Manufacturing composites is a complex process that can be greatly improved through the use of diamond tools. Diamond tools offer many advantages over traditional metal cutting tools. Some of the more notable advantages include longer tool life, faster cutting speeds, and reduced scrap rates. Composite materials vary widely in their compositions. Some materials are hard and abrasive while others are soft and tacky. Choosing the right type of diamond tool and the right grit will make processing difficult-to-cut materials a lot easier.
It is common to see the manufacturing of standard and custom-made diamond tools, specifically for niche applications in the composites industries that include aerospace, transportation, nautical, consumer-goods manufacturing, sporting equipment, military and defense wearables and clean energy.
5 Benefits of Diamond Tools for Composites Manufacturers
There are different benefits to using diamond tools in composites manufacturing. Here are five common benefits.
- Longer tool life: Diamonds are extremely durable and have the ability to withstand high temperatures due to friction and abrasive forces that wear down other materials over time.
- Faster cutting speeds: When applying the correct grit selection based on the application, diamond tools can cut through composites faster than traditional metal cutting tools. This ultimately results in reduced manufacturing times.
- Reduced scrap rates: The superior performance and accuracy of diamond tools leads to less scrap material and improved yields. Diamond electroplated and vacuum brazed tooling will maintain their shape and accuracy throughout the lifespan of the tool.
- Great for machining difficult materials: Composites are difficult to cut and process due to their physical qualities. Resins can be tacky. Meanwhile fiberglass is often extremely abrasive whereas plastics may be brittle. In general, understanding the physical quality of the material is crucial when designing and developing the right tool for the job.
- Precision: A diamond tool maintains its shape and offers tighter tolerances, which leads to more precision.
3 Factors to Consider When Choosing the Right Diamond Tools
You need to consider the specific applications and materials when choosing the right diamond tool to work with. Here are 3 factors to consider when choosing the right diamond tool.
- Geometry and size of the part: The shape and design of the diamond tool are dependent on the geometry and size of the part being cut or processed. So, it is important to select a tool that is up to the task.
- Type of material being cut: Composite materials may vary widely in their composition and physical characteristics. Ultimately, it is important to understand the materials’ rigidity and abrasiveness when selecting the right diamond tool.
- The material removal rate: In order to achieve the highest material removal rate possible, it is important to select the correct grit and diamond application for the particular job. And it is important to understand the distinction between electroplated and vacuum brazed diamond tools in order to make the best diamond tooling decision.
Frequently Asked Questions About Diamond Tools & Composites
Here are a few frequently asked questions about diamond tools and composites.
What are diamond tools?
Diamond tools are cutting tools that use diamonds as the primary wear surface. This makes them extremely durable and capable of cutting through a wide range of composite materials such as fiberglass, resins, plastics, and Kevlar.
Why are diamond tools used in composite manufacturing?
The exceptional durability, performance and accuracy of diamond tools make them perfect for composites manufacturing. The versatility of diamond electroplated or diamond vacuum brazed tooling makes them an ideal match for the variable consistencies of composite materials.
How do diamond tools work for composite materials?
Diamonds are the hardest natural material on earth, which makes them the perfect choice as a cutting surface. The fully exposed diamond grit in electroplating and vacuum brazing processes guarantees a direct and aggressive grinding mechanism.
What types of diamond tools are available on the market?
There are many different diamond tool options for composites manufacturing. In some cases, a standard diamond tool will be enough. However, many may opt for a custom engineered diamond tooling solution for their unique application.
- Diamond cutting blades: These types of blades are perfect for cutting and machining composite materials.
- Diamond router bits: Ideal for creating intricate profiles in composites materials.
- Diamond core bits or drill bits: Diamond electroplated or vacuum brazed core bits are the main tool of choice for cutting holes or openings in composite materials.
- Custom diamond grinding wheels: These types of wheels are great for grinding composite materials into the desired shape and size.
- Diamond-coated rotary burrs: The use of rotary burrs creates a rounded edge, which is ideal for composites manufacturing with minimal chipping or tearing.
- Diamond-coated end mills: Perfect for composites manufacturing applications with large cutting depths.
What care and maintenance are required to keep diamond tools working at their best in a composites manufacturing environment?
Diamond tools require some maintenance to ensure they keep working. Diamond composites are resistant to the high temperatures and pressures involved in composites manufacturing. And diamond tools are not affected by composites manufacturing additives, which minimize the need for frequent cleaning. Making overall maintenance a minimum.
Contact Lieber & Solow Today
Diamond tools offer many advantages over traditional metal cutting tools, which includes a longer tool life, faster cutting speeds, and reduced scrap rates. It can be a difficult process when selecting the right diamond tool for your composite manufacturing application since various factors need to be considered. Contact Lieber & Solow today to learn more about the diamond tooling industry.
When you reach out, we can go over any questions you have regarding our services.