In the ever-expanding field of composite materials, processing faces new challenges. Fundamentally, these materials are not difficult to process. The challenge now is to produce higher quality, safer holes for higher quality requirements - especially for composites with metal laminates. This requires us to develop even better tooling solutions to meet the ever-increasing demands.
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At the same time, due to the dominant position in the processing of composite materials and process equipment, the drill bit is undergoing a comprehensive transformation of cutting tool technology.
Need tool specificity
The use of carbon fiber reinforced plastic (CFRP)-based composites is becoming more common, covering the aerospace industry and other industries, particularly the automotive and defense industries. The holes in which there are a large number of fasteners on these composite parts need to be processed, and the quality of the products is becoming a key issue for competitiveness due to the safety of the products. Drilling CFRP composites involves problems such as delamination and splitting, based on manufacturing defects in the properties of the composite itself. In addition, when it is necessary to use the same tool to make holes in composite materials and metal laminates (such as aluminum alloys or titanium alloys) in various aerospace structural parts, it is very important to use a solution specific to the specific application. . As a result, the tool must also deal with completely different conditions, very different material machinability, chip formation and chip evacuation.
The parts to be machined on CFRP and CFRP/metal laminate parts are usually less than traditional metal parts, but due to the special processing characteristics of the materials, the quality requirements of key technologies are more demanding. The processing of CFRP composites involves the cutting of the fibers, in which case the tools and processing methods need to be changed in order to obtain a net cut. The thermal conductivity is poor and there is no chip formation, so that the heat generated during the cutting of the composite material is very problematic because the resin of the composite material is at great risk at high temperatures. Therefore, these materials are more difficult to process in the cutting process than metals. The attributes vary greatly and are unpredictable. On the other hand, the proportion of CFRP composite materials as part materials has increased dramatically. These aspects need to be continuously improved to ensure that the cutting process is competitive. 
Figure 1 In the process planning for drilling CFRP composite or laminated materials, there are many factors that need to be considered. It is not easy to drill holes in a large number of different component materials. At this time, the tool supplier has the test parameters.
Application recommendations and high quality technical support will help you.
In the process of cutting these materials and parts, the hole machining process dominates. In the aerospace industry, most of the processing is focused on the fabrication of fastener holes in composite-based frames and parts. That is, the use of larger structural parts to reduce the amount of assembly, hole processing still plays a decisive role in the efficiency, cost and process safety. This means that hole machining is the focus of attention when considering improvements in tool performance, workpiece quality consistency and process safety.
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