Manufacturing Methods for Cutting, Machining and Drilling Composites. Volume 1. Composites Machining Handbook
Final technical rept. 2 Aug 1976-2 Aug 1978
GRUMMAN AEROSPACE CORP BETHPAGE NY
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High-quality, low-cost manufacturing methods were established for cutting, machining and drilling of composites. Production nondestructive evaluation NDE techniques, capable of insuring structural integrity, were also developed. Materials addressed in this program included graphiteepoxy and hybridsthereof, boronepoxy, Kelvarepoxy and fiberglassepoxy. Program highlights are described below. Conventional cutting methods were compared to new technology methods such as water-jet, laser and reciprocating cutting. Although the high-speed water-jet and reciprocating cutters worked well with some uncured materials, the slower laser cutter was able to handle all of the materials studied. Several, new low-cost techniques were established for drilling of graphiteepoxy and hybrids thereof. High-speed 21,000 rpm drilling of graphiteepoxy doubled the life of solid carbide tools. The use of ultrasonic adapters on portable drilling units increased drill life by 100 percent with graphite-boronepoxy hybrids. Operating parameters were established for routing, trimming, beveling, countersinking and counterboring. In general, diamond-cut carbide router bits were effective for routing and trimming graphiteepoxy and fiberglassepoxy. A comprehensive review of all available NDE techniques that could be applied to the inspection of cut, drilled and machined composites was made. The most effective technique that could reliably be applied in a low-cost production mode was tracer fluoroscopy.
- Ceramics, Refractories and Glass
- Laminates and Composite Materials