Industries with Composite Material COMPOSITE SOLUTION

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Violet Davis
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1 SOLUTIONS FOR INDUSTRIES Industries with Composite Material COMPOSITE SOLUTION OSG Delamination

2 Market Trend for Aerospace and Automotive Applications Materials used in aerospace applications have been changing dramatically in recent years. Among composite materials, CFRP is becoming especially important. It is lighter, stronger, and more environmentally friendly. Avantages of CFRP Carbon Composite makes aircrafts Lighter for better fuel effi ency 2. Stronger for safer travel 3. Fly farther with reduced weight 4. More eco-friendly with less machining Avantages of CFRP Carbon Composite makes automobiles Lighter for better fuel effi ency 2. Stronger for safer conduit 3. Increase autonomy due to reduced weight 4. More eco-friendly with less machining

Obstacles in Machining Composite Materials (CFRP) Machining

delamination. CFRP is difficult to machine, because... 1.

is abrasive in nature and forces tools to wear quickly.

is easily infl uenced by the geometrie. 4.

3 Obstacles in Machining Composite Materials (CFRP) Machining CFRP has its own difficulties including rapid tool wear and delamination. CFRP is difficult to machine, because Carbon Fiber is hard The tools wear out easy due to high heat generation by Carbon Fiber. 2. Chips including Carbon Fiber are very abrasive Carbon Fiber is abrasive in nature and forces tools to wear quickly. Carbon Fiber chips also damage the inner-surface of holes if not evacuated quickly. 3. Carbon Fiber is thin in CFRP Carbon Fiber layer is thin and is easily infl uenced by the geometrie. 4. Matrix (resin in between layers of Carbon) is soft The use of matrix creates soft-hard-soft formations. This is conducive for de-laminations to occur.

4 OSG'S Solution in Machining Composite Material For many years, OSG has been committed to producing cutting tools for aerospace, in Japan as well as in the USA, Canada, Brazil and Europe. We started engaging in newly developed materials such as CRFP and β-ti since All tools are designed to meet the range of requirements and applications and tested to ensure their superior performance. In order to minimize de-lamination, roll-over, fiber breat-out, hole expansion, and burnt material, OSG'S tools come equiped with the blend of below feature. - Proven edge angle to yield low cutting force - Carefully selected tool material to be highly wear resistant - Special flute geometry to create smooth chip evacuation Troubles working with conventional tools Rolled over De-lamination De-lamination of un-cut fiber De-lamination for exit side Conventional Top view Side view

5 OSG's Tool Performance The best benefit for the customer is the tool that produces quality holes and that has long tool life. This is what OSG Tool can offer as the best customer benefit. OSG Top view Side view

6 Milling Solutions for CFRP Herringbone Cutter Our new end mill series for CFRP incorporates a herringbone fl ute design which diverts cutting forces inwards eliminating delamination. In addition our patented diamond coating with it s fi ner grain structure allows for a sharper cutting edge which in turn helps prolong tool life and produce a superb surface fi nish. OSG Special geometry diverts cutting forces inwards eliminating delamination OSG'S Various Tools for Composite Materials Diamond-coated Router Designed primarily for trimming of CFRP, we offer a variety of router styles to accommodate our customers needs including a multi-fl ute type with nicks for high effi ciency, Herringbone fl ute type for reducing cutting resistance, a surface finish nish-focused type, and more. Herringbone Cutter High effi ciency type: Coarse-cross-nick router High effi cient type: Fine-cross-nick router Cross-fl ute router The sharp edges perform slot milling in CFRP without delamination of the side and top surfaces. Finishing router In CFRP honeycomb material, there are no tiny burrs on the top and bottom surfaces nor peeling off or fraying of the core material. Note: see page xxxx for details on OSG's innovating end mills.

Specialty Aircraft Tools: Solid Micrograin Carbide Nutplate Drill/Countersink Carbide

External thread and 60 degree cone seat straight shank style with pin spanner wrench

Type 56 Threaded Square Shank Adapter Drill Carbide step adapter drills are manufactured

Used for drilling hard, tough, high tensile strength materials in confi ned areas.

without delamination around the hole or fraying the composite material.

PATENTED Ultra Fine Crystal Diamond Coating OSG s new patented diamond coating is made

7 Specialty Aircraft Tools: Solid Micrograin Carbide Nutplate Drill/Countersink Carbide drill and countersink with 135 degree split point. External thread and 60 degree cone seat straight shank style with pin spanner wrench holes. Application: Nutplate and motors with nutplate pressure foot attachments. Type 56 Threaded Square Shank Adapter Drill Carbide step adapter drills are manufactured similar to NAS 907 construction with 135 degree split points. Used for drilling hard, tough, high tensile strength materials in confi ned areas. Dagger Drill This carbide drill is designed to produce holes in composite materials without delamination around the hole or fraying the composite material. Even the Ultra Fine Crystal Diamond Coating can be removed and recoated. PATENTED Ultra Fine Crystal Diamond Coating OSG s new patented diamond coating is made from ultra fi ne diamond crystals in an innovative new process. It will give a better surface fi nish and performance and is only available from OSG. Ultra Fine Crystal Diamond Coating Competitor's Diamond Coating

8 Diamond Coated Carbide Drill For outlets and inlets: triple-angle drill PAT.P. Two types of drills are available. One is a drill designed for eliminating delamination around the outlet of the hole (PAT.P.) (lower photo). The other type is for eliminating delamination around both the inlet and outlet of the hole (PAT.P.) (upper photo). On both types, the new fl ute form reduces and disperses cutting force and produces holes of exceptional quality. For outlets: high helix, double-angle drill PAT.P. A good quality hole A poor quality hole, drilled by a competitor The diamond coating and sharp cutting edges prevent delamination. Delamination is present around the drilled hole. OSG'G G Unique Regrinding Services Diamond Coated Tools are diffi cult to regrind. Diamond, regardless of its form, is the hardest material on this planet. A tool cannot be correctly regrinded and recoated without taking off the Diamond Coating. OSG is the only tool maker in the world that does exactly that: t: take off the Diamond Coating. After the tool is uncoated and given its desired form OSG will l recoat it with Diamond Coating again. Please inquire your nearest OSG technician for more details.

9 OSG'S Experience with Machining Composite Material Performance of OSG Trimmer Overall cutting length (m) Cutting Dia: 9,525 mm (3/8 ) Cutting speed: 96 m/min, Feed rate: 348 mm/min, Coolant : none (dry) CFRP Trimming with OSG Nacelle CFRP + Ti Stack Before OSG S Service Drilling process took 150min with 7 different drills and a reamer With OSG S Service Drilling process took 50min with 3 different drills and a reamer With OSG s service, the customer not only resolved his bottleneck, but also helped reduce defective holes.

10 OSG'S Patented Diamond Coating Comp B: Diamond Coated Tool Bigger crystals give a dull cutting edge OSG s Diamond Coating Cutting Edge with Perfection! Cutting Force Comparison CFRP Thickness 11 mm Drill Dia. 14,5 mm V=125m/min, f=0,1 mm/rev, Water

11 Milling Solutions for CFRP Tool Dia ø 9,525mm (3/8") Work Material CFRP Milling Method Side Milling Milling Speed 96 m/min (3.200 min -1 ) Milling Length (m) Feed Coolant Machine Tool Life 348 mm/mln (0,1 mm/rev) Dry Vertical Machining Center Resin Welding OSG Diamond Coated Herringbone Cutter Competitor Drilling Solutions for CFRP High Helix, Double-angle Drill The drilling of composite materials is becoming more common. Our CFRP drills combination of sharpness, lowresistance design, and outstanding diamond coating offers maximum performance. Customer Data Number of holes (holes) OSG Diamond Coated Drill Average 303 Holes OSG Tool Dia ø 6,375mm (0,2510") Competitor Competitor A PCD Drill Average 184 Holes Work Material CFRP Drilling Speed 60 m/min (3.000 min -1 ) Competitor B PCD Drill Average 140 Holes Feed Depth of Hole 17 mm/mln (0,076 mm/rev) 5,7mm Depth Three-layer Stack (Through) Competitor C Diamond Coated Drill Average 26 Holes Coolant Dry Machine Tool Life Special Machine for Drilling Delamination

230508 Fax + 32.10.230531 E-mail: info@osgeurope.

com TOOL COMMUNICATION Tool specifications subject

com OSG EUROPE s.a. All rights reserved.

EURCOMPOSITE08R11 The contents of this catalogue

They are not intended for reproduction either in

They cannot be copied, used to create derivation

express, written permission of the copyright owner.

12 Our contacts in Europe Av. Lavoisier 1 B-1300 Wavre Nord Belgium Tel Fax info@osgeurope.com TOOL COMMUNICATION Tool specifications subject to change without notice OSG Europe: OSG EUROPE s.a. All rights reserved. OSG Europe EURCOMPOSITE08R11 The contents of this catalogue are provided to you for viewing only. They are not intended for reproduction either in part or in whole in this or other medium. They cannot be copied, used to create derivation work or used for any reason, by means without the express, written permission of the copyright owner. If prices are stated, they are netto unit-prices and any eventual tax(es) have to be added. The company is not responsable for any printing error in technical, price and/or any other data.

Diamond-coated Router

Diamond-coated Router Designed primarily for trimming of CFRP, we offer a variety of router styles to accommodate our customers needs including a multi-flute type with nicks for high efficiency, Herringbone