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.

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.

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.

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.

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:

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.

This is an Open Access article distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Performance of hard turning is greatly influenced by the parameters, i.e., cutting velocity, feed rate, and depth of cut. Various researchers performed hard turning operation to predict machinability on different hardened steels by varying cutting parameters. The purpose of the investigation reported in Suresh and Basavarajappa [35] was to reveal the impact of process parameters: depth of cut, velocity and axial feed rate on flank wear of coated ceramic tool, and surface finish of hardened AISI H13 steel (55 HRC) by conducting the dry turning experiment in CNC lathe. The results indicated that cutting speed predominantly affects tool wear while feed is high influencing factor in surface finish. Rashid et al. [36] revealed that lower feed produces improved machined surface finish, but causes high tool wear, so the choice of a suitable feed must be determined by trade-off between the quality and cost consideration. In a study, Bensouilah et al. [37] observed that growth of surface roughness and cutting force components substantially affected because of cutting parameters namely cutting velocity and feed. During hard turning of AISI D3 steel with uncoated (CC650) and coated (CC6050) ceramic inserts. Regardless the development of flank wear for both cutting tools within control limit VB = 0.3 mm, surface finish of the machined part was better i.e. did not exceeded 1.6 µm (as good as manufactured by grinding), but better surface is improved by coated ceramic tool when differentiated to the surface developed by the uncoated ceramic. In an experiment on AISI 52100 steel with CBN tool, it shows that cutting force is directly proportional to feed rate and depth of cut, while decreases with cutting speed. Cutting force was mostly influenced by depth of cut followed by feed and cutting velocity [38]. The higher cutting force at a lower cutting velocity is because of low temperature and formation of built up edge. As cutting velocity increases, flank wear of the tool is also increased leading to immediate deterioration machine surface quality. Surface roughness is greatly influenced by feed as it increases with increase in feed, followed by cutting velocity, whereas depth of cut has negligible impact on surface roughness [39].

The floor space is also an important factor. CNC lathes used for hard turning have less of a foot print than grinders in general. Tool changes can be made in less than 2 min, without the production time losses necessary for a wheel change. Worn PCBN tools may be quickly indexed to a new edge or removed and replaced with new inserts, and do not require truing or dressing to maintain the cutting profile. This flexibility allows for fast, cost-effective production, even in small batches of parts. Further, the structure of most PCBN grades permits for productive machining in difficult conditions, including interrupted cuts, and typically does not require the use of coolant. This helps to keep costs down while eliminating the environmental concern associated with coolant use. Just the cost of coolant and taking care of grinding residues are many times higher than taking care of the dry turning chips and swarf. An additional bonus of hard turning is avoiding cutting fluids. The possibility of dry machining means saving considerable costs otherwise caused by buying, monitoring, treatment, and disposal of cutting fluids.

In complex hard turning process, large volume of heat is generated due to vibration and exhaustive involvement of heavy mechanical load as well as high temperature on cutting tool, therefore ultra-super hard materials such as ceramic and coated carbide tools are useful for hard turning from technological point-of-view, but in most of the cases, CBN tools are used to machine hardened steel as they have high hardness, coefficient of thermal conductivity, and thermal resistance.

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.

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.

Large dynamic thrust force is generated while machining of hard material. Therefore, the machine tool associated with following attributes like rigid tool, part rigidity, rigid location, high surface speed, etc. should be considered in the machining system which is beneficial for hard turning.

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.

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.

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.

Selective research works have been performed to understand the impact of tool geometry design and in its influence to performance in hard turning, as shown in Table 1a. Cutting process is greatly affected by tool's cutting edge angle. This is because, for a given feed and depth of cut, cutting edge angle defines the uncut thickness, width of cut, and hence the life of tool [6]. Proper tool nose radius improves the machinability by increasing the tool life, as it can reduce the temperature generation at tool's tip and also increase surface finish, and it also increases strength and cutting edge's life without significant increase in the cutting force [15]. An experimental study investigated the impact of rake angle, entering angle of cutting tool and cutting velocity on machining force, and temperature at tools tip [16]. Larger entering angle produces greater feed force but less thrust force. When the cutting speed was raised, the cutting forces were reduced but the temperature was increased. For the increased positive rake angle, the cutting forces were decreased, which means less force/power is required. Edge hone radius also effects the machining in hard turning as surface roughness is directly proportional to edge hone radius. Thrust force is also affected by edge hone radius. When compared to chamfered edge, the force was smaller in small hone radius [17]. Cutting force and tool life are greatly affected by chamfer angle. With increase in chamfer angle, force in cutting also increases. Another study suggests that in order to get maximum tool life, chamfer angle should be 15° [18].

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

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.

How to machinehardened steelon a lathe

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.

Hardened steelvs stainlesssteel

Hard turning was developed in early 1980s. Machining of hardened steel by hard turning was earlier used in automotive industries for manufacturing of transmission components. Because of wear resistance and improved strength of hardened steel, it has a huge demand in gear-shafts, bearings, machine tools, camshafts, punch, and die manufacturing [5]. Tools that are commonly used in hard turning are cubic boron nitride (CBN), PCBN, ceramics, and carbides. A lot of research work has been done on hard turning suggests that under suitable condition, hard turning can produce components with great dimensional accuracy and better surface finish. In terms of performance, properly configured machine tool can produce a hard-turned part with a surface finish of 0.4 μm, diameter tolerance of ±3–7 μm, and size control of the range of 2–5 μm [6]. Since hard turning is usually performed dry, i.e. without the use of any coolant, it not only reduces the cost of production but also reduces environmental pollution [7]. Also, machining center used in hard turning consumes less electricity when compared with grinding machine, hence reducing the cost of production. In hard turning, chips can easily be recycled, whereas in grinding operation, the sludge produced needs a costly separation process. Material removal rate is 4–6 times higher in hard turning when compared with grinding process, also there is reduction in the machining time to about 60% in this process [8] and especially, if hard turning could be applied to the manufacture of complex parts, manufacturing costs could be reduced by up to 30%, as mentioned by Huang et al. [9]. A qualitative overview is shown in Figure 2.

Cite this article as: Abhishek Anand, Ajay Kumar Behera, Sudhansu Ranjan Das, An overview on economic machining of hardened steels by hard turning and its process variables, Manufacturing Rev. 6, 4 (2019)

1 Department of Mechanical Engineering, Siksha O Anusanhan, Deemed to be University, Bhubaneswar 751030, Odisha, India 2 Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India

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:

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.

Cutting tool geometry plays a very significant role in hard turning process. Parameters like surface finish, tool wear, heat generation (produced by cutting temperature), chip formation, and cutting force are greatly affected by the tool geometry, as demonstrated in Figure 5. The cutting edge and alignment of the tool face are most important geometric parameters for chip formation. Cutting tool materials used for hard turning have extremely high indentation hardness and high thermal stability. However, they are also brittle and prone to fracture. There is generation of high temperature and force for cutting in hard turning. To overcome these problems, cutting tool is provided with negative rake angle, but if this rake angles value is increased, then it gives rise to high compressive stress (Fig. 6) [14].

The primary aim for any manufacture is to produce product of high quality with reduced machining time and cost in order to sustain in this competitive machining industries. Traditional machining operations cover a wide range of processes. Today's hardened high-surface steel parts are becoming increasingly important in many engineering applications because of the increasing challenge along with necessity and use of high precision parts to acquire critical performances and due to their excellent essential qualities (high indentation resistance, high value of hardness-to-modulus of elasticity ratio, and low ductility with high abrasiveness) and in particular, these are truly hard-to-cut materials [1]. Traditional method of machining hardened steels involves an expensive and time-consuming technological chain of operations. In this way, machining operations need to continually adopt newer, more efficient, and cost-effective manufacturing approaches to assess the machining of difficult as well as hard-to-cut materials. In recent past, hard turning has emerged as solution to overcome these problems of traditional machining operations. Hard turning is a machining process to machine material having hardness value greater than 45 HRC which presents embryonic benefits as well as interests in preference to conventional cylindrical grinding; (1) by without losing the product quality in connection with more flexible, less expensive, and more eco-friendly production, and (2) by employing appropriate and very hard futuristic tool materials under critical machining condition. The advantages of hard turning lead to substantial shortening of the traditional technological chain (forming, annealing, rough turning, heat treatment, and finish grinding). In particular, the hard turning process offers greater process flexibility, reduction of manufacturing cycles and production costs, decrease of setup time and energy consumption, achievement of improved surface integrity and productivity, elimination of hazard cutting fluid by environment friendly finish dry cutting has made this a preferred choice over grinding in many applications from economical and ecological point of views [2,3]. Figure 1 illustrates the economic benefits of production process of hardened steel components, when the process is changing from grinding to hard turning.

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.

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.

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.

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.

Speeds and feeds for millinghardened steel

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.

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Tool geometry has significant effect on improvement of finish hard turning. As the nose radius increases, improved surface roughness is achieved. With increase in edge hone radius and chamfer angle, cutting force also increases.

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.

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.

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.

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 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.

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.

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:

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.

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.

Hard turning process is dependent on machine technology, process technology, materials and tooling technology, cutting technology, and work-holding technology. The key change drivers in the case of hard turning are consisting of various machining process variables, shown in Figure 3. In order to replace cylindrical grinding, the following factors should be considered for successful hard turning which are associated with the machining parameters: (1) a machine with a high dynamic stiffness, (2) proper work holding devices, (3) a correctly chosen cutting tools and advanced insert materials, (4) high quality cutting edges, (5) rigid tool mounts, (6) appropriate machining parameters, (7) component part rigidity, and (8) chip management and cooling system.

For a deeper understanding of the economic benefits of hard turning, it helps to consider a few factors that are sometimes overlooked. These process factors are illustrated below.

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.

Hard milling cutters

The overview presented in this paper is a collective work on machining and machinability improvement of hardened steels by hard turning which is being adopted successfully in automotive and mold as well as die making industries. A worthy attention related to hard turning was surveyed in an attempt to find the achievable part quality and techno-economic efficiency of hard turning process in comparison with grinding on the basis of varying machine tool, tool geometry and material, cutting parameters, and cooling methods. After reviewing a long string of literatures, following conclusions were reported. Large dynamic thrust force is generated while machining of hard material. Therefore, the machine tool associated with following attributes like rigid tool, part rigidity, rigid location, high surface speed, etc. should be considered in the machining system which is beneficial for hard turning. In complex hard turning process, large volume of heat is generated due to vibration and exhaustive involvement of heavy mechanical load as well as high temperature on cutting tool, therefore ultra-super hard materials such as ceramic and coated carbide tools are useful for hard turning from technological point-of-view, but in most of the cases, CBN tools are used to machine hardened steel as they have high hardness, coefficient of thermal conductivity, and thermal resistance. Tool geometry has significant effect on improvement of finish hard turning. As the nose radius increases, improved surface roughness is achieved. With increase in edge hone radius and chamfer angle, cutting force also increases. Dry cutting technique is used in hard turning which results the process to be economical and also environment friendly. It can be concluded from the recent studies that use of high-pressure coolant system, cryogenic cooling, and MQL can improve the performance in hard turning operation by enhancing the tool life. When compared with grinding, hard turning is techno-economical because of low setup time, faster cycle time and has a higher material removal rate. To meet the rapidly growing demands not only for increasing productivity, quality, and economy of conventional materials but also for satisfactory machining of exotic materials, environment friendliness, and ultra-precision finishing lot of possibilities are rapidly generated and remarkable improvements and use of novel but simple techniques and technologies are coming up.

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.

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.

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.

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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.

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

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.

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.

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.

Although hard turning technology is effective and competitive than grinding process with respect to cost, time, and environment yet it encounters problems because of uncertainties related to tool wear pattern and tool life prediction. So, there is a need for suitable cutting tool material with low wearing capabilities as high cutting force is generated. There are enormous varieties of cutting tools used for hard turning. Carbide and ceramic tools are also used for hard turning but the main drawback of these tools is their toughness, these tools are not tough as CBN, and cannot withstand high thermal shock. Among the above-mentioned tool materials, most commonly used tool for machining, CBN has a great demand in metalworking industries to machine hardened steel [12], since it is one of the hardest known material and retains its hardness even at high temperature. In comparison to other tools like ceramic or carbide, CBN generally has more wear resistance and shows chemical stability at elevated temperature, and also exhibits properties like high coefficient of thermal conductivity as well as thermal resistance [13]. However, the difficulty associated with compact CBN processing (high temperature and high pressure) and the high cost of CBN tools have shifted the challenges for hard turning from technological feasibility to economical viability. On the other hand, properties such as low thermal conductivity and low toughness make it unsuitable as tool materials in hard turning of interrupted surfaces. PCBN is obtained either by sintering individual CBN crystals together or bonding with binder materials to form a large mass CBN with a metallic-type binder having excellent abrasion resistance, high thermal conductivity, and higher toughness. PCBN has crystals, which are either sintered with a binder phase usually metallic and ceramic or integrally bonded to a tungsten-carbide substrate. A wide range of grades of PCBN tool can be made by varying the percentage of binder phase and CBN crystal during sintering.

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.

Hardened steel is generally machined dry condition in turning operation [29]. Dry cutting produces smoother surface finish as the heat produced in the cutting zone can make shearing easy by reducing the shear strength of the workpiece [30]. Heat degrades the metallurgical properties of a steel workpiece surface. In hard turning, the largest proportion of heat is evacuated into the chips. A well-controlled hard-turning operation will rarely cause thermal damage to the part surface. There are two major types of surface damage that can be caused by hard turning are white layer formation and tensile residual stress distribution. Also, the absence of lubricants and fluids reduce cost of machining and also protect labor and environment. However, due to the tool and workpiece friction in hard turning, heat is generated in the cutting zone that can cause effect life of tool, and also increases the thermal damage of the work piece. Reduced tool life can add to the cost of production. Cutting fluid reduces the cutting force, hence reducing the energy consumption and also helps to cool the cutting area and hence increases tool life. Currently, application of cutting fluids by different cooling and lubricating methods have made tremendous effort to improve the efficacy as well as cutting performance of hard turning process, as in Figure 7. However, the application of cutting fluid is restricted because it adversely affects the environment. The problem of cutting fluid can be reduced by using solid lubricants in machining, cryogenic cooling by liquid nitrogen and minimum quantity lubrication (MQL). The solid lubricant, molybdenum di-sulfite (MoS2) assisted hard turning, reduces surface roughness and also reduces cutting force as compared dry hard turning condition, but does not greatly affect tool life and wear [31]. Another experiment with minimal fluid application in presence of grease and 10% graphite resulted in improved cutting performance when compared to dry turning and turning with minimal fluid application [24]. In a study with synthetic oil having 6% of concentration in water, it was found that cutting in dry environment requires less power and gives better surface finish compared to wet cutting [32]. In an experiment, MQL with vegetable oil, it was concluded that machining with MQL produces improved result than in dry machining as the wear of tool is reduced and also improves tool life [33]. In comparison to MQL assisted hard turning, it was found that there was 23.52% reduction in cutting temperature in minimal cutting fluid application (MCFA). Also, it is more environment friendly. Machining can also be performed by replacing conventional fluids with cryogenics such as liquid nitrogen or solid carbon dioxide. Hard turning with cryogenics (i.e. cryogenic machining) helps to remove heat during cutting at a faster rate, which helps to increase tool life and also improves the surface finish [34]. Cryogenic cooling can be performed in three ways. One way is by cryogenic pre-cooling of the work piece, where work piece is cooled before machining. In second way, cooling is performed without the direct contact of cryogenic on workpiece or tool. The third way is by cryogenic spraying at the cutting zone to remove generated heat.

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:

Hard turning differs from other conventional machining as it involves the machining of hard material having hardness greater than 45 HRC. A high surface speed of 250 mm/min or even more than that can be achieved in this turning process, so there is a need of proper machine tool rigidity, high surface speed along with constant surface speed for profile to be finished [11]. The surface finish, size control, and tool life are hugely affected by the dynamic stiffness of machine tool. So any improvement in dynamic stiffness of machine tool will lead to; (a) less operating vibration, (b) considerably improved tool life, (c) considerably improved part quality, (d) higher through-put, and (e) minimum machining parameter adjustments [8]. Large dynamic thrust force is generated while machining of hard material. Poor, stiffness, and damping characteristics of the machine setup lead to the vibration in the machine tool, which affect the accuracy and surface finish of the machined parts. Vibration in machine tool is also the cause of tool failure due to edge fracture. Therefore, not all conventional machine setup and turning centers are suited for hard turning applications. For this, various machine tool attributes should be considered in the machining system for the production of critically hard finished steel component, which are illustrated in Figure 4. Type of structure material greatly influences material removal rate of machine tool, accuracy, and total cost. Common materials used for machine tool are cast iron and steel, although granite and epoxy concrete have been developed and used for structures.

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.

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.

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.

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.

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.

Turninghardened steel

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.

Hard milling techniques

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.

Dry cutting technique is used in hard turning which results the process to be economical and also environment friendly. It can be concluded from the recent studies that use of high-pressure coolant system, cryogenic cooling, and MQL can improve the performance in hard turning operation by enhancing the tool life.

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.

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.

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.

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).

Best inserts for turninghardened steel

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.

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.

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.

When compared with grinding, hard turning is techno-economical because of low setup time, faster cycle time and has a higher material removal rate.

Data correspond to usage on the plateform after 2015. The current usage metrics is available 48-96 hours after online publication and is updated daily on week days.

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.

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.

Milling cutters forhardened steel

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.

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.

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.

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.

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.

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.

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.

Producers of machined components and manufactured goods are continually challenged to reduce cost, improve quality, and minimize setup times in order to remain competitive. Frequently the answer is found with new technology solutions. In the recent years, there has been increasing interest in hard turning over grinding for machining of hardened steels in automotive, bearing, mold-die making industries. Hard turning is greatly affected by factors like machine tool, cutting tool geometry and materials, cutting parameters, and cooling methods. There are some issues in the process which should be understood and dealt with such as friction and heat generation at the cutting area that can affect the tool life and surface finish apart from other machining results to achieve successful performance. Researchers have worked upon several aspects related to hard turning and came up with their own recommendations to overcome these problems. This article presents an overview on all the factors that influences hard turning operations performance and is an attempt to give a proper understanding of the process. A summary of the hard turning techniques is outlined and further a comparison of hard turning and grinding is discussed with regard to certain evaluation criteria based on process economical efficiency.

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.

Apart from further influencing criteria, the material removal rate is a most important economical aspect to evaluate the productivity of a cutting process. For finishing operations, additionally the generated surfaces are of high importance. In finish grinding, high values of material removal rate more than 20 mm3/mms can be reached, in finish hard turning, feasible process removal rates are able to achieve values exceeding 200 mm3/mms. Compared to the material removal rate, the surface rate gains particular importance in the case of machining smaller workpiece diameters with lower over measures and smaller cutting depth. As a typical example, the efficiency of centerlines grinding of roller bearings can hardly be achieved in turning. However, the productivity effect of the turning process in appropriate cases is due to the high form flexibility. Different surfaces and shapes can be machined with one tool. Furthermore, in most cases only one machine tool is needed for outer and inner diameter machining. Because of these advantages, in many applications the machining time can be shortened significantly by hard turning. However, the final determination of machining times and costs can only be made according to a specific production task.

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.