How do you cut composite materials?

# How do you cut composite materials?

Trimming composite materials is a delicate operation that requires a thorough understanding of the characteristics of these materials. Composites are widely used in various industries due to their exceptional strength-to-weight ratio. However, their complex structure poses specific challenges when trimming, including the risk of delamination and the need to achieve clean, precise cuts. This article explores best practices for routing composite materials while minimizing the associated risks.

# Understanding Composite Materials

Composite materials consist of two or more components with distinct properties, usually a matrix and reinforcing fibers. The matrix can be polymer, metal, or ceramic, while the fibers can be glass, carbon, or aramid. These materials are valued for their lightness, stiffness, and corrosion resistance, making them ideal for applications in aeronautics, automotive, construction, and high-performance sports.

# The Challenges of Composite Clipping

The main challenge in trimming composites lies in the risk of delamination. Delamination occurs when the layers of fibers separate, compromising the structural integrity of the material. This can be the result of improper cutting techniques, ill-fitting tools, or incorrect cutting parameters. In addition, composites are often abrasive, which can lead to rapid wear and tear on cutting tools. So, it's crucial to choose the right tools and techniques to avoid these issues.

# Composite Trimming Techniques

Composite clipping can be done using a variety of techniques, including water cutting, laser cutting, waterjet cutting, and mechanical cutting. Each method has its advantages and disadvantages, and the choice depends on the specific requirements of the application. The routing of composite materials, whether glass, carbon or aramid fibers, presents several technical and logistical challenges. One of the main problems is the high risk of delamination. This phenomenon occurs when the layers of fibers separate, compromising the structural integrity of the material. To minimize this risk, it is crucial to choose appropriate cutting methods. Among the most common techniques, wet cutting is often preferred because of its ability to reduce heat and vibration, two main factors in delamination. This method uses a high-pressure stream of water, sometimes mixed with abrasives, to make precise cuts without generating excessive heat. Laser cutting, although very precise, can sometimes induce thermal damage, which requires highly controlled cutting parameters to avoid any risk of delamination. Waterjet cutting, similar to water cutting, also uses abrasives to improve cutting efficiency. Finally, mechanical cutting, carried out using saws or milling cutters, must be carried out with tools specially designed for composites to reduce wear and vibration. In addition to choosing the right method, it is essential to maintain sharp cutting tools and follow strict cutting parameters to ensure clean, precise cuts. 

# Delamination Hazards and Clean Cut Needs

Delamination is one of the main risks associated with the routing of composites. During cutting, mechanical forces can cause the fiber layers to separate, compromising the strength and integrity of the material. To avoid this, it is crucial to use sharp and well-fitting tools, maintain proper cutting speeds, and minimize vibration. The need to cut clean is also critical to ensuring the quality and performance of composite components. A clean cut reduces rough edges and surface defects, which improves the durability and aesthetics of finished parts. To achieve clean cuts, it is recommended to use non-thermal cutting techniques, such as water or waterjet cutting, and to keep tools in good condition.

# Best Practices for Effective Clipping

To efficiently trim composite materials while minimizing the risk of delamination and achieving clean cuts, it is important to follow some best practices:

1. Selecting the right tools : Use cutting tools that are specifically designed for composites, such as continuous cutting edge cutters and fine-tooth circular saws. These tools are designed to minimize vibration and reduce wear.

2. Control of Cutting Parameters : Adjust cutting speeds, feed rates, and depths of cut based on the type of composite and material thickness. Proper cutting parameters help reduce mechanical forces and the risk of delamination.

3. Use of lubricants and coolants : Applying lubricants and coolants during the cutting process helps reduce heat and minimize tool wear. This also improves the quality of the cut.

4. Regular Tool Maintenance : Keep cutting tools in good condition by sharpening them regularly and replacing worn parts. Well-maintained tools ensure clean, precise cuts.

5. Use non-thermal cutting techniques : Prefer non-thermal cutting techniques, such as water or waterjet cutting, to avoid thermal damage to composites and reduce the risk of delamination.

Trimming composite materials is a complex operation that requires a thorough understanding of material properties and proper cutting techniques. By following best practices and using the right tools and methods, it is possible to minimize the risk of delamination and achieve clean, accurate cuts. Whether in aeronautics, automotive or sports equipment, mastering the routing of composites is essential to guarantee the quality and performance of finished components.

# TIVOLY's Z1 cutter: an innovation for composite routing

The TIVOLY Z1 Cutter represents a major breakthrough in the machining of composite materials. Showcased at JEC World 2024, this cutter is specifically designed to provide increased versatility and efficiency. It allows you to work on a variety of composite materials with remarkable precision. Players in various sectors, such as POS, communication and signage, and PVC and aluminium joinery, benefit greatly from this tool. The Z1 cutter is capable of generating a large volume of chips while ensuring a smooth, scratch-free surface. This performance is made possible by optimized geometry and the use of high-quality materials in the manufacture of the cutter. In addition, TIVOLY offers specific adaptations to meet the unique needs of each project, allowing professionals to achieve tailor-made results. The Z1 Cutter is not only a cutting tool, but a complete solution to improve productivity and quality in composite machining.