Carbon fibers are fibers with a wide range of use in many industries. They have unique properties which guarantee and cement their status as the material of choice for many functions. While a material on its own, common carbon fiber fabrication is CNC machining.
In a bid to understand carbon fiber and its relation to CNC machining, this article will introduce carbon fibers, their properties, and their applications. It will then introduce the CNC machining usage with Carbon fiber, its benefits and possible tips to note. Let's dive into it!
What is Carbon Fiber?
Carbon fibers/graphite fiber/carbon graphite is a fiber obtained from organic polymers such as polyacrylonitrile, rayon, and petroleum pitch. It comprises this long string of molecules which is about 5 to 10 microns in diameter well intersected by carbon atoms.
Carbon fibers have versatile functions based on their properties. Consequently, it is an important material in many industries for example automotive, aerospace, and military
Properties of Carbon Fibers
There are many types of carbon fibers. However, they all fall into the same property ranges although with slight differences. Below are the important properties of carbon fibers that might make them enticing for your job.
● High Strength to Weight Ratio
Carbon fiber has a high strength-to-weight ratio. Therefore, it is light and strong. Its strength/weight ratio is comparable to materials such as aluminum and titanium. Therefore, carbon fibers are ideal materials for replacing them, especially in the aerospace industry.
● Corrosion Resistant and Chemically Stability
Carbon fiber is corrosion-resistant and chemically stable. Therefore, there is no need to protect it against deterioration from sunlight or other chemicals. However, because there are many grades of carbon fibers with different material compositions, there is a high chance you will notice sensitive materials such as epoxy. Consequently, there might be a need to protect it from such an environment
● Fire Resistance/Non-Flammable
Depending on the manufacturing process you use, you can make carbon fiber into non-flammable material. This is because carbon fiber is chemically inert.
● Electricity and Thermal Conductivity
Thermal conductivity refers to the ability to allow the transmission of heat through a material. It measures how easy it is for heat to flow through a material. Generally, carbon fibers have low thermal conductivity. Although, it is possible to design carbon fibers with high and low thermal conductivity. Carbon fibers are also electrically conductive. This can be a blessing or a curse. As a blessing, it is used by aerospace engineers in making asphalt in airports. Therefore, when there is ice, electricity can be passed through. This will generate heat and melt the ice.
Applications for Carbon Fiber
With the development of technologies, except the common CNC machining process, 3D printing also developed could work for carbon fiber, which could make carbon fiber have a wide range of industrial applications.
● Aerospace Industry
The aerospace industry was among the first industries to adopt the use of carbon fibers. Properties such as high tensile strength, high strength to weight ratio make it the ideal material to replace aluminum, titanium, etc. For example, in making the parts used in Boeing 787 Dreamliner, the plane structure is majorly carbon fiber. Carbon fiber is also ideal for making asphalt as previously discussed.
● Sporting Goods
Carbon fiber materials are used in making sporting goods such as tennis rackets, clubs, bats, etc., due to their high performance. The material is ideal for such use since it is light and strong.
For example, it is applicable in making rackets, because rackets must be light yet able to hit the ball fast and hard (i.e., strong). Consequently, many sporting goods such as rackets, bikes, and bicycles utilize carbon fibers.
● Wind Turbine Blades
Carbon fibers are also the ideal material for making wind turbine blades. This is because they can provide the necessary stiffness without adding enormous weight. Consequently, carbon-fiber turbine bland are lighter and can efficiently create electricity.
● Automotive
Carbon fibers are an important set of materials in making high-end cars such as Formula 1. Carbon fibers are ideal for such use based on their functionality and aesthetic value.
● Medicine
Carbon fibers are also important in medicine. For example, due to being transparent on x-ray images, it is used in x-ray equipment. Also, because it is strong and light it is applicable in making prosthetic limbs.
● Others
With CNC machining and 3D Printing machines, you can also fabricate carbon fibers from the comfort of your home. For example, you can make use of the material in making furniture, utensils, and even fireproof clothes.
Benefits of Using CNC Machining for Carbon Fiber
There are many techniques used in manufacturing products from carbon fiber composites. Common methods include making a 3D print using 3D printing and CNC machining. However, the latter is the most common method due to its benefits. Below are the benefits of using CNC machining services for Carbon fibers composites.
● Precision
CNC machining is a highly precise rapid prototyping process. Machining carbon fibers for the industries highlighted above requires high precision which CNC machining can deliver with ease. Consequently, CNC machining of carbon fibers is becoming popular in such industries.
● Productivity
The automation associated with CNC machining increases the productivity of machining carbon fibers. However, productivity is directly linked to your knowledge of CNC machines or the knowledge of the team in the CNC machining service you hire.
● Cost-Effectiveness
CNC machining is a cost-effective process. There is an increase in productivity with a reduction in errors. Consequently, no extra cost will be linked to such an anomaly since it is absent. Also, training operators is easy, as operators can learn about the process virtually
Carbon Fibre CNC Machining Tips
(Photo : cnc machining tips)
Machining carbon fiber might be a little challenging. However, with the right tips, you have an ace up your sleeves. Below are some machining tips you can incorporate.
● Use Water Jet Machining If Possible
If possible, you should use the water jet machining process for carbon fiber instead of rotary machining. This is because the former doesn't produce dust or accumulate heat. The accumulation of dust and problems with heat dissipation can lead to many problems during carbon fiber machining. Also, water jet machining does not lead to material layers delamination.
● Use PCD Tool
What if water jet machining is not available? Then you have to use the rotary machines. However, in such circumstances, you should use polycrystalline diamond (PCD) tools due to their abrasion resistance property. PCD tools are better than counterpart carbide. They can operate at a better speed (x3) and have a longer lifespan than carbine tools (about 25 times). However, when using PCD tools, always monitor the tools to prevent problems such as delamination.
● Remove Dust
Dust accumulation is a cogent problem in CNC machining. The dust produced is harmful to the operator. It is also electrically conductive which might pose many problems to other electrical equipment. Therefore, you should vacuum the dust frequently. Also, machinists should wear protective materials to protect their lungs and skins
● Note the Type of Material
There are many types of carbon fiber each with its peculiar characteristics. This might not look important. However, they affect the settings such as feed rate, revolution per minute, and tool choice. Consequently, it is important to know the type of material you are working with.
● Improve Heat Dissipation
Heat dissipation also plays a crucial role in the CNC machining of carbon fibers. Since carbon fiber has a low thermal conductivity, it does not dissipate heat like other metals. This can lead to the damage or burning of the resin that holds the carbon fiber together. It also results in tool wear. To prevent the build-up of heat during the process, you can use coolant liquid. Also, you can make sure the feed rates are lower than the metal.
Final Thoughts
Carbon fibers have wide industrial applications due to their properties. For example, they are used in making products applicable in the automotive, aerospace, and military industries. There are many methods used in fabricating carbon fibers. This article introduced CNC machining of Carbon fibers. It talked about carbon fibers, their properties, and their application. It then highlighted the benefits of using CNC machining with carbon fiber and various tips you can follow.
