tooling and strategy for carbon fiber?

[scudzuki]

I have to machine a "plaque" out of 1/16" carbon fiber sheet for a friend, profiling the outside (a 16" x 5" ellipse) and some letters inside. I think the largest end mill I can use for the letters is 1/8". I suspect that multiflute is the way to go, more like machining titanium than aluminum, lots of flutes since CF is so abrasive.

Are there carbon fiber composite specific end mills?

I only have 6000 RPM available, too.

Anybody have experience with something like this?

I imagine I'll be standing over it with a shop vac, too. CF dust can't be particularly good for coolant or ways.

Joe

 

[alliancefab]

I have been told to use these before but they are $$$$ so I always use the same 3 flute cutters I use for harder steels with a small cr

Link:
Exactaform PCD Endmills and Drills for carbon fiber composite machining

jason,

 

[Question Boy]

I've done a fair amount of CF routing, mostly non production. I'd stick the CF sheet to a sheet of acrylic using double sided tape. Use a cutter like the one pictured. I've seen them referred to as routers, burrs, rotary rasp, etc., the end should be like the one pictured, a 'fish tail', or 'plunge point' that allows you to drill through the material at the start of the profile. Even with only 6K rpm you should be able to run 10 IPM with a 1/8" dia. cutter. The dust is bad for your machine, and you, so do keep the shop vac a couple inches from the tool while cutting. You won't need any special coating on the cutter if you're only doing one part.



QB

 

[scudzuki]

Thanks for the help guys.

Joe