With KOMET RHOBEST® diamond coating technology, the surfaces and properties of tools for machining composite materials can be individually tailored to meet the requirements of the particular application. KOMET RHOBEST® diamond coating technology has made it possible to manufacture ultrananocrystalline, highly pure and extremely hard diamond coatings that join with the tool surface to form a compact and stable unit.Download the Full Brochure
Lightweight construction – COMPOSITE MATERIALS
In an era of increasing awareness of the issues surrounding energy, energy conservation and energy efﬁciency, the lightweight construction segment is becoming more and more important. At a rapid pace, composite materials are carving out ever larger market shares.
Outstanding material properties, however, also present challenges for the manufacturers of precision tools. The extremely high strength and complex make-up of these materials are placing new demands on the tools that work them: the high degree of abrasiveness means that conventional tools in drilling and milling setups last only a few metres.
In light of this requirement, the KOMET GROUP has developed a brand new class of tools distinguished by their innovative geometry, suitability for new machining strategies involving very high cutting parameters and also by the use of intelligent cutting materials. These new solutions range from single-edge to multi-tooth milling cutters and from drills with a new chamfer geometry to indexable tools having a special insert arrangement.
Cutting materials have also followed the trend: KOMET RHOBEST® diamond coatings and PCD solutions are demonstrating that they are fully equipped for the task.
Nano technology in lightweight construction
Since 1994, RHOBEST has been developing and continually adapting the nanocrystalline diamond coating to the tools used in speciﬁc machining processes. In 2011, this nanotechnology became part of the KOMET GROUP.
With KOMET RHOBEST® diamond coating technology, the surfaces and properties of tools for machining composite materials can be individually tailored to meet the requirements of the particular application. KOMET RHOBEST® diamond coating technology has made it possible to manufacture ultrananocrystalline, highly pure and extremely hard diamond coatings that join with the tool surface to form a compact and stable unit.
Thanks to this nanostructure, the geometry and surface of the optimised tool are retained, thin coatings are compact, wear-resistant and high-performing. The sharpness of the tool – an important prerequisite for the machining of ﬁbrous composite materials – is preserved.
With KOMET RHOBEST® diamond-coated tools, we meet the requirements for machining new lightweight materials – absence of burr and ﬁbre, a smooth, ﬂat cutting edge, suitability for painting and bonding, short machining times and long tool life.
Classiﬁcation of composite materials and typical applications
Fibrous composites are inhomogeneous materials that are essentially an assembly of three components – ﬁbres and matrices or binders.
Typical ﬁbres include carbon ﬁbre (CFRP), glass ﬁbre (GFRP) or aramid ﬁbre (AFRP). With respect to their tensile strength, they are categorised into HT (high tenacity), UT (ultra high tenacity) and IM (intermediate modulus). Depending on the properties desired, the ﬁbres differ in length, thickness and relative orientation (unidirectional, bidirectional, multidirectional).
As matrices, there are currently more than 100 different resins/polymers available on the market, which is just a hint at how varied these materials are. “Cold” cutting is generally recommended for duroplastics (90%) and thermoplastics (PEEK, PEI, PPS, etc.), while elastomers (PUR) should be cut at “high speed”.
Aerospace, automotive, medical industry, sports industry, wind farms, transport, building/architecture
Hybrids are material combinations of at least three layers of metals, polymers and ﬁbrous composites.
These materials are usually three-layer composite constructions with a honeycomb-shaped core made, for example, of aluminium, polycarbonate or polypropylene and are therefore characterised by their extremely lightweight and highly stiff properties.
Satellite engineering, packaging industry, exhibition stand, model and aircraft construction