Machining Composite Materials with Diamond Cutting Tools

Composite materials such as high-density fiberglass, Carbon Fiber and G10-FR4 are very abrasive materials. They also test the adhesion of the diamond film to the base carbide. Many of our competitors fail in these applications due to poor adhesion of the diamond film to the carbide.

CVD Diamond has had excellent results in these materials achieving as much as 70 times the life of a bare carbide tool!!

The wear pattern on a tool made by CVD Diamond shows no sign of damage to the diamond film other that the wear even after it is completely worn out.

Read an article by Joe Brennan regarding the "Five Facts about Diamond-Coated Tools" at the Mold Making Technology website.

Worn out Diamond Coated tool -
note even wear pattern indicating
adequate adhesion

What follows is a suggestion of starting parameters for machining Fiber composite materials.

Many customers have been successful at machining at much higher speeds. For more information please call 1-877-457-9903

Suggested Starting Parameters for Endmilling Fibre Filled Plastics
Cutting Diameter	Machine speed (rpm)	Cutting speed (sfm)	Feed Rate (fpt)	Operation
1/16"	13,700 - 7,300	60 - 120	.001 - .002	General
1/16"	5,200 - 10,400	85 - 170	.0005 - .001	Finish
1/8"	3,600 - 7,300	120 - 240	.001 - .002	General
1/8"	5,200 - 9,200	170 - 300	.0005 - .001	Finish
3/16"	4100 - 7,100	200 - 350	.001 - .002	General
3/16"	6,100 - 10,200	300 - 500	.0005 - .001	Finish
1/4"	4,600 - 6,900	300 - 450	.002 - .004	General
1/4"	5,300 - 8,400	350 - 550	.001 - .002	Finish
3/8"	4,100 - 5,600	400 - 550	.003 - .005	General
3/8"	3,500 - 6,600	350 - 650	.001 - .003	Finish
1/2"	3,400 - 4,600	450 - 600	.003 - .005	General
1/2"	2,600 - 5,700	350 - 750	.001 - .003	Finish

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