Answer: Carbon fiber is a lightweight, strong material composed of carbon atoms bonded together in a crystalline structure. It is commonly used in applications where high strength and low weight are necessary, such as in aerospace, automotive, and sports equipment.

Answer: While worse than blue laser heads, diamond-coated abrasive cut-off blades are the best blades for cutting carbon fiber since they can avoid splintering or delamination.

Kyocera Precision Tools Inc., Hendersonville, N.C., has developed its JCT (Jet Coolant Through) toolholders for ID and OD grooving for improved chip evacuation, better surface finish and longer tool life, according to Todd Rucker, technical center engineering manager, Indexable Tools Division. “For ID or OD grooving, getting sufficient coolant to the cutting edge is critical. The deeper you go, the more chance there is that coolant can be shielded from the cutting edge,” Rucker explained. “Part-off is a little different animal. When you part off, you’re always going to leave a little nub on one side or the other. As you get close to center, centrifugal force will separate what you are cutting, sometimes requiring secondary processing like facing to produce a clean part with a good finish.”

In a groove turning operation, the operator should plunge down to depth and then retract up to 0.01" (0.254 mm) and then do side turning, according to Andersson. “In groove turning, you actually want the blade to deflect, creating clearance and reducing the cutting forces,” he said. “With deflection, the leading corner will dig in the material. By retracting, you basically go to depth, retract a few thousandths, side turn, go to depth and do that in a zig-zag motion from left to right, right to left utilizing both corners. That’s the most efficient way to get the best quality part and maximize tool life.”

Iscar’s blade-and-block system features different pockets for the Tang Grip single-ended blade and the Do-Grip double-ended blade. Typical applications are parting off of thicker wall parts, 0.5-4.7" (12.7-119.4 mm). “We start with a lot more material under the pocket of the insert and have created a block that holds and supports the blade underneath so the cutting forces go back into the blade. In a typical block-and-blade system, the blade is sticking out and adapter systems don’t actually support the blade underneath,” East explained. “Depending on the diameter of the material, we’re starting off with three blades that are very tall compared with the industry standard of 32 mm.”

The Multi F Grip part-off and grooving tooling line introduced by Iscar Metals Inc., Arlington, Texas, in June 2019 has lived up to expectations to dramatically increase feed rates for parting and grooving, according to Clay East, national product manager for GRIP products. “The reasons are a robust design and high-pressure JetCut Coolant delivered right to the cutting edge. We’ve really changed how shops are parting off material with the Multi-F Grip family of products,” said East, noting that the tools are designed for part-off but can also be used for plunge grooving but not side turning.

When making holes in carbon fiber, a drill can be an indispensable tool. Using a drill bit designed for composite materials, you can create starting points for other cutting tools or complete tasks like adding bolt holes or mounting points. To prevent splintering, it's best to place a piece of scrap wood under the carbon fiber while drilling and to use a slow, steady speed.

Configuring the laser head for optimal performance is crucial to achieve the best results when cutting carbon fiber. With Opt Lasers, you have the power to adjust various settings to suit your specific cutting needs. Make sure to position the laser head at the ideal distance from the carbon fiber surface to ensure precise and efficient cutting. This is typically the working distance (WD) of the given laser head, minus half the thickness of the material. Fine-tune the WD of the laser beam to achieve clean and sharp cuts without any charring or damage to the material.

If you continue to experience issues with misalignment, it may be necessary to contact the manufacturer for further assistance. They can provide guidance on troubleshooting steps or arrange for professional servicing to realign the laser and optimize its performance.

Blue laser heads are considered the best option for cutting carbon fiber due to their superior energy efficiency, precision and control. Typically operating at a wavelength of around 440-450 nm, blue lasers can achieve highly focused laser beams, which translate to much cleaner cuts with minimal heat-affected zones. Blue lasers can cut carbon fiber with precision as high as 0.05-0.2 mm, depending on the laser head in question.

“Ceramics are used mainly for grooving,” he continued. “You can’t use ceramic for turning cut-off except for certain diameters. Material that breaks off during the cut-off operation can be catastrophic for the ceramic. Depending on the material, whiskered grades offer high wear resistance but with some limitations on feed rate.”

Rucker pointed out that JCT cut-off and grooving toolholders not only direct coolant to the top or rake surface of the insert, but also from the bottom up to the flank below the nose of the insert. “The result is always having coolant hitting exactly where you need on the cutting edge,” Rucker said.

Due to its manual nature, a coping saw offers a high degree of control, allowing you to work meticulously on delicate sections of carbon fiber. However, it also requires patience and steady hands to avoid damaging the material. By working slowly and carefully, you can achieve detailed and accurate results, making the coping saw an invaluable tool for intricate carbon fiber cutting projects.

Manual cutting tools like hacksaws, Dremel tools, angle grinders, and jigsaws can produce fine carbon fiber dust, splinters and particles that are harmful if inhaled or if they come into contact with the skin. It is also much easier for CF splinters, dust and particles to land on your skin and clothes while doing manual cutting, since you are much closer to the CF material being cut than when using CNC machines. Therefore, it is essential to wear much more appropriate personal protective equipment (PPE). This includes:

Greenleaf Corp., Saegertown, Pa., offers ceramic and carbide inserts for grooving and cut-off that can be used interchangeably in its toolholders. The benefits of having the choice are obvious for meeting one of the most important customer metrics—lowest cost per part, according to Martin Dillaman, manager applications engineering. “To achieve the best value, the highest productivity and highest metal removal rate by application, Greenleaf offers a full range of PVD- and CVD-coated carbide and coated whiskered ceramic grade inserts that are designed consistently to deliver the longest tool life.

To achieve the best performance, you need to use your laser at the correct working distance. Typically, you move your laser head so that the distance between the surface of the carbon fiber and the laser head is equal to the working distance in the laser head's technical specification. Then you normally need to adjust this distance by half the thickness of your material. Doing so ensures that the beam focuses exactly in the middle of the material. For thin carbon fiber sheets you may however chooso to fine tune this distance, moving the laser's focus closer to the fibers of the CF rather than the epoxy layer. In general accurate calibrations ensures getting precise and consistent cutting results every time.

Cutting carbon fiber can be a precise and delicate task. When it comes to cutting this durable material, using the right tools is essential. Opt Lasers' Blue Laser Heads offer a solution that provides both accuracy and efficiency for carbon fiber cutting. In this guide, we will show you how to cut carbon fiber effectively using various methods available, and what each method is good for. With Opt Lasers, mastering how to cut carbon fiber has never been easier.

However, both CNC methods and manual tools share a common drawback: tool wear. Because they use contact methods to cut carbon fiber, the cutting edges of these tools gradually become blunt, reducing their effectiveness over time. This requires regular maintenance and frequent replacement of cutting tools, adding to the overall cost and effort.

Secondly, ensure that the cutting speed and power settings are appropriate for the material thickness and type of carbon fiber you are working with. Making adjustments to these settings can help improve the consistency of your cuts. Additionally, inspect the condition of the laser lens and clean it regularly to maintain optimal performance.

For CO2 lasers, it is quite different. CO2 lasers require frequent, difficult and time-consuming calibration. In addition, regular calibration is necessary for CO2 lasers to maintain cutting quality and efficiency over time. Having a well-calibrated CO2 laser is crucial for achieving precise cuts without compromising the integrity of the carbon fiber material.

Answer: Yes it is - blue laser heads can cut carbon fiber with excellent results and smooth edges that won't cut your skin in turn.

For blue diode lasers, you should not see any issues with misalligment once you do the calibration on your first laser job. Instead, you should take a look at the front lens or the frontal protective window. Observe whether dust and debris has accumulated on it, and try to clean it gently.

Inconsistent material warping and distortion can pose challenges when cutting carbon fiber with a laser. To address this issue, start by ensuring that the material is securely positioned and supported during the cutting process. Use clamps or fixtures to hold the carbon fiber in place and minimize movement that can lead to warping.

CO2 lasers, operating at a wavelength of 10.6 micrometers, are widely used in various industries for cutting non-metallic materials. While they are capable of cutting carbon fiber, they are not as precise as blue laser heads. CO2 lasers waste 95-96% of provided energy, and generate much more heat, which can affect the edges of the carbon fiber, leading to potential fraying and damage to the polymer matrix. This heat can also cause the resin to degrade and produce harmful fumes at a much greater scale. Despite these drawbacks, CO2 lasers are relatively versatile and can be used for a variety of materials, making them a more generalized tool in workshops and manufacturing environments.

The Walter Cut MX grooving system uses dowel pin location to prevent improper assembly of inserts into the holders. The dowel pin location along with the horizontal seating surface provide positioning accuracy and diameter repeatability for the inserts. This eliminates the need for “test cuts” after every change of the cutting edge of the insert, according to Walter. The four-edge indexable inserts can be used even after one or more cutting edge breaks. The inserts also have Walter-specific precision cooling and the Tiger·tec Silver coating grades, which extend tool life, according to the company.

“The advantage of coolant-through toolholders lies in achieving good chip evacuation that curls chips nicely and directs them away from the workpiece. Keeping the cutting edge cool minimizes edge wear and maximizes tool life by keeping normal flank wear from progressing too quickly,” Rucker explained.

This precision reduces the risk of damaging the carbon fiber's polymer matrix and ensures the structural integrity of the material is maintained. Additionally, blue laser heads are highly efficient, consuming less power while delivering high performance. Compared to CO2 lasers, blue lasers are 4-5 times more energy efficient.

One of the most common manual tools for cutting carbon fiber is the hacksaw. Equipped with a fine-toothed blade, a hacksaw can effectively cut through carbon fiber sheets and tubes. Typically, the thickness of a hacksaw blade used for cutting carbon fiber ranges from 0.5 mm to 1 mm. To achieve the best results, it's crucial to use a blade specifically designed for cutting composite materials. When using a hacksaw, ensure that the material is securely clamped to prevent movement, and cut slowly to minimize fraying and ensure a clean edge. Hacksaws are ideal for straightforward cuts and smaller projects where precision is not paramount.

Answer: To cut carbon fiber with a blue laser head from Opt Lasers, you should first set the laser parameters such as power, speed, and focus according to the material thickness and desired cutting quality. Next, securely place the carbon fiber material on a flat surface and position the laser head accurately over the cutting area. Start the cutting process and ensure proper ventilation to remove any fumes generated during the cutting process.

CNC router end bits are another excellent tool for cutting carbon fiber. These bits are designed to work with CNC routers, which are known for their speed and versatility. CNC routers equipped with the right end bits can swiftly cut through carbon fiber, achieving precision typically within the range of 0.1 mm to 0.05 mm. The end bits come in various shapes and sizes, each designed for specific cutting tasks, such as straight cuts, detailed patterns, and beveled edges.

Challenging applications range from machining difficult-to-machine materials like superalloys; micro-sized turning part applications; deep, heavy-duty grooving; and small-part machining. Small-diameter Swiss-style part-off and small-diameter ID and OD face grooving applications pose their own challenges.

With new Walter Capto monoblock tools (C3–C6), the MX system can now also be used on machines with Capto interfaces. In addition, new parting blades work with automatic lathes and multi-spindle machines. Walter has completed the range with new grooving inserts and toolholders for larger insert widths. Where previously only 0.031" (0.80 mm) to a maximum of 0.128" (3.25 mm) were possible, the insert width now ranges up to 0.222" (5.64 mm)—including the very common dimensions of 0.125" (3.18 mm), 0.157" (4 mm) and 0.196" (5 mm). Maximum cutting depth is 0.24" (6 mm). These extensions are intended to make new applications possible for users of the MX grooving system, from small-parts production, where a high degree of precision is needed, to job shops, where the focus is on fast, precise tool changes and cost efficiency.

If you find that the issue persists, consider conducting test cuts on a small scrap piece of carbon fiber to fine-tune your settings and identify any potential factors affecting the cut quality. By systematically troubleshooting and making adjustments, you can overcome inconsistent cut quality and achieve the desired results.

This section will delve into the details of each cutting method, highlighting their advantages and limitations, and providing comprehensive safety guidelines to ensure a safe and effective cutting process for your carbon fiber projects.

Cutting carbon fiber requires a high level of precision, which can be achieved by configuring the paramters of your laser for optimal performance. Adjust the laser power, airflow rate, and cutting speed based on the thickness and type of carbon fiber you are working with. Experiment with different settings to find the perfect combination that delivers clean cuts with minimal heat-affected zones.

In addition, blue lasers' ability to cut complex shapes and designs makes them ideal for advanced manufacturing and prototyping. Blue lasers are mounted on a CNC machine, and the automated process allows them to cut carbon fiber 24/7. It however worth noting that whilst blue lasers are ideal for cutting carbon fiber cloth and fabric, and they perform well on carbon fiber veneer, they should not be used for carbon fiber laminates.

CNC mills are widely used for cutting carbon fiber due to their high precision and control. These machines operate by using rotary cutters to remove material, allowing for detailed and accurate cuts. CNC mills can typically achieve precision within the range of 0.1 mm to 0.01 mm, making them particularly effective for creating complex geometries and precise patterns in carbon fiber sheets and components. They are ideal for producing parts that require tight tolerances and high dimensional accuracy, such as aerospace components, automotive parts, and custom-fitted equipment.

To perform the working distance calibration, you need to engrave a set of lines on a piece of material, with each line corresponding to varying height above the material. For best results and precision, perform this test at low laser power on a piece of black anodized aluminium, or anodized aluminium business cards. Depending on the laser head and your anodized aluminium, a laser power of 5-10 Watts will be absolutely sufficient for this task. For black anodized aluminium, the closer you are to the perfect working distance, the more visible the engraving will be, as the laser beam engraves deeper into the anodization layer around the focus distance. As a result, you should see a pattern of decaying engravement thickness the further away you are from the perfect working distance (in both directions).

Adjust the cutting parameters to reduce the heat input and prevent excessive thermal stress on the material. Fine-tuning the speed and power settings can help minimize the risk of warping and distortion. Additionally, consider using a sacrificial layer or backing material to provide additional support and absorb excess heat during cutting.

Fiber lasers are known for their high power and efficiency, operating at wavelengths around 1.064 micrometers. Unfortunately, their suitability for cutting carbon fiber is limited due to the significant amount of heat they generate per pulse. This excessive heat can severely damage the polymer matrix in carbon fiber, degrading the resin and causing it to burn. The resultant damage compromises the material's integrity and can release harmful fumes, posing health and safety risks. While fiber lasers excel in cutting metals and other hard materials, they are quite inferior for carbon fiber cutting due to these heat-related issues.

Compared to manual tools like hacksaws and Dremel tools, CNC mills and CNC router end bits offer several significant advantages. CNC methods provide superior precision and control, allowing for more accurate and detailed cuts. They also operate at higher speeds, reducing the time required to complete projects. Additionally, CNC machines can handle more complex designs and produce consistent results, which is challenging to achieve with manual tools.

As for the CO2 lasers, you should inspect all the mirrors and lenses for any signs of damage or misalignment. Even a slight deviation can have a significant impact on the quality of your cuts. Regular CO2 laser maintenance and alignment checks are vital to prevent misalignment issues and ensure consistent cutting performance.

Excessive heat generated during the cutting process can lead to damage and deformation of the carbon fiber material. To minimize these risks, ensure that you are using the correct laser parameters and cutting techniques. Adjusting the power, speed, airflow rate, and working distance of the laser can help you control the amount of heat generated and reduce the risk of damage to the material.

Kyocera offers JCT technology across many of its product lines. For example, the KGD standard dog-bone style, two-ended cut-off tooling is offered with coolant through in the universal 3 mm and 4 mm widths for grooving and cut-off. KGD toolholders without coolant-through are available in widths from 1.3 mm up to 8 mm in two styles, a single piece integral or switchblade style that can use one body for many different blades for facing, face grooving, etc.

When cutting carbon fiber, safety is paramount. Different cutting methods require different safety precautions and protective gear to ensure the health and safety of the operator. Nevertheless, using blue lasers is in general the safest method for carbon fiber cutting as it doesn't generate the dust or splinters.

Notwithstanding, Opt Lasers' XT8 laser head allows you to enjoy more leeway with the way you position it. Effectively, for CF cut depths up to 3 mm, you can simply position it so that the distance between the laser head and carbon fiber surface is simply equal to its workinging distance. This is for instance useful for cutting carbon fiber sheets, which are comercially available in 0.25mm, 0.5 mm, 1 mm, 1.5 mm, 2 mm, and 3 mm thicknesses for a variety of sheets sizes. It will also be useful for cutting carbon fiber rods that are thin.

There are several useful tips and techniques that help you improve the efficiency of your carbon fiber cutting station and mitigate the chances of any issues occurring.

One thing that’s certain in developing the most cost-effective solutions for part-off and grooving applications is that there is not just one way to approach the problem and meet basic process requirements for chip evacuation, tool life and surface finish. The end result, whether in ID or OD grooving or part-off, depends on matching the right cutting tool and toolholder and coolant delivery system with the right material application.

“With ceramics, you can’t generate a chip form as you can with carbide inserts,” he continued. “Most ceramic inserts will just have a flat top on them without a chip form. Typical applications include high-temperature alloys for aerospace applications that can be run at higher surface footage with decent feed rates to achieve high levels of productivity. Materials include Inconel, Hastelloys and Monels, materials that are very difficult to machine with carbide. Carbide can be used for finishing at a slower speed where there may be sensitivity to the heat generated by ceramics, switching the carbide insert in the same holder.”

Cutting carbon fiber can be approached in several ways, each with its own set of tools and techniques. On the more manual side, tools like hacksaws, Dremel tools, drills, coping saws, angle grinders, and jigsaws are commonly used. These tools can be effective for smaller projects or when precision is not the primary concern. However, they require a steady hand and a lot of patience to achieve clean cuts, and often result in more waste and less precise edges.

Kyocera has also developed a line of JCT holders for small parts machining with widths from 0.5 mm to 3 mm. The KGD-JCT series for external grooving and the KTKF-JCT holders for Swiss-style automated lathe machining are for applications like turning, grooving, back turning and cut-off. “The challenge with Swiss-style machines is to keep coolant directed at the various machining processes, some of which, like cut-off, grooving and back turning, are usually done away from the spindle. It’s possible for coolant to be blocked by the subspindle. The farther they are from the coolant source, the less coolant they are likely to get,” Rucker said.

By understanding the various manual methods for cutting carbon fiber, you can choose the right tool for your specific project needs. Each method has its strengths and limitations, but with the right approach and technique, manual cutting can yield precise and satisfactory results.

What follows are examples of product families that allow insert blades to be easily changed out and a look into the future of real-time tool monitoring for micro turning applications.

The non-contact nature of laser cutting also allows for greater flexibility in cutting complex shapes and fine details. It reduces the risk of material damage and ensures consistent performance throughout the cutting process. As a result, laser cutting is increasingly becoming the preferred method for many carbon fiber cutting applications, offering significant advantages over both manual and CNC methods.

A jigsaw offers a versatile option for cutting carbon fiber, capable of handling both straight and curved cuts. Using a fine-toothed blade designed for cutting composites, a jigsaw can navigate various shapes and patterns. Typically, the thickness of the jigsaw blade used for carbon fiber cutting ranges from 0.5 mm to 1 mm. This fine-toothed blade helps ensure smooth, precise cuts with minimal fraying.

Whatever laser you choose, make sure to follow the manufacturer's guidelines for calibrating your system to ensure optimal performance. By keeping your laser properly calibrated, you can increase productivity in your cutting projects.

Kyocera’s KGBF-JCT triangle platform for shallow grooving delivers coolant through the top clamp. “The main grooving depths from 0.6 mm to 3 mm maximum are much less than that possible with a dog-bone style, but there are three edges and the insert can be flipped in case of damage, so there are still two usable edges,” he said.

For more automated and precise methods, CNC cutting tools such as mills and CNC router end bits are popular choices. These tools offer greater control and accuracy compared to manual methods. They are suitable for larger projects or when intricate designs are needed. While CNC methods improve precision and reduce manual labor, they still fall short in terms of efficiency and the quality of the final cut when compared to laser cutting technology.

For instance, using a lower power setting and/or a higher cutting speed can help reduce the heat-affected zone and minimize the chances of material deformation. Additionally, employing techniques such as air-assisted cutting or using a compressed air supply can help dissipate heat more effectively, further reducing the risk of damage to the material. By following these guidelines, you can achieve high-quality cuts while preserving the integrity of the carbon fiber material.

To achieve high-quality cuts when working with carbon fiber, it is important to maintain a consistent laser power output. Fluctuations in power can result in uneven cuts and affect the overall quality of your work. CO2 lasers are prone to this issue, while for high-quality blue diode lasers (like XT8 laser head) it is negligible as the power barely fluctuates.

The use of CNC mills in cutting carbon fiber also offers the advantage of repeatability. Once a design is programmed into the CNC machine, it can produce identical parts with consistent quality, making it perfect for mass production and large-scale projects. Additionally, CNC mills can handle various thicknesses and sizes of carbon fiber, providing flexibility in manufacturing different types of components.

CNC mills and CNC routers equipped with end bits also generate dust and particles during the cutting process. While the precision and speed of CNC methods reduce the need for extensive manual labor, the following safety measures should be observed:

The image on the left below showcases the cleanly cut edges of a carbon fiber fabric circle, cut using Opt Lasers' blue laser heads. On the right, you can see the unburned surface of various black carbon fiber and white fiberglass sheets, all precisely and cleanly cut with a 45W XT8 blue laser head:

“Once you get within the width of the insert, the force is going to be much greater than the tensile strength of the material being machined so basically that means you are going to break the component off. So you get the pip at the very end. Also, carbide is extremely strong in compressive stresses but not in tensile stresses. In cut-off, you have compressive stresses all the way to when the part breaks off and now you go from compressive to tensile stresses,” Andersson explained.

Additionally, just like with any cutting method, ensure that you are working in a well-ventilated area to minimize the concentration of airborne particles.

Cutting carbon fiber manually involves a variety of tools and techniques that, while less automated than modern methods, offer a degree of control and accessibility that can be invaluable in certain situations. Whether you are a DIY enthusiast or a professional working on a specific project, understanding these manual methods can help you achieve precise and effective results.

Contary to common belief, a blue diode (or even CO2) laser cutter with the correct settings will not cause a visible burned cut line by burning the epoxy before it cuts the fibers. In particular, blue lasers are much less prone to this phenomenon than CO2 lasers. Notwithstanding, each of them can be tuned to cut your carbon fiber with exceptional top-notch results. In fact, laser cutters are revolutionizing the way carbon fiber can be cut, offering precision, efficiency, and flexibility. Among the various types of lasers available, blue laser heads and CO2 lasers are the only suitable laser types as of July 2024 for use in CF cutting. However, each has its strengths and weaknesses, making it essential to understand their suitability for cutting carbon fiber.

For very detailed work, a coping saw can be an excellent choice. This tool, with its thin, replaceable blade, allows for intricate and precise cuts. Typically, the thickness of a coping saw blade for cutting carbon fiber is around 0.3 mm to 0.5 mm. This thin blade helps ensure clean, precise cuts, making it especially useful for making interior cuts or navigating tight curves.

Cutting carbon fiber with CNC mills and CNC router end bits offers precision, efficiency, and versatility, making these methods highly suitable for both industrial applications and custom projects. Compared to manual tools, CNC methods provide superior accuracy, speed, and consistency, addressing many of the challenges associated with traditional cutting techniques.

If you use the CO2 laser, make sure to regularly check and calibrate your laser system to ensure a steady power output throughout the cutting process. This will help you achieve precise and uniform cuts every time.

The PTS consists of a force sensor inserted into the turning tool that provides information on its condition during machining. The extremely small piezo sensor can measure even the tiniest cutting forces to a high resolution, allowing the machine operator to identify a defect in the material being cut or tool breakage immediately, resulting in minimum waste and maximum quality.

On occasion, you may encounter problems with inconsistent cut quality when working with carbon fiber. This can be frustrating, but there are steps you can take to address the issue. Start by adjusting the working distance of your laser with better precision using black anodized aluminium. A well-focused beam is vital for achieving clean and precise cuts.

Misalignment of the laser can lead to issues with cutting accuracy and precision. If you notice that your cuts are not as clean or precise as they should be, the first thing to check is the alignment of the laser head.

Cutting CF with blue laser heads or CO2 lasers involves different safety measures due to the non-contact nature of the laser cutting process. Here are the specific precautions:

Toolmaker Paul Horn GmbH, Tübingen, Germany, and the Kistler Group, Winterthur, Switzerland, a global producer of dynamic measurement technology, have worked together to develop the Piezo Tool System (PTS) for real-time monitoring of tools used in micro-turning applications. Developed specifically for monitoring Horn’s new WT geometry for parting-off titanium, the WT geometry has proved its practical value almost immediately for parting off titanium bone screws, according to the companies. In addition to reliable chip breaking, the adapted geometry ensures a soft cut, making higher feed rates and faster machining times possible. Horn reports that tests have shown that service life is increased by up to 60 percent.

Angle grinders are another powerful tool for cutting carbon fiber, especially when speed is of the essence. Fitted with a diamond or carbide cutting disc, an angle grinder can quickly slice through carbon fiber sheets and panels. However, due to the high speed and power of angle grinders, they can produce a lot of dust and generate significant heat, which can damage the carbon fiber if not managed properly. It's important to wear appropriate protective gear and ensure adequate ventilation when using an angle grinder.

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Greenleaf’s whisker-reinforced ceramics include WG-300 for machining nickel and cobalt-based super alloys; WG-600 with thermal properties and shock resistance for rough and finish turning; and WG-700 whisker-reinforced Al2O3 ceramic substrate for machining difficult-to-machine materials. The newest addition is the XSYTIN-1 phase-toughened ceramic for machining steels, cast and ductile irons, high-temperature alloys (interrupted cuts), scale and abrasive casting materials.

“What is probably most important in groove turning is that you plunge you turn, you plunge you turn,” he continued. “And you must have sufficient feed rate to get deflection in the blade to create clearance, without moving the insert. That’s always been the challenge in those operations.”

Regardless of the cutting method chosen, safety precautions are paramount when working with carbon fiber. Manual cutting tools can produce fine dust and fibers, which can be harmful if inhaled or if they come into contact with skin. Using proper personal protective equipment (PPE) such as masks, gloves, and protective eyewear is essential. Similarly, CNC machines and laser cutters require appropriate ventilation systems to manage dust and fumes. Additionally, when using laser cutters, it's crucial to follow manufacturer safety guidelines to prevent burns, eye damage, and other injuries.

When comparing blue laser heads, CO2 lasers, and fiber lasers for cutting carbon fiber, it is evident that blue laser heads offer the best performance. Their precision and efficiency make them superior in maintaining the integrity of the carbon fiber, while also ensuring cleaner cuts and less material waste. CO2 lasers, although versatile, fall short in terms of precision and heat management, making them less suitable for delicate carbon fiber work. Fiber lasers, despite their high energy efficiency, generate too much heat per pulse, leading to potential damage and safety concerns.

The new PTS system is suitable for use in micro range turning applications where alternative measurement methods aren’t practical and can’t detect minute variations in the drive power of the main spindle motors. Even measuring acoustic emissions would not deliver satisfactory results consistently when small workpieces like bone screws are being machined. Visual monitoring also has to be ruled out due to the use of coolant and the high rotational speeds involved in the machining process.

Greenleaf continues to regard developing the next levels of inserts for higher feed rates and better wear resistance as a priority. “XSYTIN-1 inserts can be fed at a higher rate but wear resistance isn’t as good as with the whiskered grades,” said Dillaman. “One thing that is extremely helpful for our customers when building tooling—whether ceramic or carbide—is that they fit into the same holders. They don’t have to buy multiple toolholders to handle ceramic and carbide.

Chip formation and management are critical to process stability, said Andersson. “You don’t necessarily break a chip in grooving; you form the chip into a clock spring, which is slightly compressed to be narrower than the groove you are generating (to avoid chip packing). You want to steer this chip so it doesn’t wrap around the part, the tool or cause chip evacuation issues in the chip conveyor,” he said.

In contrast, laser cutting offers a non-contact method that eliminates the issue of tool wear. Blue laser heads, such as those from Opt Lasers, use focused laser beams to cut through carbon fiber without physically touching the material. This non-contact approach means that users do not have to worry about the cutting tool becoming blunt. Additionally, laser cutting provides high precision and clean edges, further enhancing the quality of the final product.

Answer: To cut carbon fiber without fraying it is recommended to use a blue laser head, for instance Opt Lasers' XT8. Using XT8 at correct speed and power will elimiate all fraying.

Walter USA LLC, Waukesha, Wis., has added Walter Capto toolholders and insert widths to its Walter Cut MX grooving system. Capto toolholders feature enhanced rigidity and modularity, while the tapered polygonal shape easily handles both torsional and bending forces, according to Walter. This interface can be used for lathes, and for turning/milling centers.

In grooving and cut-off processes, stability in the pocket, predictability and tool life are the hallmarks of productive operations, according to Jan Andersson, director, indexable inserts, YG-1 Tool Co., Vernon Hills., Illinois. To achieve that stability, YG-1’s TD part-off and grooving platform uses a longer insert, 20 mm, that prevents twisting or movement of the insert in the pocket.

For somewhat more precise manual cuts, a Dremel tool can be highly effective. This versatile rotary tool can be equipped with various attachments, including cutting wheels and abrasive bits, making it suitable for detailed work on carbon fiber. Typically, the thickness of Dremel cutting wheels used for carbon fiber ranges from 0.8 mm to 1.0 mm. Despite the slightly thicker blades, the Dremel tool's high speed and rotary motion allow for more precise and controlled cuts compared to a hacksaw. It's essential to work slowly and steadily to avoid overheating the material, which can cause delamination.

Answer: To cleanly cut carbon fiber, you should use blue laser heads as they can provide the cleanest cut. For best-of-class results, you should also cover the cut edges with epoxy to seal them.

Tang F Grip features a high-feed (HF) chip former that is tangentially mounted in the pocket and is performance driven. “With the high-feed chip former, we are able to push feed rates of 15 to 20 thou per revolution, which is three, four, and even five times faster than your average shop, parting off steel, alloy steel and cast iron with a 3-, 4-, or 5-mm insert. We’re testing it for other materials like Inconel 718 and getting fantastic results. We have to back off the feed rate for the Inconel 718 so instead of going 18 thou per rev we’re going 12 thou per rev but that’s still three times faster than the customer was doing before we walked in the door,” said East.

The new PTS solution is compatible with selected standard turning toolholders offered by Horn. It doesn’t require any adjustment to be made at the control and can be used on any machine. Sensors can be replaced quickly and easily, according to Horn. Type 224 inserts with the new WT geometry are available in increments of 2, 2.5 and 3 mm in grade IG35. They are designed for type H224 holders.

At this point, you can start seeing chipping of the insert. As a result, programming is very important. “Once you get within the width of the insert, it’s advisable to reduce the feed by 75 percent. What that does is give full feed rate on the width of the insert while reducing the change from compressive to tensile stresses. That will add significant life to the tool,” he said.

Unlike manual or CNC cutting methods, laser cutting does not typically require special clothing or gloves since there is no physical contact with the material or particularly its cutting dust or splinters. However, always follow the manufacturer's safety guidelines to prevent accidental exposure to the laser beam.

Iscar’s Do Grip option is a double-ended insert like a traditional dog-bone. “What differentiates our tool is when you get up to the 4-mm width and above, we have a twisted geometry which avoids the problem with traditional dog-bone inserts. When you are parting off or plunging with the traditional dog-bone insert, once you reach a depth that is equal to the length of that insert, you’re going to start rubbing on the backcutting edges of that insert. Our twisted inserts sit in the pocket where back-side cutting edges are angled so you have clearance on either side with the result that there are no depth limits with the twisted geometry insert,” he said.

Answer: A blue laser head is often preferred for cutting carbon fiber due to its high energy density and precise control. Blue lasers can produce clean, accurate cuts on carbon fiber material without causing damage or melting, resulting in smooth edges and minimal waste

As with other manual methods, clamping the material securely and working slowly are key to preventing frayed edges and achieving a clean cut. It's essential to use blades specifically designed for composites to avoid excessive wear and tear on the blade and the material. Jigsaws are particularly beneficial for projects that require a variety of cuts and shapes, offering both flexibility and control to the user.

For ID grooving, Kyocera’s SIGE system for small diameters with 8-mm minimum bore has two cutting edges in a unique L-shaped tool and is coolant-through capable for flushing chips. “We have added a new tool, the SIGC, for very deep reach in 8-mm minimum bores without deflection,” Rucker said. “The SIGC insert is a very sturdy, single-edged round insert that screws on to the end of the boring bar, providing excellent coolant-through capability for superior chip evacuation performance.”

Among the various cutting technologies available, using blue laser heads stands out as the most efficient and effective method for cutting carbon fiber. Blue laser heads, like those from Opt Lasers, provide unparalleled accuracy and clean cuts, significantly outperforming manual tools, CNC methods, and even other laser types like CO2 lasers. The focused energy of blue lasers allows for precise cuts with minimal material wastage and reduced edge fraying, making it the superior choice for all professionals working with carbon fibre. In addition, they benefit from high energy efficiency, and are very easy to integrate into existing setups.

“In parting and grooving, you can’t have torsional twist or movement in the pocket,” said Andersson. “That will show up in tool wear. If you see an insert with significant flank wear on the outside of the radii or flank wear that is further back on the insert on the lower side below the cutting edge, that’s almost always due to torsional twisting. You can tell from how the insert actually wears what is happening in the pocket. A longer insert gives additional contact area and stability to avoid insert movement.