What tooling wear issues occur when cutting composites?

Cutting composites presents unique challenges due to their heterogeneous structure and abrasive nature. One of the most significant issues is tool wear, which can drastically reduce tool life and machining efficiency. Abrasive wear is a common problem, as the hard fibers in composites, such as carbon or glass, erode the cutting edge over time. This leads to a dulled tool, poor surface finish, and increased cutting forces.

Another issue is edge chipping, where the cutting edge fractures due to the brittle nature of some composite materials. This is particularly prevalent when machining carbon fiber-reinforced polymers (CFRPs). Thermal degradation is also a concern, as high cutting temperatures can soften the tool material, accelerating wear and reducing precision.

To mitigate these issues, selecting the right cutting tools is crucial. Diamond-coated tools or polycrystalline diamond (PCD) tools are often recommended for their hardness and wear resistance. Additionally, optimizing cutting parameters, such as speed and feed rate, can help minimize wear and extend tool life. Understanding these wear mechanisms is essential for improving the efficiency and quality of composite machining processes.