cutting carbon composite laminate

[juzwuz]

Hi! I have two carbon composite laminate plates that I need to cut out some parts for an rc airplane. One plate has some foam sandwiched between the carbon fiber sheets and the other plate has balsa. They both use 5.7oz carbon fabric with mgs epoxy resin from aircraftspruce on both sides. The foam sandwich plate is about 1/8th inch thick and the balsa one is around 1/4th inch. I was planning on just using a 2flt carbide endmill 0.062 diameter from:

http://www.bitsbits.net/index.php?ma...b875f5f5228fd9

Will this work? Do you have any suggestions for spindle speed and feedrate? I was also thinking of maybe using a smaller diameter 0.032 diameter bit. I think from what I've been reading, I would want a high spindle speed (16krpm) and low feed rate (20 ipm). Does that sound OK? What about depth of cut? I'm a little worried about the foam layer melting on the bit.

I think I only need a few parts cut out so maybe a diamond coated bit isn't cost effective. Where do people buy diamond coated (CVD, PVD) bits?

Thanks!

[svenakela]

Scroll down or serach in this forum and you will get the answers. Cutting composites is debated in several threads.

[jetski]

I deal with a guy that does waterjet work. I used to know a guy 10 years ago that built his own water jet for cutting out prototype RC planes at Midwest in Hobart. He used a flat bed plotter and a Ford power stearing pump (2000 psi) and water only. Cut out ply wood and balsa accurate and like butter no sanding to fit (once you have the beam comp right. A water jet will cut what you need fast. I am a tooling engineer and am having 1-3/8 thick P-20 steel pocket 8" x 11" cut in about 15-20 min. About $75.00 per pocket. The stuff you are cutting it should fly through and leave a clean cut. Check around your area. Give them a dxf file to quote off of. Hope this helps.