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As new generations of carbon fiber reinforced plastics (CFRP) and laminates are becoming lighter and stronger, their performance continues to increase, and their position in skis, tennis rackets, military aircraft and automobiles has become increasingly prominent. Someone wrote in the December 2010 issue of Composites Technology, "No other technology can go beyond carbon fiber reinforced plastics to help automakers achieve their goal of lighter weight faster."

As a workpiece material, its long-standing main challenge is how to improve the manufacturing process, especially machining. Although it is excellent in the performance of the fuselage or ship frame, all kinds of fiber reinforced epoxy resin, polyester and vinyl plastic are high in hardness, difficult to cut, and can not tolerate a little abnormal deviation during processing. Moreover, the pre-processing added value is high, and the generation of waste products is not allowed.

Fortunately, a new generation of special tools has emerged to solve the most common processing needs of various composite materials. For example, the PCD LINE series of drills and milling cutters have a wide coverage and are proven composite machining tools. There are drill bits suitable for processing thicker materials with aluminum alloy as the bottom layer, and drill bits suitable for processing thinner materials with carbon fiber reinforced plastic as the bottom layer. A range of combination knives are also available, such as countersunk screw combination drills, drill reamer, slot milling cutters and combination drill cutters. Other products are too numerous to mention. It can be said that from the first appearance of reinforced composite materials, for the first time, you can always find an uncompromising high-performance tool for any imaginary composite processing task.

The preferred tooling solution for composite cutting today is the use of solid carbide as the base, thin PVD diamond (PCD) coating, brazed PCD inserts or sintered PCD at the cutting edge. Among the thousands of applications that are actually targeted at a variety of advanced composite materials, Iskar's above-mentioned tools are superior to most other similar products (including CVD diamond-coated carbide tools). The harder the material, the higher the density of the reinforcing fibers and the greater the room for process improvement.

The reason is obvious. From the perspective of the tool, the solid carbide tool has the rigidity and dimensional accuracy necessary to ensure close tolerances, positional tolerances and surface finish of the workpiece. Solid carbide also enables cutting geometry optimization, which reduces cutting forces, cutting heat, uncut fibers, cupping, wire drawing, fluffing, and better control of chips.

The thin PVD diamond (PCD) coating (applied to solid carbide tools or PCD inserts) provides a higher wear resistance for the cutting edge, ensuring that the tool retains its original geometry over a long machining cycle. The secret is to achieve a thin diamond (PCD) coating of PVD. They not only provide the wear resistance of the diamond, but also help to maintain the ideal cutting geometry for the machining of carbide tools. In contrast, the CVD (Chemical Vapor Deposition) coating method inevitably forms a thicker diamond coating, which is not conducive to geometric optimization.

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