49Compositi

HUFSCHMIED ZERSPANUNGSSYSTEME

Process elimination “Reworking of composites” thanks to One-Shot Process

quality in detail. The described milling process can be viewed in the video of Biesse’s YouTube channel.By combining all the described processes, high-quality CF-FMC components can be produced cost-effectively in se-ries production without costly manual rework. By reducing the machining time by at least 50%, machine-utilisation can be increased enormously. From 3rd to 5th of October 2019, the doors of Biesse in Pesaro will unlock for an open-house and the opportunity to experience the unique milling pro-cess first-hand.

No more manual finishing of composites – this is achieved with an optimal combination of cutting tool, CNC milling machine and high-quality composite materials. A shining practical ex-ample is the cooperation between precision tool manufactur-er HUFSCHMIED, the machine manufacturer BIESSE and the material supplier MITSUBISHI CHEMICAL CARBON FIBER AND COMPOSITES.Hufschmied has been developing and manufacturing cutting tools for more than 25 years and is regarded as a leader in mill-ing of composites in Europe for the automotive industry.Thanks to their special cutting geometry, Hufschmied tools ensure that composites can be machined without delamina-tion, overhanging fibres and fibre-pull-outs. Roughing and finishing is done without tool change in one operation. The test was performed using MATERIA CL, a Biesse 5-axis CNC mill, which is very effective for machining structural compo-nents (fig. 1).The Biesse CNCs product portfolio meets the automotive in-dustry’s high requirements for high-precision 3D elements. At Biesse’s upcoming open-house event in October 2019, a prac-tical example will be shown where an automotive component will be machined which places high demands on the mechan-ical properties and tight geometric tolerances. Ideally suited is the CF-FMC (Carbon Fibre Forged Molding Compound) in-termediate material from Mitsubishi. Munich-based compa-ny BLACKWAVE provides these components (fig. 2) with its advanced molding process for the tailgate assembly, which is supplied by Porsche Tier1 supplier c2i s.r.o.These frames form part of a German high-end sportscar. The ge-ometrical design possibilities of CF-FMC are many times great-er than conventional composite manufacturing due to its opti-mised manufacturing process, where 25 mm long fibres are im-pregnated with a quick cure resin system. Fibres are specifical-ly positioned and achieve positive material properties. Milling is the last step in the process chain. The jig is made using RAKU® TOOL WB-1258 board material from RAMPF, Germany (fig. 3). All machining operations are carried out with a single tool – the 066SMC from Hufschmied (fig. 4).The 066SMC can also dip in the z direction and make holes in finished quality by circular milling. Figure 5 shows the finished

Fig. 1: Materia CL from BIESSE

Fig. 2: Finished CF-FMC parts (frames)

Fig. 3: Milling process

Fig. 5: Surface quality after milling in One-Shot Process

Fig. 4: 066SMC End Mill from HUFSCHMIED