirectional reinforcement (UD), in which maximum

strength and stiffness are obtained in the direction of the
fiber
Properties:
- highest strength in direction of fiber orientation
- bad handling features
- critical machining due to high delamination risk
• Planar reinforcement, two‑dimensional woven fabric

Properties:
- uniform strength in all directions
- better handling features
- lower delamination risk

Machining composites
• FRPs are not homogeneous, therefore

several aspects affect their machinability:
• Continuous Fiber
Stacked
Curing Resin Continuous fiber can be combined with virtually
materials
all resins. They are used for weaving, braiding,
filament winding applications, uni-directional
prepreg tapes and prepreg tow for fiber placement.
Fibre Fibres Fibres • Chopped Fiber

fabric volume Chopped fibers are used in compression and
injection molding compounds to produce machine
parts. The finished products have excellent
corrosion, creep and fatigue resistance plus high
Processing Coating strength and stiffness characteristics.

Common production methods
• Prepregs
- Fibres and resin come together as a “tacky” fabric
- Are stacked up by hand
• Injection
- The dry fibres structure is injected with liquid resin
- Benefitial on large components
• Automatic placement:
- Preimpregnated fibre tapes are placed by a CNC machine
- Used on large structures

Additional features
• Glass cloth -
UV protection, paint preparation
• Gelcoat -
For surface finish, corrosion protection
• Lightning strike protection (LSP) -

Al or Cu mesh or foil
• Paint -
For aesthetics, corrosion protection, improved aerodynamics
• Erosion-resistant -
neoprene, metal sheets
• Hybrid cloth -
glass, Kevlar: white fibres

How to identify a material
• Visual inspection:
- can help to identify some features Geometry • Thickness
of the material • Application
• Finish
Surface
• Coating
• Colour
Resin
• Appearance
• Colour
Fibres
• Fabric

How to identify a material
• Geometry can suggest the application

Geometry - Thick component: primary structure
- Thin component: interiors (some secondary structure, skin)
From the application, composition can be predicted
• Structural application
- High-Medium Temperature Epoxy, HS and IM fibres
Surface
• Interiors
- Phenolics, HS carbon fibres, Glass fibres, Aramid (Kevlar)
• Non-structural applications
- Low resistance resins: polyesters, vinylesters
Resin
Fibres

Surface features
The variation of surface layers and its properties will effect hole exit and edge quality. Therefore,
the geometrical shape of the cutting tool is very important.
Geometry • Glass cloth • Paint

- a layer of white glassfibre
- glassfibre layers can possibly generate break out • Erosion-resistant
problems such as splintering, although it can help - neoprene, metal sheets
limit the delamination when applied to carbon fibre
exit face. • Hybrid cloth (glass, Kevlar)
Surface - white fibres embedded in the fabric
• Gelcoat of the external layer
- a plastic layer - as the layers have specific demands, its very important
to choose the correct drill point geometry to improve
• Lightning strike protection (LSP) hole quality.
- Al or Cu mesh or foil
- lightning strike protection can potentially rip & tear
Resin on exit. Rather than being cleaned cut it may leave
some uncut copper mesh fibres on the edge of
the hole.
Fibres

Resin identification
Typically, most common composite materials, including fiberglass, carbon fiber, and kevlar,
include at least two parts, the substrate and the resin. Epoxy resin is almost totally transparent
when cured. In the aerospace industry, epoxy is used as a structural matrix material or as a
structural glue.
Colour
Geometry
• Epoxy resins
- amber-brownish
• Thermoplastics
- in some cases blue
Surface • Shiny
- Thermosetting (Epoxy)
• Dull
- Thermoplastic, BMI
Resin • Note: that carbon fibre composites can be layered with

various type of fibres and glass layers, which can change
the apperance.
Fibres

Fibres identification
Carbon fiber is a material consisting of extremely thin fibres about 0.005–0.010 mm in diameter.
The carbon atoms inside the fibres are bonded together in microscopic crystals. There are also
other fibres such as glass fibre and aramid fibres.
Colour
Geometry
• Carbon fibres
- black
• Glass fibres
- white
Surface • Aramid fibres

- yellow
Fabric
• Unidirectional
Resin
• Woven
Fibres

Stacks
• FRPs are often used in stacks with aluminium or titanium
- primary structural components
- floor panels, for fastening
• Typical compositions
CFRP CFRP Al
Ti Al CFRP
Al
CFRP =Carbon fibre reinforced plastic
Ti = Titanium
AL = Aluminium

Health & Safety
• When machining, dust extraction is strongly

spindel required
- For the operator safety
air suction - For the machine maintenance: carbon dust is electrically conductive:
may affect electrical parts and increase wear on spindle

HOLE AND SURFACE QUALITY

Quality issues in CFRP
• Quality is not easily assessed:

- there is no chip to look at
- roughness measurement is not significant Tool wear on cutting edge
- damage can be not visible (delamination)
• The main indicator is the hole quality

(and tool conditions)
• Delamination
- Separation of the bottom layer(s) due to the “thrust” of the drill
• Splintering Delamination
- Residual fibres in the interior of the hole, due to poor cutting action
Splintering/fraying

Hole requirements
CFRP materials
• In composite materials, there can be loss of hole

quality long before tool failure
• Therefore, the hole quality determines when the tool

needs to be changed or indexed.
• Typical hole quality demands

Typical requirements in the aerospace field:
- roughness Ra < 4.8 µm
- delamination <1 mm over the diameter
- no splintering Maximum delamination area,
- cp on hole size >1.6 <1mm over hole diameter

Hole requirements
Stacked materials
• Common demands • Dimension control

- Cpk>1,33 - Holes are commonly pre-drilled
- Ra<3,2 in carbon fibre - Finish hole size produced with one shot solution if possible
- Ra<1,6 for Aluminium and titanium - Reamer to be used when high demands on finish and size control
- Hole tolerance: +/- 20 µm to +/- 40 µm
- No delamination or chipping in the hole exit
- No chip erosion on the carbon fibre from the metallic stacked material
2 mm in from Entrance
• Criteria
- Chips evacuation Material 1 Middle of material
- Lubrification through the center 2 mm from Exit
2 mm in from Entrance
Material 2 Middle of material
2 mm from Exit
Holes are usually measured as diagram shows above every 90 degree

Increasing productivity
• Increased feed and speed will improve productivity, but

another more critical factor is hole quality.
• Poor hole quality means the material must be repaired

- Expensive and time consuming!
• An improvement in hole quality and reduced secondary

operations will generate a large gain in productivity!
- Shorter lead times in the total holemaking operation
- Eliminated secondary operations possible and will reduce number
of machines
- Expensive components demand secure production process

MACHINING STRATEGIES
AND MACHINES

Machining mechanism
• Composites: brittle fracture
• The fibres are shattered and cut

- The force needed is much lower
- The tool toughness can be lower
- Coolant or lubricant are often not necessary
• On the other hand, fibre hardness is extremely high

- Highly abrasive
• Resins are weak

- Interlayer fracture → delamination
- Elastic mismatch → irregular surface
- Easy pull-out of fibres → enhanced splintering

Machining strategies
• CFRP
- Quality must be checked both at hole entry and exit: different cutting
conditions may be needed.
- Quality at exit is usually more difficult to achieve due to cutting forces. 10
• Stacked materials feed rate: 0.15 - Entry layer

- Cutting speed on a stacked metallic material, such as titanium, usually
needs to be lower than the CFRP. 10 - Mid layer
- The best cutting condition, for the metallic material, may be too slow
2 mm
for good productivity on the composite material. Therefore variable cutting - Exit layer
data can be favourable.
10 feed rate: 0.05
Application example =
Entry layer : CFRP
Mid layer : Al or Ti
Exit layer : CFRP

Peck cycle metalic structure
Begin Cycle
Begin cycle at fast approach Drill retracts fully to

level (FAL). Typically 2.5mm FAL between pecks.
above material.
Drill CFRP until the drill point is

0.5mm (0.020”) above metallic
material.
Reduction of feed rate on exit

reduces risk for delamination
and splintering.
Beging peck cycle, 1mm (0.040”)

for titanium or 3mm (0.115”) for
aluminium.

• Top and bottom surface are often different, hole quality Hole quality issue
can therefore depend on where the drill enters or exits.
• A coating or surface layer on the carbon fibre can

change the output completely.
For example:
Splintering/ fraying Delamination
- Lightning Strike Protection (LSP): a fine or coarse copper mesh, allows for
higher feed rate
- Glass-cloth coating: increases the risk of delamination
- Both materials can be more easily machined by chosing the correct geometry.
Solution
CoroDrill 854 CoroDrill 856
CoroDrill 854: Point geometry designed to prevent

splintering and fraying.
CoroDrill 856: Designed to reduce delamination

problems.
Lightning Strike Protection (LSP) layer on CFRP with glass-cloth coating

CFRP material

Machine types
CNC and PKM (Parallel Kinematic Machines)
• Facts
- CNC controlled
- Stable environment
- Short tool overhang
- High and stable RPM (20.000 +)
- Milling, drilling and reaming applications
- CFRP and stacked materials
• Requirements
- Cylindrical tools possible in collet or hydraulic chucks
- Carbide and PCD tooling utilized depending on work piece material
• Common applications:
- Surface milling
- Edging
- Holemaking: drilling and reaming

Machine types
Robots
• Facts
- CNC controlled
- Flexible solution
- Short tool overhang
- Holemaking primary focus
- CFRP or stacked drilling
- Machines with end-defector for tool localisation
• Requirements
- Drilling focus
- Cylindrical tools possible
- Carbide and PCD tooling
- Holemaking: drilling, countersinking and reaming
- Rivetting

Machine types
Power feed machines
• Facts
- Electrical or pneumatic versions
- Holemaking applications
- Machinel adapted tooling
- Low rpm (100-2000)
- Limited flixibility in cutting data
• Requirements
- Drills with threaded back end
- Cylindrical tools possible in tool adapters
- Carbide or dedicated PCD tooling
- Holemaking: drilling, reaming and countersinking.

Machine types
Power feed and hand tools
• Facts
- Holemaking
- Machinel adapted tooling
- Low rpm (100-2000)
- Limited flixibility in cutting data
• Requirements
- Drills with threaded back end
- Cylindrical tools
- Carbide or dedicated PCD tooling

APPLICATIONS

Typical component features
• Holemaking
• Edging
• Trimming Holemaking in carbon fibre Holemaking in carbon fibre,
aluminium and titanium
• Faces
Surface machining Trimming
Edging Edging

Application example
Holemaking in CFRP
• Facts and demands:

- Fibre rich carbon fibre - Unidirectional
- Minimal splintering of fibres
- Good surface finish and dimensions
- CNC machining centre
• Solutions
- CoroDrill 854 drill point, diameter 6.35mm
- N20C diamond coating
• Cutting data
- VC: 150m/min
- fn: 0.06mm/rev
• Benefits:
- Excellent hole quality with no splintering
- 800 hole tool life
- Good hole production economy
CoroDrill 854

Application example
Holemaking in CFRP

- Resin rich material
- Minimal delamination of fibres
- CNC machining centre
• Solutions
- CoroDrill 856 drill point, diameter 6.35mm CoroDrill 856
• Cutting data
- VC: 130m/min
- fn: 0.05mm/rev
• Benefits:
- Excellent hole quality, minimal delamination
- 800 hole tool life
- Good hole production economy

Application example
Holemaking in CFRP/AL stack

- Carbon fibre and aluminium stack
- Reduced burr on exit
- Pneumatic power feed machine
• Solutions
- CoroDrill 854 drill point, diameter 9.525 mm
• Cutting data
Powerfeed CNC machine
- VC: 60 m/min - 120 m/min
- Fn: 0.03 mm/rev - 0,04 mm/rev
• Benefits:
- Excellent hole quality: surface and dimension
- Tool life: 200 holes
CoroDrill 854

Application example
Holemaking in CFRP/Ti stack

- Carbon fibre and titanium stack
- Pneumatic power feed machine
• Solutions CoroDrill 86PT

- Sandvik Coromant - Precorp drill solution
- 86PT point geometry diameter 9.525mm
- CD10 diamond tipped drill
• Cutting data
- VC: 12m/min
- fn: 0.05mm/rev
• Benefits:
- Excellent hole quality with stable dimension
- Stable manufacturing with 90 hole tool life

Application example
Holemaking: hand drilling in CFRP

- Carbon fibre
- Hand held pneumatic machine design
• Solutions
- PHT hand held drill
- Right hand cut drill point
- Left hand helix for drill stabilization
• Cutting data
- VC: 60m/min
- fn: 0.05mm/rev
• Benefits:
- Good hole quality
- Reduced drill grab eliminating splintering and delamination

Application example
Holemaking: hand drilling in CFRP/AL and CFRP/Ti stack

- Carbon fibre and metal stacks
• Solutions
- CMD: drilling of CFRP and metallic stacks
- CMDP: drilling of pre drilled CFRP and metallic stacks
CMD CMDP
• Cutting data
CFRP/Aluminum CFRP/Titanium
- VC: 118m/min - VC: 20m/min
- fn: 0.05mm/rev - fn: 0.05mm/rev
• Benefits:
- Maintaining hole tolerance
- Good surface finish and minimal exit burr

Application example
Edging of carbon fibre

- Primary structure carbon fibre
- High material removal rates
• Solutions
- CoroMill 390
- Cutter: R390-032A32-11H
- Diamond coated inserts (enginnered solution)
• Cutting data
- VC: 200m/min
- Fz: 0.15mm/tooth
Co
ro
M
ill
39
0

Application example
Sturtz milling: profiling of carbon fibre

- Tilting of tool 2-10 degrees
- High rpm and feed rate
- 2D and 3D feature solutions
• Solutions
- CoroMill 390
- Cutter: R390-032A32-11H
- CD10 PCD inserts (3mm modied radii)
• Cutting data
- Vf: 1800 mm/min
- 2mm depth of cut.
- 5 degree sturtz angle.
- fz: 0.2mm/tooth
• Suitable process for large areas of shallow curvature, i.e.

many aircraft wing and fuselage components.

Ball end scanning Vs Sturtz
• 32mm diameter tools used with the same cutting data.
Tool
32mm Ball 32mm Sturtz
Surface Speed (M/min) 2011 2011
RPM 20000 20000
Feed/ Tooth (mm/min) 0.12 0.12
Table feed (mm/min) 12000 12000
No of flutes 5 5
Step over (mm) 3.52 11
Passe / Sq Metre 284 91
Time for 1 Sq Metre 23.7 7.6

Over 3 times faster generating
the surface.
• Typical to use smaller ball end tools resulting in even

greater productivity when switching to Sturtz techniques.

Application example
Surface machining of carbon fibre
CoroMill Century

- Minimal splintering of fibres and delamination
• Solutions
- CoroMill Century with PCD inserts
- Cutter: R590-04C3-11M
- Inserts: R590-1105H-PS2-NL CD10
• Cutting data
- Cutting speed: 300m/min
- Fz: Roughing: 0.16 / Finishing: 0.1mm/tooth
- Ap: Roughing: 2.5mm / Finishing: 0.5mm

Application example
Edging of carbon fibre

- Carbon fibre skin
- Minimal splintering
- Good surface: Ra value of 1.25 μm
• Solutions
- CoroMill Plura engineered solutions
- 1: Diamond coated carbide cutter
- 2: PCD brazed cutter
- Cutter diameter 10mm with 2 cutting edges
• Cutting data
- Speed: 10.000 rpm, tabel feed: 3200mm/min
- Fz: Roughing: 0.03 – 0.08mm/tooth CoroMill Plura
- Fz: Finishing: 0.02 – 0.04mm/tooth

PRODUCT OFFER

Product solutions
Machine type Operation Material Solution
Hand drill Drilling CFRP PHT
Hand drill Drilling CFRP/AL/Ti CMD-P
Hand drill Chamfer CFRP Countersink
Power feed Drilling CFRP CD 854, 856, 85
Power feed Drilling CFRP/AL/Ti 86PT
CNC machine Drilling CFRP CD 854, 855, 856, 85
CNC machine Drilling CFRP/AL/Ti 86
CNC machine Edging CFRP Plura PCD/N20C
CNC machine Surface machining CFRP CM 590/390 PCD

Product solutions
CoroMill Century
• Standard products
Holemaking
- CoroDrill 854 and 856 composite geometries
Milling
- CoroMill Century and CoroMill 390 CoroDrill 854 CoroDrill 856
• TailorMade products
Holemaking
- CoroDrill 854, 855 and 856 (dimensions, grades)
CoroDrill 854 CoroDrill 855 CoroDrill 856
• Engineered solutions
Holemaking
- PCD drills, reamers and countersink tools
Milling
- PCD milling cutters
- Diamond coated milling cutters
CoroDrill PCD

Product offer drilling
CNC – automated machine
• CFRP
- Fibre rich material CoroDrill 854 Carbide / PCD
- Allround geometry CoroDrill 855/85 geometry Carbide / PCD
- Resin rich material CoroDrill 856 Carbide / PCD
• CFRP/Aluminium
- Carbon fibre stack CoroDrill 854 Carbide / PCD
- Carbon fibre stack 86A geometry PCD
• CFRP/Titanium
- Carbon fibre stack 86B geometry PCD
*Carbide tools available as uncoated or with N20C, diamond coating.

Power feed machine
• CFRP
- Fibre rich material CoroDrill 854 Carbide* / PCD
- Allround geometry CoroDrill 855/85 geometry Carbide* / PCD
- Resin rich material CoroDrill 856 Carbide* / PCD
• CFRP/Aluminium/
Titanium
- Carbon fibre stack CoroDrill 854 Carbide* / PCD
- Carbon fibre stack 86PT geometry PCD

Hand tool
• CFRP
- Fibre rich material PHT geometry Carbide*
• CFRP/Aluminium/
Titanium
- Carbon fibre stack CMD geometry Carbide*
- Carbon fibre stack CMDP geometry Carbide*
• CFRP/Titanium
- Carbon fibre Counter sink PCD

Product offer edging/slotting
• CFRP
- Carbon fibre CoroMill Plura Carbide*
- Carbon fibre CoroMill Plura PCD
- Carbon fibre Compression router Carbide*
- Carbon fibre CoroMill Plura - ball nose PCD

Product offer edging/slotting
• CFRP
- Carbon fibre CoroMill 590 PCD
- Carbon fibre CoroMill 390 PCD

CoroDrill grades
Grade comparison
• N20C, Solid Carbide with • N30C, Solid Carbide with • CD10, veined PCD tip
Diamond coating Diamond like carbon coating - High hardness
- Low friction coefficient - Thin wear resistant coating - Long and stable tool life
- Stable hole dimensions - Limited life, lower tool cost. - Cost efficient
- Cost efficient - Regrindable - Regrindable
- Not regrindable
Grade comparison
N20C: Available on standard products

and as TailorMade
N30C: Available as TailorMade option
CD10: Available as engineered solution

Tool life
Tool cost/drilled meter
N30C N30C (incl.3 N20C CD10

reconds)

Geometry selection guidelines
Material usage & curing temperature
CFRP
CD 855 or Cutting
Material CD 854 85/85C CD 856 conditions
Primary
- (medium-high T epoxy) 0 0 X MS LF
- Low temperature Epoxy 0 X X MS MF
- Non structural skin (Epoxy-Phenolic) 0 - X MS LF
Thermoplastic - X X LS MF
With glass skin - X MS LF
With LSP X X X MS HF
X = recommended MS = medium speed

0 = acceptable LF = low feed
- = not recommended MF = medium feed
HF = high feed

Geometry selection guidelines
CFRP stacked material
Material CD 854 86PT* CD 856

(for power feed and (For stable CNC)
unstable CNC)
Aluminium stack X X X
Titanium stack - X X
Ti/AL stack X X
-
X = recommended
0 = acceptable
- = not recommended

SOLUTION/PROBLEM SOLVING

Cutting data
• Tipycally:
- speed 60-120 m/min
- feed rate 0.02-0.15 mm/rev
• PCD allows for higher feed and sometimes speed
• With positive geometries high feed rate must be

avoided (>0.1mm/rev)
• Low feed rate reduces delamination, especially at

the hole exit
• High speed can melt/damage the resin (especially

thermoplastics)
• Diamond coated and PCD drills have a higher

thermal conductivity, which results in reduced
effects on hole dimension variation.

Problem Solution
Delamination • Reduce feed rate

• Consider a change in geometry
Splintering • Consider a more positive geometry

• Increase speed
• Increase feed rate
Poor tool life • Consider a different grade

• Consider a less positive geometry
Poor quality on a coated material • Consider drilling from the opposite side
Disparity of quality on entry and exit • Consider variable feed rate

Head office:
AB Sandvik Coromant
SE-811 81 Sandviken, Sweden
www.coromant.sandvik.com
E-mail: info.coromant@sandvik.com
C-2920:30
© AB Sandvik Coromant 2010.03

SANDVIK FRP TOOL SUMMARY c-2920-30

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USER’S GUIDE

Machining carbon fibre materials

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 2

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 3

• Carbon fibre is being utilized at a greater

• Carbon fiber can be made to become

• Carbon fibre is commonly used to reduce

• As the material develops it gets more difficult

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 4

• Driving forces taking advantage of saving

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 5

By comparison, the 777 uses 12

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 7

• Metal Matrix Composites (MMC’s) - Increasingly found in the automotive industry,

• Ceramic Matrix Composites (CMC’s) - Used in very high temperature environ-

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 8

• Can be in unidirectional tapes (UD) or woven fabrics

Typical Cost of ~300g/m2 Woven Fabric (£/m2)

0 1 2 3 4 E-Glass E-Glass S-Glass Aramid HM HS IM

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 9

• Epoxy The high-quality standard

• Phenolic Fire resistant

• BMI, cyanate High temperature

• Polyester, Vinylester Low cost

• Thermoplastic (PEEK, PEKK) High impact resistance

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 10

• Unidirectional reinforcement (UD), in which maximum

• Planar reinforcement, two‑dimensional woven fabric

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 11

• FRPs are not homogeneous, therefore

Fibre Fibres Fibres • Chopped Fiber

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 12

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 13

• Lightning strike protection (LSP) -

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 14

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 15

• Geometry can suggest the application

From the application, composition can be predicted

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 16

Geometry • Glass cloth • Paint

SANDVIK COROMANT USER’S GUIDE - COMPOSITE SOLUTIONS 17

Resin • Note: that carbon fibre composites can be layered with

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Surface • Aramid fibres

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• When machining, dust extraction is strongly

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• Quality is not easily assessed:

- damage can be not visible (delamination)

• The main indicator is the hole quality

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• In composite materials, there can be loss of hole

• Therefore, the hole quality determines when the tool

• Typical hole quality demands

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• Common demands • Dimension control

Material 2 Middle of material

Holes are usually measured as diagram shows above every 90 degree