The counterboring process usually involves making a cavity of the size and thickness of the head of the fastener, allowing the fastener to remain completely below the surface level of the workpiece. Typical tools for counterboring involve special drills that have two different cutting diameters – one to make the hole for the fastener body and the other, of a larger diameter, for making the cavity for the head of the fastener.

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As for surface, you can apply a glossy layer of gelcoat to a dry carbon fibre part, and you can have a matte finish in a wet-layup process. Mostly, the glossy/matte finish is depending if your mold has a matte or glossy finish, or you can just simply grit with soft sandpaper a glossy part to get a matte finish.

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For making counterbore cavities of large diameters, it is customary to use blade type counterbores. The blade material is generally high speed steel and the size of the blade must be chosen for the application. The blade fastens to the shank by socket-head cap screw. Two types of blades are available, one for forward cutting and the other for backward.

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Dry carbon fibre is a completely different process, wich consist of having “pre-impregnated” (also reffered as prepreg) fibres. This means the carbon fibre cloth is already impregnated by resin by manufacturer. Prepreg carbon fibres usually need to be stored at -20°C to not cure by themselves at room temperature. Then, in most cases, the prepreg part is cured in an Autoclave. This results in better quality parts for various reasons, mostly beceause more pressure applied on the part during vaccum, and thus reducing the resin/fibre ratio needed in the part. This is reffered as “Dry” carbon fibre beceause you do not actually need to manually “wet” the carbon fibre witih epoxy since they are already pre-impregnated.

Dry carbon fibre is a very costly process, beceause first, you need an autoclave, prepreg carbon fibre is way more expensive than just buying carbon fibre cloth and epoxy, and then, the molds and vaccum tooling need to be of higher quality and high temperature resistant since prepreg usually need to cure at higher temperature than usual lamination epoxies. For example, you can realise a mold for a “wet-layup” process with just a gelcoat and some polyesther, while you’d use an aluminum machined mold for high temperature autoclave applications.

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Not all counterbores involve fasteners. For example, diesel engine blocks often need counterboring when repairing them. Usually, the engine block and wet liners develop a leak and the counterbore seats in the engine block need to be resurfaced during an engine overhaul. This requires counterbore cutter plates and a very accurate counterbore-machining unit that can be centered automatically and be clamped by means of an electromagnet. Since the technicians place the machine directly on the sealing surface of the engine block under repair, the refaced counterbore seats are automatically aligned in parallel to the sealing surface. Usually, these counterboring machines are portable types, allowing them to be used for refacing procedures not only on installed engines but also removed engine blocks or on underfloor engines as well.

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The forward counterbore cutting blades are plunge style tools meant for use on predrilled holes. You can use these tools on a manual mill as well as on a CNC milling machine. Used on a manual or a CNC lathe, a forward counterbore may also be used for a profile bore or a plunge bore on almost all types of metals.

Flat-bottomed counterbore drills are used where the surface is irregular or there is need for spot facing. Typically, these flat-bottomed counterbore drills are a no-dish design, ideal for drafted or concaved surfaces, rounded parts and castings. These drills are useful for straightening misaligned holes or for a process that requires flat bottom reaming. Usually made of solid Carbide, the counterbore drills have four flutes with a 15 helix. The cutter diameter, flute length, shank diameter and overall length of the flat bottomed counterbore drill depends on the type of application and the user must select the tool from a chart offered by the manufacturer.

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Mostly, the strenght of carbon fibre depends of the density of the part, wich is greater in dry carbon fibre parts beceause of the autoclave curing process, is highly dependent of curing temperatures and propreties of the epoxy used itself. Strenght comes from the carbon fibre itself, so, more fibre – less resin is a must, but not too low to avoid “air voids” into the part wich would cause structural issues. Autoclave allows for a lower resin/fibre ratio without having structural problems beceause the higher pressure in the autoclave vaccum increases the “compactation” of the part.

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Wet carbon fibre means carbon fibre has been impregnated in epoxy by hand, and ususally cured in an oven, or even at room temperature, and the terminology of “wet” carbon fibre is beceause in the process of manufacturing the part, you actually have to manually “wet” the carbon fibre cloth with epoxy. Infusion is a wet carbon fibre technique wich consist of infusing the carbon fibre with epoxy resin by “soaking” epoxy into it while the part is under vaccum pressure, wich often produces better results when mastered than just applying resin directly onto the cloth while laying it up into the mold.

The back counterbore, or back spot facer as it is commonly known, is a versatile tool intended to go through a pre-bored hole to produce a counterbore on the backside of the hole. You can use the back counterbore tool in a lathe setting for profiling an ID in a hole. Usually, a through-hole in the tool provides means to supply coolant to the cutting edge. Back counterbore tools are used in a variety of industries such as automotive and valve industries for numerous materials.

For maintenance, it actually depends more if the part has a gelcoat or a varnish applied to it or not. If not, the fibres are closer to the surface, and you’d risk to damage it by using inappropriate products. Gelcoat-Varnish parts are actually better protected.