Content 议题 Composite materials 复合材料 Carbon Fibre Reinforced Plastics (CFRP) cutting process 碳纤维增强塑料 ( 碳纤维 )- 加工工艺 Jabro Composite tooling standard too

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1 ISMCME 2010 COMPOSITE MACHINING 复合材料加工 focus on machining Carbon Fibre Reinforced Plastics (CFRP) Edward Su 苏国江 Seco Jabro Product Manager JABRO Dec 11th, 2010 Beijing , All rights reserved 1

2 Content 议题 Composite materials 复合材料 Carbon Fibre Reinforced Plastics (CFRP) cutting process 碳纤维增强塑料 ( 碳纤维 )- 加工工艺 Jabro Composite tooling standard tool range Jabro 加工复合材料标准产品系列 Milling CFRP-application examples 铣削碳纤维 - 应用举例 Composite tooling drilling solution 复合材料孔加工解决方案 PCD tools for composite 复合材料 PCD 刀具加工 2

3 Composite materials Definition 定义 在复合材料中, 纤维 晶须 颗粒或织物被分散在基体内, 使用一种聚酯基树脂作为基体, 而各种不同的纤维材料 ( 如玻璃纤维 碳纤维和芳纶纤维 ) 用作增强剂 复合材料结构上是由分层或夹层构成, 并能包含钛合金和铝合金叠层材料 填充材料可以是分层的 蜂窝状 铁基或非铁基的 , all rights reserved 3

4 Composite materials History 历史 'Fibreglass', as we know it today was invented in 1938 by Russell Games Slayter and it is now marketed as Fibreglass, the trademark. 玻璃纤维 ( 玻璃钢 ), 于 1938 年由 Russel Games Slayter 发明, 现在使用 Fibreglass, 作为商标 Carbon fibre was invented in the early 1960s at the Royal Aircraft Establishment at Farnborough, Hampshire (England). 碳纤维,1960 年代初在英国的 Farnborough, Hampshire 皇家航空发明 4

5 Composite materials benefits 优点 Composite material benefits compared with other materials: 复合材料与其他材料相比优点 Reduced weight 减轻重量 Corrosion-resistant 耐腐蚀性 Recyclable material 可循环利用 Very high tensile strength 非常高的抗拉强度 Very low thermal expansion rate 非常低的热膨胀系数 5

6 Composite materials - industry trends 行业趋势 Composite industry trends / demands 复合材料行业趋势 / 需求 : Reduced material and manufacturing costs 降低材料和生产成本 Larger commercial usage 扩大商业应用 Improve repair and maintenance 改进维修与维护 Adaptation to automation 采用自动化生产 Components with more complex structure 更复杂结构工件 6

7 Global Composites Markets 全球复合材料市场 Aerospace 航空 F1 Medical 医疗 Sport 运动 Marine 游艇 Leisure 休闲 Transport 运输 Components 零部件 Automotive 汽车 7

8 8

9 9 Quelle: IIR-09

10 MILLING CFRP CFRP material identification and cutting process 材料定义与切削工艺 10

11 CFRP material identification 材料定义 CFRP 碳纤维 Hybrid RP Sandwich Materials/ Stacks 三明治材料 / 堆叠 CFRP Al CFRP Ti Al CFRP Al 11

12 CFRP work piece quality demands 工件质量要求 Quality demands on CFRP parts to determine machining operation strategies methods 碳纤维工件的质量要求决定了加工工艺 - 方法 Breakout & de-lamination of composite when machining 加工过程中材料断裂或分层 Splintering 碎片 Part crumbling or flaking 工件崩碎或脱落 Melting 熔化 Sub surface damage 次表面损伤 12

13 CFRP operations 加工工艺 Besides drilling (50%), milling represents an estimated (40%) of the operations on CFRP components; 除了孔加工 (50%), 铣削大约在碳纤维工件加工的 40% Drilling 钻孔 Milling 铣削 - Side milling, or trimming flash, remove excess material (after moulding) 侧铣, 修整飞边, 去除多余材料 ( 成模后 ) - Face milling 平面铣削 - Edge routing 周边铣削 Turning 车削 Orbital drilling 铆钉钻 Reaming 绞削 13

14 Milling CFRP, the SECO offer 铣削复合材料, 山高提供 14

15 The SECO offer grade 山高提供 - 设计 Carbide Grade 硬质合金等级 New Geometries 新切削角度 DURA Coating Dura 涂层 15

16 The SECO offer DURA coating 山高提供 - 设计 Dura 涂层 The Jabro SECO carbide grade provides an excellent bonding for the DURA coating (CVD process) 山高 Jabro 硬质合金提供优异的与 DURA 涂层接合性能 (CVD 工艺 ) DURA coating is a high wear-resistant diamond coating for extended tool life DURA 涂层是高耐磨性的金刚石涂层, 具有优异的刀具寿命 DURA has a relatively low friction coefficient DURA 涂层具有相对较低摩擦系数 DURA is not as thick as normal Diamond coating DURA 涂层比普通金刚石涂层更薄 coating substrate 16

17 The SECO offer JC800 series 山高提供 -JC800 系列 17

18 The SECO offer JC840 geometry 山高提供 - JC840 This double helix cutter is initially designed to machine stacked (sandwich) materials. 双螺旋角原始设计为加工叠层 ( 三明治 ) 材料 Standard available with cylindrical shanks in both METRIC (6mm-12mm) and INCH sizes (¼, ⅜, ½ ). 标准产品提供直柄公制尺寸 (6mm-12mm) 和英制尺寸 (¼, ⅜, ½ ). Stable machining in unstable conditions (clamping, feed machines) 在不稳定条件下实现稳定切削 ( 装夹, 机床等 ) Very good surface finish in (stacked) CFRP, no finishing or rework needed Split line = ap =1/2*dc 在叠层材料加工中实现非常好的表面质量, 无需精加工或人工处理, 分界点为 1/2dc 18

19 The SECO offer JC850&880 geometry 山高提供 -JC850&JC880 These general use cutters are designed for a variety of applications. 这两款通用刀具设计用来加工各种应用 JC850 Standard available in metric (3mm-6mm) with ap 3 x Dc JC850 标准尺寸为公制 (3mm-6mm), 切削刃长 3 x Dc JC880 Standard available in metric sizes (6mm-20mm) with ap 3 x Dc and corner radius. JC880 标准尺寸为公制 (6mm-20mm), 切削刃长 3 x Dc Low axial forces generated due to flat 20 helix angle, ideal when vacuum clamped. 20 度螺旋角产生较低轴向切削力, 当真空夹紧时更加理想 Capable to do all machining methods in CFRP 可以加工各种复合材料 19

20 The SECO offer JC860 geometry 山高提供 -JC860 This cutter was specifically designed for side milling and slotting in honeycomb sandwich materials 本刀具专门设计为侧铣和槽铣蜂窝材料夹层板 JC860 Standard available EX stock in metric with cylindrical shank in diameters (Dc): 6mm-16mm with cutting lengths (ap) 3 x Dc JC860 标准型号库存为公制尺寸直柄 6mm-16mm, 切削刃长 (ap) 3 x Dc LH helix to create downward axial cutting forces. 左旋产生向下的轴向切削力 Chip splitter to break the honeycomb material into smaller piece 断屑槽将蜂窝材料切为更小碎屑 20

21 The SECO offer JC870 & 871 geometry 山高提供 -JC870 These routers are multi-purpose cutters which operate in a variety of materials and applications. 这些菠萝铣刀为多功能铣刀, 可以适用于多种材料和应用 JC870 & JC871 Standard available with cylindrical shank in METRIC (3-12mm) and INCH (¼, ⅜, ½ ). sizes. Also available as a uncoated version. More than a normal router; JC870 & JC871 标准系列产品为直柄公制尺寸 (3-12mm) 和英制尺寸 (1/4-1/2), 并且提供涂层系列和非涂层系列 性能远超普通菠萝铣刀 21

22 Milling CFRP, the SECO offer 铣削复合材料, 山高提供 A full range of solid carbide end mills with specific geometries to machine composite materials of all kinds. 完整系列整体硬质合金铣刀, 专用角度设计 加工各种复合材料 On stock 库存产品 Catalogue available 样本提供 Cutting data in catalogue 切削参数提供 22

23 MILLING CFRP 铣削复合材料 Application example 应用举例 , All rights reserved 23

24 Milling CFRP - application examples 1 应用举例 -1 Customer 客户 Part 工件 Machine 机床 Operations 操作 Materials 材料 Coolant 冷却 Tool 刀具 Goal 目标 German (Aero-) space centre 德国航空中心 Diverse 多样 3-axis HSK 32A Spindle 3 轴 HSK32A 主轴 Drilling, slotting, side milling, facing 孔, 槽, 侧铣, 面铣 (Stacked) CFRP s 叠层复合材料 Air 空气 Flat helix solid carbide end mill JC880060R020Z4.0-DURA Find a versatile cutter for roughing and finishing (Stacked) CFRP 找到一款粗加工和精加工叠层复合材料刀具 Current tool in use is a ø6mm pcd tool. 现用刀具为 6 mm PCD 刀具 24

25 Milling CFRP - application examples - 1a 应用举例 -1a Aerospace CFRP, 60 vol. %. prepreg. Plunging and full slotting form. Part dimensions est.: 200*100*3.5mm Criterium: de-lamination <1.0mm, visual surface quality 航空复合材料, 碳纤维含量 60%, 插铣后铣槽成型, 工件大小 200*100*3.5 mm, 标准 : 材料分层 <1 mm, 目视表面质量 JC880060Z4.0-DURA D c [mm] Zn eff a p [mm] a e [mm] v c [m/min] n [1/min] f z [mm] v f [mm/min] Q [cm³/min] <0,2mm delamination 25

26 Milling CFRP - application examples 1b 应用举例 -1b Aerospace Stack CFRP-UD dry Plunging and full slotting form. Part dimensions est.: 400*200*4mm Criterium: de-lamination <0.5mm + Minimum spreading of steel layer 航空叠层材料碳纤维 +304 不锈钢, 插铣后槽铣成型 工件尺寸 400*200*4 mm, 标准 : 材料分层 <0.5mm, 最小不锈钢层分离 JC880060Z4.0-DURA D c [mm] Zn eff a p [mm] a e [mm] v c [m/min] n [1/min] f z [mm] v f [mm/min] Q [cm³/min] UD 26

27 Milling CFRP - application examples 1c 应用举例 -1c Aerospace Hybrid CFRP prepreg + AFRP Plunging and full slotting form. Part dimensions est.: 400*100*7.5mm Criterium: de-lamintion top layers <0.5mm + Minimum AF pull out 航空复合材料叠层 碳纤维 + 纺纶纤维 插铣后槽铣成型, 工件尺寸 400*100*7.5 标准 : 上层分层 <0.5mm+ 最小的纺纶纤维拉出 JC880060Z4.0-DURA D c [mm] Zn eff a p [mm] a e [mm] v c [m/min] n [1/min] f z [mm] v f [mm/min] Q [cm³/min]

28 Milling CFRP - application examples 1 应用举例 1 Observations and findings during machining with the flat helix cutter JC880060Z4.0-DURA: 使用小螺旋角铣刀 JC880060Z4.0-DURA: 实际加工效果 Efficiency increase in all materials compared with PCD 与 PCD 刀具相比, 加工各种材料, 效率均得到提升 no finish pass or manual re-work required 加工后无需后续手工 Reliable process 工艺可靠 No or light de-lamination and or splintering (<0.5mm) 无材料或纤维分层 (<0.5 mm) Smooth machining, no high vibrations. Much better than PCD tool. 切削平稳, 无振动, 比 PCD 加工效果提高明显 Tool wear stabilizes at 0.08mm (measured on relief) 刀具磨损稳定于 0.08 mm( 检测后刀面 ) 28 Tool still not worn out, more tool life to go 刀具没有严重磨损, 仍可继续测试

29 Milling CFRP - application examples 2 应用举例 2 Customer 客户 Part 工件 Machine 机床 Operation 操作 Material 材料 Coolant 冷却 Tool 刀具 Remark 备注 1st tier aerospace supplier, Belgium 第一迪尔航空, 比利时 Test part 试验件 5-axis Jomack 156 HSK 63A Spindle 5 轴 Jomack 156 HSK63A 主轴 Slotting 铣槽 CFRP 60% CF content, prepreg, aerospace 60% 碳纤维含量复材 Air + additional water flow to prevent debris becoming airborne Solid carbide router SECO Jabro JC870 ø20mm Test was part of manufacturing process optimisation 测试优化工艺 Cutter was challenged to side-rough for at least 15 metres to be competitive with pcd 与 PCD 刀具对比, 刀具必须能够在保证侧面质量情况下切削 15m 29

30 Milling CFRP - application examples 2 应用举例 -2 Findings during side milling roughing with the JC870 router: 采用 JC870 菠萝铣刀实际加工效果 : Feed increase compared with PCD 进给相对 PCD 得到提高 Reliable process 工艺稳定 No or light de-lamination and or splintering (<0.8mm) 无或轻微材料和纤维分层 (<0.8mm) Smooth machining, no heavy or high vibrations 切削平稳, 无明显震动 Possible usage of multiple ap-zones (ap tool=55mm) 可使用更大切深 Tool wear stabilizes at 0.25mm (measured on relief) 刀具磨损 0.25mm( 测量后刀面 ) Tool life exceeding expectations 刀具寿命超过预期 30

31 Milling CFRP - application examples 2 应用举例 2 PCD Tool D c [mm] 20 Zn eff - a p [mm] 10 a e [mm] 10 v c [m/min] 150 n [1/min] 4774 f z [mm] - v f [mm/min] 800 Q [cm³/min] 80 Toollife [M] 27 JC870 router D c [mm] 20 Zn eff 13 a p [mm] 10 a e [mm] 10 v c [m/min] 150 n [1/min] 4774 f z [mm] 0,019 v f [mm/min] 1500 Q [cm³/min] 150 Toollife [M] 27 2M 31

32 Milling CFRP - application examples 2 应用举例 -2 Instant benefits when side milling roughing with the JC870 router compared with PCD: 采用 JC870 菠萝铣刀加工时相对 PCD 刀具优势 Increased feed, higher efficiency 提高进给, 更高效率 Reliable process 可靠的加工工艺 Possible usage of multiple ap-zones (ap tool=50mm) 可以采用不同切深区域 ( 切削刃长 -50 MM) Lower price level compared with PCD 与 PCD 刀具相比更低价格水平 Tool wear after 27M 32

33 Milling CFRP - application examples 3 应用举例 -3 RUSAVIAINTER Stringer 机身桁条 33

34 Milling CFRP - application examples 3 应用举例 -3 RUSAVIAINTER JC840; D=12 mm; Z=9 Contouring 轮廓铣削 Ae=5 mm Ap= part thickness = 8 mm V=180 m/min n = 4777 rpm Fz=0.02 mm F= 860 mm/min Climb milling 顺铣 Smoothly cutting 切削平稳 34

35 Drilling CFRP 复合材料孔加工 Drilling composites (CFRP) 复合材料孔加工 35

36 Drilling CFRP Range 孔加工刀具范围 Seco Feedmax range 整体硬质合金钻头系列 Single diameter drill 单直径钻头 Chamfer drill (one shot drill) 带倒角钻头 36

37 Drilling CFRP Geometry 孔加工刀具结构设计 Geometry 刀具设计 Operation 操作 Application / Material 应用 / 材料 C1 geometry C1 设计 C2 geometry C2 设计 Drilling 钻孔 Stack drilling 叠层材料钻孔 C1 geometry to be used when drilling in plain composite material. It should also be used when drilling stack which ends in composite material. C1 设计主要用于加工复合材料板材 也可以用于叠层材料中出口材料为复材情形 Stacked applications, composite and aluminum/titanium, exiting in the metal material. Improved chip breaking will give good chip evacuation and secure surface quality of the composite material. 叠层材料, 复材和铝合金 / 钛合金叠层, 出口为金属材料情形 改进断屑将得到更好排屑并保证复合材料部分表面质量 C1-geometry C1 设计 C2-geometry C2 设计 37

38 Drilling CFRP Hole Quality 钻孔质量 Delamination 分层 Uncut fibers 未切除纤维 Splintering 碎裂 Spalling 散裂 Hole quality 钻孔质量 Different parameters compare to metal 与金属加工相比区别 Delamination 分层 Peel-up delamination (entrance) 材料上翘 ( 入口 ) Push-down delamination (exit) 材料下翘 ( 出口 ) Splintering 碎裂 Spalling 散裂 Uncut fibres and resin 未切除纤维和基体 Surface finish 表面质量 Marks from metal chips (stacked material) 金属表面痕迹 ( 叠层材料 ) Melted resin 基体熔化 38

39 Drilling CFRP C1 geometry 孔加工 C1 设计 Application example: exit in composite 应用 : 出口为复合材料 Plain CFRP/GFRP (exit in composite material) CFRP/GFRP 碳纤维 / 玻璃纤维板 ( 出口为复合材料 ) CFRP/GFRP CFRP/GFRP Tool 刀具 Double angle point geometry 双顶点角设计 Reduce axial forces 减少轴向力 Delamination free drilling 减少分层 Dura diamond coating Dura 金刚石涂层 Long tool life 长刀具寿命 Application 应用 Exit in composite material 出口为复合材料 Plain composite 复合材料板 Stacks with composite as last layer 叠层复材为最底层 CFRP 39

40 Drilling CFRP C2 geometry 孔加工 C2 设计 Application example: stacked material CFRP 应用举例 : 叠层材料 Sandwich material (exit in Al/Ti) Alu 三明治材料 ( 出口为 Al/Ti) CFRP/GFRP Al or Ti Tool 刀具 Straight cutting edge (180 angle) 平面顶尖角 (180 度 ) Good chip breaking and evacuation 好的断屑和排屑 Secure good hole quality 保证孔的质量 Surface finish of the composite intact, not damaged by the metal chips. 安全接触复合材料表面, 无金属屑接触 Dura diamond coating Dura 金刚石涂层 Long tool life 更长刀具寿命 C2 geometry Application 应用 Stacks with exit in metal material material 叠层材料金属出口 Aluminum 铝合金 Titanium 钛合金 40

41 Drilling CFRP Success Story 孔加工应用举例 Tests Medical 测试 - 医疗行业 Competitor 竞争对手 : TiCN SC drill. TiCN 涂层钻头 Tools 刀具 : Diamond coated solid carbide drill with CFRP geometry, internal coolant 金刚石涂层硬质合金钻头 C1 设计, 内冷 Machine 机床 : Hermle C30U 80 bar internal coolant pressure 80 巴内冷却压力 EPB shrink fit 5803 EPB 热胀刀柄 Part 工件 : Bracket for head fixation 头部支撑托架 Material 材料 : Medical CFRP 医疗碳纤维 Results 效果 : - surface quality outstanding; 表面质量优秀 the roughness made with the Ref. tool could not even be measured. 表面粗糙度几乎不能用仪表检测出来 - size & shape of the hole outstanding 尺寸和孔形状优异 - Vc 600 m/min - feed 进给 1600 mm/min holes without size degradation (within mm tolerance) 2800 个孔后尺寸无变小 ( 在 内 ) against 800 holes of the Ref. tool with far lower parameters and not even comparable hole tolerances. 金争对手刀具寿命 800 孔, 非常低切削参数, 孔的尺寸公差也无可比性 41

42 Drilling CFRP Success Story 孔加工应用举例 Test drilling specifications Aerospace 钻孔测试 - 航空 Hole dimensions 孔直径? Dimension 6,14 6,12 Al CFRP Dimension 6,1 6,08 6,06 Min Max? Al? CFRP DLC coated Soled carbide drill (210 holes)dlc 涂层刀具 Dura coated solid carbide drill (910 holes) (std grade) DURA 涂层刀具 6,04 6, Number of holes Dura coated solid carbide drill, optimized grade and coating (+1200 holes, still working)dura 涂层刀具优化材质和涂层 ( 加工 1200 孔后仍然可以使用 ) 42

43 Drilling CFRP Success Story 孔加工应用举例 Stacked material CFRP/Alu 叠层材料 CFRP/Alu CFRP Al Achieved results 获得效果 : Surface finish Al Ra<1,0 铝表面质量 Ra<1 Small exit burrs (much smaller than the maximum of 0,2mm in standard) 微小出口毛刺 ( 比 0.2mm 的标准要求小很多 ) no visually detected chipping/splintering in CFRP 无可视崩齿 / 碳纤维碎裂 Dura coated solid carbide drill Dura 涂层整体硬质合金钻头 Test done in 测试 CFRP+Al CFRP+Ti 43

44 Composite Machining AOB 复合材料加工 AOB Centre for Composite machining 复合材料加工中心 AoB, France should become a Competence center for round PCD tools for composite machining AOB 将成为整体 PCD 刀具加工复合材料的竞争中心 With AoB, Seco will aim for becoming a leading, global supplier of PCD round tools for future 通过 AOB, 山高将成为全球整体 PCD 的全球领先提供商 With the R&D and manufacturing competence of AoB and Seco being a certified supplier with existing relations to several key aerospace customers globally Seco will aim to become a total solutions provider for the Aerospace industry 通过研发和生产竞争中心,AOB 和山高将成为现有的大型航空客户的认证提供商, 山高将成为航空行业完整解决方案提供商 44

45 Composite Machining AOB Products AOB 产品 Wood working Automotive 木工加工 汽车行业 Aerospace 航空行业 45

46 AOB Offering AOB 产品提供 PCD offering PCD产品 PCD sandwich drills PCD三明治钻头 Step drill Chamfer drills 阶梯钻 倒角钻 Drills 钻头 Optimized geometries 优化角度 Configuration 形状 Chamfer drills 倒角钻 Step drills 阶梯钻 End mills 立铣刀 Routing cutters 菠萝铣刀 Double helix cutters 双螺旋角铣刀 CFRP end mills 复合材料立铣刀 46

47 Composite materials here today. Edward Su 苏国江 Seco Jabro Product Manager JABRO 47

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