Aggressive cutting with large chips also helps minimize heat buildup in the material by transferring the heat through the chip and to the tool. This is especially important when working with thermosets and thermoforms, so the material doesn’t adhere to the tool. In many applications, managing heat with coolants is not typically an option because of the amount of dust produced by composites. The dust mixes with the coolant and creates an abrasive paste. Coolant can also get in between the composite layers and ruin the integrity of the material. To keep heat down, shops can use a cold air gun in the cutting zone with an adequately sized dust collection system as a low-cost solution.

With so much variation in composite materials, getting the right machine setup with the right processes and the right cutting tools may seem overwhelming. Testing on a new component or material can be extremely difficult, especially if you cannot afford to take a machine out of production.

This article was written by David DenBoer, Aerospace Specialist Round Tools, Sandvik Coromant (Mebane, NC). For more information, visit here  .

Composites are often made up of multiple layers of carbon fiber and other materials that are prone to separation during ineffective machining processes. This separation of layers, also known as delamination, can have detrimental consequences on the structural integrity and surface quality of the component.

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A typical machine operator listens during the cutting process and tends to reduce the cutting speed and feed rate when something doesn’t sound right. This is also a common practice to try and conserve tool life. But this careful approach to machining will often lead to problems in composite materials. The sounds of composite machining are much harder to read and going too low on the feed and chip load (the width of chips produced by a cutting edge on each rotation) will lead to rubbing, chatter and delamination.

Composite materials play an important role in aerospace manufacturing. The light weight, durability, and ability to create complex shapes from molds make these materials ideal for frames and structural components that enable lighter, more fuel-efficient aircraft.

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To find the square footage of your roof, measure the length and width of each plane of your roof, including the sides of all dormers, into valleys, and all other roof design details that are covered with roofing materials. Find the area of each plane by multiplying the length and width.

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If you need to measure the amount of roofing squares your roof contains, you can do this simply by measuring the total square footage of your roof, and then using that amount to calculate the number of roofing squares it contains. Let’s go over 4 steps to do this safely and effectively.

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Using PCD tools that can withstand the abrasive nature of composites offers clear advantages in terms of machine uptime, surface quality and process security. They maintain their sharpness longer and provide a cleaner cut in composite materials, reducing the risk of fraying or failure that can lead to scrapped components.

Steelmachining composite

Diamond tools may have a diamond coating on the surface, applied using a chemical vapor deposition (CVD) process, or they can even be made with diamond veins that are sintered into the carbide. Veined tools represent a significant advancement in composite machining because they allow for cutting geometries specific to CFRP materials that are normally not possible.

We find the roof slope by plugging the rise and the run into the pythagorean theorem, where the slope of your roof, or the rafter length (squared) = the rise (squared) + the run (squared).

A good tool provider will run extensive tests on PCD tools using composite materials to provide clear data on performance and life expectancy to help drive more predictable results. They’ll also be able to extend the life of the tool through reconditioning, which is an area that has seen improvement in recent years. Where previously you could resharpen a PCD tool two or three times, you can now resharpen some tools up to 10 times. The cost of resharpening is typically 20 percent the cost of a new tool, so this dramatically increases the return on investment.

Keeping tools sharp is critical here. Don’t push the limits on the life expectancy of your cutting tools; change them out when they begin to lose their edge. Managing tool wear by utilizing different cutting edges of the tool will also help maintain that tool sharpness longer. Positioning a tool to cut further up on the flutes in a side milling operation, for example, will help disperse tool wear more evenly and extend the life of the tool — minimizing risk of pushing and delaminating the material.

Now that you know how to measure your roof, calculate a roofing square, and find your roof’s slope and pitch, you should have all the information you need to order materials for your roof! It’s always a good idea to check your calculations with a professional roofer and make sure all materials are installed correctly to give your roof the best, longest-lasting protection.

Composites are notorious for wearing down tools. And when you’re machining large structural components like a fuselage component or wing box, or drilling thousands of holes for rivets, frequent tool changeouts can become a serious drag on productivity. In these applications, investing in polycrystalline diamond (PCD) tools are well worth the cost, because they’ll last 10 to 15 times longer than a standard tool.

You can find the pitch of your roof by dividing the rise by the run. Using our example that would be 0.5 or 50 percent. If you want to express this percent as an angle, you’ll need to plug the percentage into this equation using a scientific calculator or an online tool:

For help calculating the total roofing squares in your home’s roof, some manufacturers offer free roofing square calculators online, or you can have your roof assessed and receive a free quote from a professional roofing company. Or, you can DIY by measuring your roof yourself.

To avoid delamination, it’s essential to use tool geometries that minimize lifting of the material. For example, choosing a milling tool for material removal with a low helix angle — maybe 10 degrees or 15 degrees at most — will keep milling operations from pulling the material apart. Additionally, choosing tools that maintain a sharp edge longer, like drills with PCD tips, will minimize risk of delamination. Once a tool begins to dull, it will immediately begin pushing the material, rather than making a smooth cut, and cause splintering.

Rigid and secure tool holding is essential, otherwise your investment in good tooling will be wasted with chatter in the cut. Hydraulic chucks will minimize run-out and the chance of tool pullout, either of which makes for a bad day when plowing through a $40,000 airfoil. And at higher spindle speeds (anything above 20,000 RPM) it’s best to have the tool holders balanced as a complete assembly, with the cutting tool and retention knob installed.

Here’s where the right tool provider becomes more of a partner; besides tooling recommendations, they can be an invaluable resource to help get new component production up and running. It’s important to work with a provider that has engineering and support services, not only to guide in tool selection, but also to help with tool path programming, simulations and actual machining in a test facility using the same type of equipment as your shop.

Looking for a bit more roofing information? Whether you’d just like a bit more help figuring out how many roofing squares are in your roof, or you’re interested in a brand new roof, the experts at Werner Roofing would love to help. Give us a call or reach out to our team online with any and all roofing questions.

Composite machining often involves tolerances that are just as tight as metal machining and with just as many cutting variations. Using the right tools, the right setup and the right techniques will help ensure success with more reliable aerospace production.

Adding to the challenge, the makeup of these materials can be very diverse, with a wide variety of characteristics. Some composites will be stacked with different materials, like metals, or with fibers aligned in different directions; others will be meshed in a unidirectional material. Some composites are prone to fraying or delaminating, while others, like polyaryletherketone (PEAK) materials, are heat-sensitive and can adhere to cutting tools.

Keep in mind that roofing squares is not the only information you need when estimating the required materials for completing a roof replacement or installation. Roofing pitch also factors into the total amount and cost of materials for your roofing job. The higher the pitch of your roof, the extra materials you’ll need to cover your roof effectively. Also, if your roof has many complicated details like dormers and valleys, it will need more specialized materials to make sure these sensitive areas are reinforced against leaks or damage.

The term roofing square does not refer to square feet or yards. In fact, it is a unit used to express 100 square feet, in order to simplify the grouping and ordering of roofing materials such as shingles, tiles, or other supplies. Roofing squares are commonly used to calculate the materials needed for roofing projects, so you may hear your roofing contractor or your materials supplier refer to your roof in these terms.

When cutting into composites, it’s critical to stay aggressive, maintaining cutting parameters of 6,000 to 10,000 rpm and high chip loads in the range of 0.002"-0.003" per tooth/min. If you run tools under a 0.001” chip load, you’ll destroy your tools very quickly. Using PCD tools here will allow operations to maintain the aggressive cuts needed.

CompositeMachinist jobs

Roofing pitch is described in degrees, relative to a right angle. To calculate your roof pitch, you need to know the rise and the run of your roof.

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Contending with these variables can make it tricky to find the best tool and process for the job. However, there are a few general tooling strategies and cutting principles that shops can apply when machining composites to improve the efficiency and quality of their production.

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The way roofs are measured and roofing materials are calculated is not always simple. When trying to estimate the amount of shingles or other roofing supplies, you may have found that your calculations don’t match up with the way roofing companies or suppliers talk about their products. Instead, they may refer to roofing supplies in terms of roofing squares. What is a roofing square and how can we use it to calculate the roofing materials you’ll need? Let’s find out.

Composites come with a wide variety of physical and chemical properties. They can have a wide range of constituent materials that are incorporated through matrices or layered reinforcements. Understanding your material and how it behaves during the machining process is essential for achieving an optimal machine setup.

For example, a unidirectional material composed of a single layer can create unique challenges in machining operations. Shops will need to approach the cut from the proper angle and direction, and in some cases will need to use a compression style tool that approaches the cut from both the top and bottom of the material.

Machining compositepdf

While composite structures can weigh up to 20 percent less than their metal counterparts, these materials can often be more difficult to machine. The extremely abrasive nature of carbon fiber reinforced polymers (CFRPs) will wear down standard cutting tools more quickly than almost any other material. A standard carbide cutting tool may only hold up to cutting a few feet of CFRPs before its dimensional stability fails, while in traditional metal machining that same tool might last 20 to 50 times that before wearing out.

Adding to the challenge, composites are often stacked with other materials, like titanium, aluminum or copper, in all sorts of combinations to enhance the materials’ properties or structural support. When drilling through these multiple materials, shops need to understand how each material will interact with the tool. With stacked carbon fiber and aluminum, operators can maintain the same aggressive cutting speed for the duration of the cut, but if the composite is stacked with harder materials like titanium, they may need to adjust the cutting speed and feed rate accordingly for each layer.

Gripping the composite workpiece is also important. Vacuum fixtures are useful if the workpiece has enough surface area to create sufficient gripping force. In most cases, special jigs are the best option, especially for the complex, three-dimensional shapes common with composite workpieces. Jigs should be designed to avoid any unsupported cutting areas while still gripping securely enough to prevent movement and vibration in the part.

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First, make sure you have all the right equipment to get onto your roof and measure it safely. This will include a tape measure, a small notebook and pencil, a sturdy ladder, and a buddy to hold the ladder still and supervise while you’re on your roof. Tread carefully on your roof so you don’t slip or cause damage to your roof.

To find the number of roofing squares your roof contains, convert the square footage to roofing squares by dividing number you found in Step #3 by 100. For example, if the total square footage of your roof was 1700 square feet, your roof contains 17 roofing squares.