Machining Composites Using PCD Diamond Tooling | BVM 5700 CNC Mill | DN Solutions
ฝัง
- เผยแพร่เมื่อ 17 พ.ย. 2024
- Using the Kennametal PCD PolyCrystalline Diamond coated tools, Barry Setzer shows how the right tools can increase productivity and potentially lower costs when machining glass-filled composites like G10.
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#CNC #Machining #Machinist
![เปิด อาณาจักร หมื่นล้าน "สาระตั้ม" l [Nickynachat]](http://i.ytimg.com/vi/3XE0nPF4YkQ/mqdefault.jpg)
22 min 17 sec
Lol
Off by literally under 5 seconds 😂
Nice job!
Damn I just programmed a similar part and stole my paths and times. Crazy!! Also those are imperial minutes, just to clarify.
@@TITANSofCNC I belive the saying is "we'll pin ya"
As a computer engineer now machinist thank you for saying PC Board instead of PCB Board!
But think about all those PCB Boards that are inside those ATM Machines
🙃🙃
same like LCD Display :P
I bet PIN number makes you have convulsions.
I will stop saying that now ASAP as possible
ATM machine
I'm building some tooling from G10 right now, searched high and low for this video last week lol. Thanks for putting it out there!
The multi flute endmill would likely be CVD, not PCD as the diamond is coated onto the carbide blank using Chemical Vapour Deposition. PCD is a layer of grown crystals. And normally brazed onto the cutting tool. Once the CVD diamond layer is consumed, tool wear occurs rapidly. Normally seen by a 'shine' on the cutting edge which is polished carbide. PCD tooling costs $$$ but can actually be reground and used multiple times using EDG (Electrical discharge grinding) and is perfect for production composite machining.
I see that shine all the time while making graphite electrodes... I can't get away from it. And the cutters bought specifically for graphite lasted even less time than the cutters for hard steels...
That drill was diamond coated as you say, but they also have a PCD version with the same geometry (a PCD yip brazed into the center of the drill, again as you said).
Chemical vapor deposition would also generate a polycrystalline diamond film
@@alejandromorcillo9896 yes. CVD is the process that would be used to coat a carbide tool. PCD generally refers to a diamond tip that is brazed in to the round tool. When you say "PCD" and "diamond coated" you're talking about tools with different features and functionality.
6min & 56sec diamonds & rust
KEEP them coming Barry!!BOOM!!
Love hearing knKut name out there they make great bits.
I've used PCD for years cutting epoxy composites. A two flute 1/4"dia.x 7/8"loc, cost us well over $300 four years ago. We still use it in production. It still holds a thousandths tolerance.
Awesome display of tools Barry! Some sick looking cutters! Great info on how to use them as well!
We use PCD endmill and reamers for aluminium hpdc. It's great solution in regard to tool cost per part, tool life, surface quality and proces stability. Olso we can run tool with almost max spinde rpm so cycle time is reduced.
Spindle speed can be a limiting factor that keeps some machines in carbide tools instead of PCD. Why spend the money if you can't run at optimal speeds?
Just finished a bunch of G10 parts for the NGVLA radio telescope receiver!
So Barry, by saying “today we’re gonna pull a Trevor” does that mean today you’re going to make us a nice part? Haha love the video man, I learned a lot!
Great video, it took 15 minutes to machine part without toolchanges and probing.
G10 makes a wonderful print bed for 3d printing applications. Markforged is using g10 on the MARK II. An UNheated bed which has no adhesion problems while printing their ONXY matetial which is a nylon mixed with chopped carbon fiber. Pretty crazy that it sticks. I bed more 3d printers start to use it in the future
I thought that material looked familiar
First time seeing such a cool CNC machine, the moment it uses the arm to swap the tool is epic 😂
Greetings from Germany
Awesome video Barry! Thank you for expanding our knowledge base for more unique applications!
15:30 looks great
we machine about 1200 molded fiberglass parts a day . no coolant allowed due to contamination. we use downcut carbide endmills followed by furnace brazed diamond tools to clean the cut. dust collection is mandatory. final bits of sanding by hand . all in 1 minute / part
12:30 minutes I would guess.
And yes when processing GF or CF based materials make sure you can justify using PCD tooling asap. With carbide you're constantly chasing tolerance because of toolwear. In the beginning I put in new tooling for every job which was included in the job quote.
You can get relatively high SFM with the pcd, but the feeds are limited.
Part like this can be done in about 13 minutes
man, if i was given such a material, i wouldnt even know how to machine it even if i was given all the nessecary tools
You know, now!!😂
It's a beast to machine, tooling is expensive. I've done half inch material in my small shop in my garage, not fun but doable.
working on bikes in free time. and sometimes you have to saw or file some carbon fibre tubes and stuff. used HSS tool, took so long. diamond tools just demolish the material. but yes doing it wet now too since the dust is horrible. you have to clean a lot and be carefull
Nice video brother! Just goes to show you that tool selection can make or break your day!
Good Morning Brother🤙
Good morning to you brother 🤙🏼
I've seen people say anything from 48 mins right the way down the 2 min 30 sec.... I really would have hoped for a tighter range out of you guys than that...
But seriously, my guess is going to be 12 minutes +/- 30 seconds👍
About with out setup time around 3 to 4 minutes ish
Just thought if you have a multi part setup you can drop that to 2:30 to 3:30 mins,
your have a jig setup on one side of the table for opp 1 and a jig setup for opp 2. That way evey time you run a cycle your take a completed part of the mill, if you set the jigs up to hold more you get more. In the end your compleat the order faster and save time. Same with setup time.
@@elanjacobs1 ty for the correction 👍
So my Business is defently more the lahte. But i will guess its about 9,15 minutes to finish this Part.
And by the way "nice work Barry"
Salutation from Switzerland 🤟
I'm guessing maybe around 20 minutes. It'll take some time to just cut the surface with the first tool. The the bore to allow for the probe. Then the probe itself has to run all sides and the center. Then the rest of the tooling. I'd say about 20 maybe 23 min
Normally when I cut g10 I use a 3 flute carbine em. Spin it like I'm in mild steel but feed like I'm in aluminum. Last time I made all the required parts and only used one of each tool required for the job.
Done a bunch of g10. Pcd is the only way to go
Have you ever got internal delam due to incorrect feeds and speeds? Say like diamond chamfers or saws cutting composites. Thanks for your videos.
13min 45sec. That’s for op 1&2. Nice looking part.
9m30s cycle time for both operations… never worked with the material and I’m a spinner, so that’s just a wild guess based on watching the video 😅
Love that video man wish to be like you one day 🔥🔥
And I think it's take about 8:30 minutes 🤔
What happens to the sludge mix of coolant and fibreglass? Can you reuse it for the next machining job or do to have to throw it away? How do dispose of it?
Filter and throw away the solids
do you have recommendations for coolant filtration setups? I've seen ones that recycle it through a filter, then press, bake dry and roll off into a disposal bin. Are there other kinds?
industry standard for GFRP/CFRP seems to be to use dust collection, but that seems to be an impossible feat to do properly. we're talking extremely fine particles.
secondarily, materials like G10 are often used in electrical insulation applications. is there a recommendation for a kind of coolant that will not contaminate the material with respects to dielectric properties?
Hmm, I feel like I see a little bit of fiber chip out on the back side of those chamfered holes... Glossed over a bit maybe. Carbon is a challenge. At my company, we do it day in and day out though. I'd like to see you guys tacking SiC CMC composites and see what you can do there. We seem to be able to rough it well enough with diamond tools, but because of microfracturing that can extend below the machined surface, we finish everything with diamond grinding tools. It's slow and expensive.
Here idea for a challange to program. Make a part, but the rouging makes a song (different kinds of cutting parameter makes higher or lower notes)
16 minutes and that’s after waking up after a nap.
Do you have a carbon/glass pack on that machine and a coolant paper filtration system for the tank and the pumps?
I didn't have much experience but i guess its take one hour approx for 1st and 2nd operations
11mins total ❤
can you still use the coolant when machining other materials or will it be set aside for this composite stuff ?
Genuine question, do people really have time to switch out coolants for different materials like that? Our shop barely let's you stop to clean the filters out 😬
That abrasive slurry has got to be GREATLY filtered otherwise it'll wear the machine ways, etc.
No way they just trashed all the coolant.
@@thatdrillguy7889 sure they didnt TRASh it ,but it could be set a side and used on composites only. or its some cheap stuff ,that works well for this ? the fluid was vey clear so it must heavily diluted ?
@@fijs653 Blaser coolant from Switzerland is clear. Smells good and easy on skin.
Great Sir 👍
Super cool! What is the lifespan of the PCD tools?
About 50 times longer than Carbide, PCD is mainly used for extremely abrasive non-ferrous materials. I manufacture custom and standard PCD End Mills and drills
I’m looking for advice on profiling .1 width X 2.6 height Delrin. Ramp it depth cut multi pass? Any and all advise is more than welcome. Thanks team.
Barry did you just Drill in the jaws ? 😏😎 28min for the part
Hahaha i predrilled holes in the jaws oversized
@@barrysetzer 😄 nice one
time: 20minutes
"Diamonds on my neck
Di-Diamonds on my drill!"
3.17 Min. Start to Finish😁
Whats the little orange thing on the way cover?
Hey Barry
What up Ty!
Just as a matter of interest can you tell me if any machine maker incorporates a window and inside cabinet spray to clean the swarf off windows and walls at end of cycle?
Why for OP2 did the roughing endmill come out twice? Wouldn't it be faster to have it do everything and then change tools?
I believe a close up of 24 minutes!!
I would estimate we would have that part done in 1/2 to 1/3 the posted time depending on the glass content of the material (G10 can vary alot).
As someone who deals almost exclusively with these types of materials… there’s some things that are done right and also some red flags.
Educate me more. Please 🙏
Have you guys ever machined metal matric composites?
Hazards
G-10 is generally safe to handle outside of extreme conditions.
Hazards can result from cutting or grinding the material, as glass and epoxy dust are well known to contribute to respiratory disorders and increase the risk of developing lung cancer. For any work of this kind, the work space should be appropriately ventilated and masks or respirators must be worn.
wet like 'the steam'(mens sauna) inside the box.
I guess I wouldn't have drilled those flange holes last, in order to minimize the exiting problem.
But it was a good demo to show that there is a drill that can eliminate exit burring when necessary.
I actually had the same thought as you
4h Considering the inspections etc.
im guessing about 48 min, also in my line of work we cannot use coolant on any part that has to be bonded inside the aircraft. I assume that's not the case for this particular part.
Likely just a demo part that doesn't have those constraints I'd guess.
Why can't you use coolant? Does it mess with the integrity of the material where the coolant touches?
Can you design some sort of mini waterproof motorised wipers for your gopro cameras? 😅
😂 stay tuned
What are you running like 3% coolant concentrate? That looks like straight water. Hopefully RO water.
23 minute cycle time.
So close 😊
Okuma repair guy not long ago told me I was gonna trash my machine because you can't run straight water in a cnc..... I laughed real hard and asked if he's ever seen a synthetic coolant before. I run 6% and its clear as water.
Sir
Can you suggest the end mill for the o ring groove milling on vmc with 3-4 mm width and 3 mm depth for CS/SS316 material..
We made some sort of catheter part out of g10 years ago.
Solid!
Top KEK!
7:03 what is the apparent slight step on the side of the flange?
I would say between 12-14 min rough estimate
Hmm, knowing as you like to push your tool's to the limits to make all operations fast, mb 3 mins fost 1st setup and 5 to the 2nd
did it take 42:06,9 to machine?
I work with graphite, I'm calling 21 minutes.
@Barry, you could at least eliminate this line/miss match on side face 😉. My eye just couldn’t ignore it and I had to let you know. 🙏
My gut said 17+ glad I was in the ballpark
Cycle time from setup till end estimate 35min.
Perfect ❤️
1.5 hours total, op#1 and 2
without tool change and setup I was thinking around 8 mins, but with all that maybe 15-20 mins
Hmmmmm diamond tools are worth their weight in gold? Must be an expression ;o) but hey cool video! Thanks!
you need high rpm for pcd . for small diameters it's more like a router 20 - 30 k rpm.
I guess that it took about 2h 30 min to manufacture whole part
Those tools are moving way quicker than you may think.
@@thatdrillguy7889 i dont talk only about cycle time. I talk also about making program, setting up machine for 2 operations . He asked how long it take to manufacture the part instead of "guess what the cycle time was "
14m:17s
1hr 35mins from program generations to complete part
Runtime total of 22mins
Im gunna guess 8min 40sec. I know you guys like to run parts fast!
5:26, if you didn't step on the break
Does anyone have resources for how to figure out feeds and speeds for lathes, depending on material?
Read on the backside off the insert box
YESSSSSSS SLUDGE
PCD works awesome on composite. Unfortunately composite with prematurely wear your machine.
17min 42sec
23.5 min is my guess
23-27 minutes
8MIN 10 SEC😁
40min that’s my guess
43:15
Stole the popcorn cutter from Trevor? Indispensible tools for roughing the majority of micro-grain graphite electrodes.
With out setup I will sy 18 minutes running time
24 minutes and 15 seconds of machining time
18:30 min millingtime
G10 sucks to machine and work with. I've worked with it before and it gums up everything. It is also bad for the ways in the machine if you can't flood the tool and material. Because it is so soft though, you can run it as super high surface speeds (unfortunately none of the machines in my shop have the spindle speed or feeds. Drilling and tapping the stuff is the absolute worst though. But a part like that, I'd say you can crank that out in no more than 8 minutes with the surface speeds that you can machine this material at. That includes both setups.
You mention it being soft and gummy.
Thats a huge problem with composites of all kinds. As with G10, generally composites are a structurally strong or hard particles or fiber bonded together with a resin.
The resin is soft and gummy while the glass is hard, brittle, and abrasive.
8:03
Most my parts are g10 but g9 sucks too /aerospace mostly high end customers
6hr. 22min
I'm guessing this is a 10-15 minutes job, because of video editing it looked short