CoroMill Plura Routers optimized for composites Delamination, fiber pullout, uncut fibers, and rapid flank wear are constant machining challenges caused by the abrasive and inconsistent nature of composite materials. CoroMill Plura routers with special coatings and advanced helix patterns are designed to provide long tool life, drive down component cycle times, and reduce costs while offering high quality results.
Challenge: Composite machining Whether machining carbon, glass, or aramid fibers, we understand the complex machining processes you face when working with composites. Compared to metals, composites break less predictably due to the greater number of variables that dictate how the composite will respond. Variables include fiber type, resin type, composite thickness, matrix hardness, heat sensitivity, fiber orientation at the point of contact, and composite construction. Common challenges with composites and carbon fiber reinforced plastics include: Splintering Delamination Poor surface finish High temperatures Material vibration Rapid tool wear
Solution: CoroMill Plura routers CoroMill Plura routers have specific geometries and coating varieties designed to run at faster feeds and speeds. In addition, these tools help reduce cycle times with fewer finishing passes while providing wear and heat resistance to ensure smooth finishes and high quality edges. Made to ensure predictable wear, the routers allow for the secure replacement of tools before failure, maximizing cutter life and reducing overall cost. CoroMill Plura compression router (2P460-OA) This dual helix router works best with special woven glass layers on both sides of the component. With an overlap between compressed flutes, it machines well in thinner materials by reducing material vibrations. The optimized flute design works best in flat components when you cannot oscillate the tool. CoroMill Plura serrated router (2P350-OA) The large flute form allows for high material removal, and the patented geometry has dual cutting action to reduce delamination and vibration. The geometry is designed for a one pass solution. CoroMill Plura low helix routers (2P050-OA and 2P051-OA) Specifically designed for smooth and burr-free finishing passes, these cutters have a lot of teeth and are made to go fast. The right and left helix options allow for flexibility in material with challenging support conditions. 3
CoroMill Plura compression router (2P460-OA) This dual helix router works best with special woven glass layers on both sides of the component. The overlap between compressed flutes enables it to machine well in thinner materials by reducing material vibrations. The optimized flute design works best in flat components when the tool cannot be oscillated. Cutting conditions can be both dry or with coolant and when geometry is a dual 40 degree helix angle. Application area Unsupported Vacuum fixture Clamp fixture Component type Aerospace Wings Stabilizers Stringer Floor beams 4 For assortment information, see page 8.
CoroMill Plura serrated router (2P350-OA) The large flute form allows for high material removal. The patented geometry has dual cutting action to reduce delamination and vibrations, and is designed for a one pass solution. Cutting conditions can be both dry or with coolant and when the geometry is a 40 degree helix angle. Application area Mandrel Unsupported Vacuum fixture Clamp fixture Component type Aerospace Wings Stabilizers Fuselage Stringer Floor beams Pressure decks Sub structure Ribs Automotive Exterior and interior panels Frame 5 For assortment information, see page 8.
CoroMill Plura low helix routers (2P050-OA and 2P051-OA) Specifically designed for smooth and burr-free finishing passes, these cutters have a lot of teeth and are made to go fast. The right and left helix options allow for flexibility in material with challenging support conditions. Cutting conditions can be both dry or with coolant and when geometry is a 5 degree helix angle. Application area Mandrel Unsupported Vacuum fixture Clamp fixture Component type Aerospace Wings Stabilizers Fuselage Stringer 6 For assortment information, see page 8.
Performance An aerospace customer was struggling with low productivity. To determine the best solution, a test between the CoroMill Plura serrated router (2P350) and three other competitor routers was performed. The customer s goal was to increase productivity by 15% while machining the part with only one cutting tool, removing the need to perform a tool change. With its patented geometry and unique chemical vapor deposition (CVD) diamond coating, the CoroMill Plura serrated router emerged as the clear winner, surpassing the customer s expectations. During the test, the CoroMill Plura proved its long tool life and process security by remaining well below the limitations. Surface roughness comparison Customer case Industry segment Aerospace Operation Continuous cut Time in cut (min/component) 10 Component Wing skin Workpiece material CFRP Emulsion Wet (external flood) Ra (μm) 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 Cutting data V c m/min (ft/min) 125 (410) f n mm/r (inch/rev) 0.15 (0.006) a p mm (inch) 8.0 (.315) a e mm (inch) 9.5 (.375) 1.0 0.0 2 m 4 m 6 m 8 m 10 m 12 m 14 m 16 m 18 m 20 m Competitor 1 Competitor 2 Competitor 3 CoroMill Plura 2P350 Ra max. 200% increase in tool life Surface finish and delamination are the criteria used when determining the quality of a machined part. Using a profilometer to measure the surface finish of the component clearly shows that the CoroMill Plura serrated router greatly outperformed competitor tools. Measurements for the test were taken perpendicular to the edge. The pictures below illustrate how the CoroMill Plura router creates a clean edge with no delamination or hanging fibers. Uncut fibers Clean cut edge
Product range DC (mm) DCON (mm) LU (mm) LFC (mm) OAL (mm) Geometry Supplement 17.1 chapter 4 4 12 15.5 40 2P050 and 2P051 D 6 6 18 23.9 60 2P050, 2P051, 2P350, and 2P460 D 6.35 6.35 19.1 25.3 63.5 2P050, 2P051, 2P350, and 2P460 D 7.94 7.94 19.1 26.7 63.5 2P050, 2P051, 2P350, and 2P460 D 8 8 20 28.2 70 2P050, 2P051, 2P350, and 2P460 D 9.53 9.53 28.5 35.8 76.2 2P050, 2P051, 2P350, and 2P460 D 10 10 30 37.5 80 2P050, 2P051, 2P350, and 2P460 D 12 12 31.8 40.6 82.5 2P050, 2P051, 2P350, and 2P460 D 12.7 12.7 31.8 41.9 82.5 2P050, 2P051, 2P350, and 2P460 D 15.9 15.9 38.1 53.1 101.6 2P460 D 16 16 38 53.3 100 2P460 D For more information and the complete CoroMill Plura range, visit: www.sandvik.coromant.com/en-gb/products/coromill_plura/ For complete details on the composite machining offer, visit: www.sandvik.coromant.com/en-gb/products/composite-solutions/ Head office: Sandvik Coromant 1702 Nevins Rd, Fair Lawn, NJ www.sandvik.coromant.com E-mail: us.coromant@sandvik.com Sandvik Coromant 2017