Machining Carbon-Filled Plastics
Carbon fiber reinforced plastics or polymers (CFRP) feature low density, high strength and stiffness, good toughness, and good resistance to creep, fatigue, wear, and corrosion. They have a low friction coefficient and can meet most dimensional tolerances, surface quality specifications, and other requirements. These characteristics make carbon-filled composites popular in many industries, but they are particularly suited to aerospace applications. Yet, for all these advantages, machining carbon fiber reinforced polymers can be expensive and challenging due to several factors.
Challenges to Machining Carbon Fiber Reinforced Polymers
Similar to glass-filled plastics, carbon fiber reinforced composite machining is no easy task. However, by ensuring you have the correct machine setup, taking the time to contain dust, and understanding the characteristics of CFRPs, you can successfully manufacture precision components with complex geometries.
Before beginning any carbon-filled plastic machining process, we recommend consulting an experienced machinist to avoid costly mistakes or unwanted outcomes.
Ensuring Your Machine Can Handle the Abrasive Nature of Carbon-Filled Plastics
Carbon fiber reinforced polymers are hard on CNC machines and tools due to their abrasive nature. Whether milling, turning, or using a multi-axis CNC machine to cut your carbon reinforced plastic parts, always be sure that you are utilizing the best equipment and processes to produce high-performing final products.
- Proper Cutting Tools & Tool Holders. CFRPs require specialty tools such as turning tools with polycrystalline diamond tips or indexable milling cutters. These tools are often more expensive than general equipment.
- Well-Maintained Tools. Sharp tools can help reduce splintering, delamination, and other flaws or mistakes while machining carbon reinforced plastics.
- Meet Necessary Parameters. Cutting speed, feed, power requirements, material removal rate, and the size and condition of your CNC machine must meet the specifications of your selected carbon-filled plastic.
If your equipment cannot meet these requirements, the best and most cost-effective option is to partner with an experienced machine shop already outfitted for machining carbon reinforced polymers.
Managing Dust Produced During CFRP Machining
Machining carbon-filled plastics produces a large amount of harmful dust. This dust can negatively impact the performance level of your final parts. For instance, dust contaminating an electronic device will severely compromise the device’s capabilities and can cause short circuits or other critical failures. Always conduct CFRP machining in a well-ventilated area and ensure that your employees are outfitted with personal protective equipment. To keep particulates and airborne CFRP dust from impacting your final machined part, seal the machine tool enclosure whenever possible and consider installing a suitable dust collector to your system.
Handling Disparate Material Requirements Within Carbon-Filled Composites
CFRPs are produced from carbon fibers and thermoplastics or thermosets to create a final product with a high strength-to-weight ratio. Due to the varying requirements of these combined materials, they are also susceptible to internal stress, oxidation, degradation from excessive heat, and delamination at cut or drilled edges. A coolant might be applied with other materials, but coolants can cause shrinkage and cracks to develop in carbon-filled polymers as time goes on. For CFRP materials, utilizing an annealing process can reduce the risk of cracking, wear, or other performance degradations.
Choose an Experienced Shop for Machining Carbon Fiber Reinforced Plastics
The best way to mitigate the challenges in machining carbon reinforced composites is to partner with an experienced machine shop like Upland Fab. We specialize in machining high-quality and reliable industrial parts made from precision plastics and composite materials, working closely with your team to ensure all specifications are met. We machine an extensive range of CFRPs in-house at our California facility, including:
- PEEK
- Torlon®
- Teflon® (PTFE)
- Vespel®
- Ultem®
- PPS
- And more.
