carbon fiber ???

NickWheeler

NickWheeler

Joined
Dec 3, 1999
Messages
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Hi guys :)

I've used carbon fiber a few times in the past and didn't have any real issues with it. However, I've been working on a fighter with a "2 way weave" that has just been a bear to work with.

Does anybody know what the recommended cutting speeds are? So I can come up with some optimal rpms and feed rates for drilling and milling it...

How about cutting it? I tried to cut the front of the block with the porta-band. I had JUST cut 1/2" thick steel on it like butter..... but it just rubbed the carbon fiber (and probably polished the teeth on the blade) :foot:

I sprayed it down with KoolMist almost like a flood coolant.... because I figured it was easier to clean up cf goop, than have the dust flying all around the shop and in my lungs for the next month.

Thanks guys :)
 
Most of my CF I cut either with a high speed and slow feed abrasive disc, or send it out for water jet. Now what thickness CF are you using? And aren't all weaves "2 way" by deffinition!? Is it a twill or crowsfoot pattern you are talking about?

Try a fine tooth blade on a wood cutting bandsaw.


-Xander
 
NickWheeler said:
Hi guys :)

I've used carbon fiber a few times in the past and didn't have any real issues with it. However, I've been working on a fighter with a "2 way weave" that has just been a bear to work with.

Does anybody know what the recommended cutting speeds are? So I can come up with some optimal rpms and feed rates for drilling and milling it...

How about cutting it? I tried to cut the front of the block with the porta-band. I had JUST cut 1/2" thick steel on it like butter..... but it just rubbed the carbon fiber (and probably polished the teeth on the blade) :foot:

I sprayed it down with KoolMist almost like a flood coolant.... because I figured it was easier to clean up cf goop, than have the dust flying all around the shop and in my lungs for the next month.

Thanks guys :)
Click to expand...



I know you can get silicon carbide, or diamond tipped bandsaw blades for abrasive materials.

I've seen pre-made sizes for the 64 1-2" blades for the 4x6"
I suppose you could get anything made if you want


http://www.bandsawbladesdirect.com/product_info.php/cPath/21_31/products_id/43

http://www.starrett.com/saws/saws-hand-tool-products/band-saw-blades/carbide-diamond/advanz-dg

Carbide premade in portaband size $100 ish for the carbide
http://www.starrett.com/saws/saws-h...saw-blades/portable-band-saw-blades/advanz-cg
http://hydraulictools.zoair.com/ite...and-saw-blades/band-saw-blades/cg4gm?&seo=110

They are expensive enough & my usage low enough, that I haven't tried them yet. -I just used the cheapie carbon blades instead of bimetals for them.



There are some discussions on CF on machining boards.- that new fighter jet seems to be mostly made of the stuff.
Mostly recommending the PCD (Polycrystlline Diamond) type of cutters


Some speeds and feeds in this product booklet
http://www2.coromant.sandvik.com/coromant/downloads/users_guide/eng/C-2920-30.pdf
http://files.engineering.com/downlo...656_Machining_Plastics_and_Adv_Composites.pdf
 
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Knifemaker87 just did a wip on a carbon fiber take down, you could send him a pm and see what he used and how it went.
 
Xander- This stuff is beastly, 1" thick!!! :eek: :) I only know enough to be dangerous here--- I know there are unidirectional based fibers, where the fiber reinforcement only goes in one direction; there is also a bi-directional (or 2 way, woven, etc.) that has the fibers crossing each other. I THINK they are more commonaly woven. Looking at my OP, I realize my description was really open ended. I don't know the exact particulars of this carbon fiber, it just had "2 way weave" on the supplier's label. Just proof I don't know what I'm talking about! :o :foot: :)

Sam- GREAT info in those links, THANK YOU! :) I wish I had a dust/debris extraction unit for my mill like the one in the Sandvik file!!! :thumbup: :cool: I ended up milling the end of the block (instead of cutting with the bandsaw) with a solid carbide endmill at full whirl, and it machined very nicely. After going through those links, I think I mostly got lucky.

tattooedfreak- You're exactly right, Chris Moss DID indeed build a knife for Lorien with cf. The only catch is Chris actually made the cf from fiber strands and resin--- So he actually formed it around the tang rather than having to drill/broach/file/gnaw/chew out a rectangular hole for the tang.


A customer and friend of mine from overseas actually builds Formula 1 racecar parts out of carbon fibre (they actually make the carbon fiber) and I will talk to him about this also... but I figured knifemakers might have more direct experience/thoughts as to what I'm doing with the stuff.

*interesting side note* The craft paper mill I used to work for is called Fibre. They trademarked the name so as to make it stand out because everyone in the US spells it "fiber." Well, everyone overseas spells it "fibre" So if you're looking at US based info it's going to be "carbon fiber" folks overseas like my friend Rick, spell it "carbon fibre." ;) :) (so I didn't have typos above, I was just respecting both sides :p :) ).
 
NickWheeler said:
Well, everyone overseas spells it "fibre" So if you're looking at US based info it's going to be "carbon fiber" folks overseas like my friend Rick, spell it "carbon fibre." ;) :) (so I didn't have typos above, I was just respecting both sides :p :) ).
Click to expand...
Ya right! When it comes to your spelling and typing, we'll believe anything you want us to Nick. That's what pals are for. :p Make sure you post us your findings, not that I have a mill, but I do have some chunks of CF I plan on working some day to go with some Ti.
 
yes, Chris did form it over the tang but he did have to cut off about an inch or so and he talked about using a bandsaw for it. He doesn't say what type of blade he used though.
 
Nick,
I have a bunch thats .75 thick that I make knuckle dusters out of about 4 times a year. I just use an 18tpi portaband blade and cut away. never had any issues with it. it dulls the blade faster than titanium but it cuts just fine. Just accept the fact that it will eat a new blade and be done with it:) might save you some frustration!!!
 
You probably already know this, but for every one else, and those who might find this later...
Please don't rely on the coolant alone to keep the dust down. You need to wear a respirator when you are in the same room with the stuff. CF dust is some of the worst stuff to breath in, worse than fiberglass Ive been told. Make sure you clean up after you cut and sand. Also I found that wearing latex gloves helps keep the dust out of the sensitive webbing between my fingers.
 
Nick, When you get it all figured out, let me know. I just got an order for a carbon fiber hidden tang, and have never actually worked with the stuff before. I am concerned about digging out the tang hole somehow. I dont know if my current method will work very well, so I will just let you do the experimenting and I will reap the rewards!:D
 
Wanted to follow up on this.... since the knife is finished and delivered now.


This stuff is kind of a pain to work with, but I really like it once it's all said and done. ;) :)

Word of advice, long sleeve shirt with some kind of gloves and taped at the wrist, a bandana and hooded shirt... and of course something over your face and eyes. I've read that Micarta is actually more dangerous as far as the dust and your lungs go... but the dust from this stuff sure doesn't go well with skin.



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[video=youtube;ZbHvL5ZFq_E]http://www.youtube.com/watch?v=ZbHvL5ZFq_E[/video]
 
Real nice Nick! You aint jokin about gearin up, and takin precautions with cf!
 
WOW!!!! I would love to see what you did with a moulded CF handle. Having a custom from you is my grail buy, but it will be many years before I will get there.
 
the best way is to use a diamond tipped bandsaw blade or a high speed router with a carbite altro bit
 
I never did do any cutting on this particular piece.

I milled the front end, and ground all the rest away.

The tang hole was a real beeyotch. :eek: :grumpy: I sharpened the drill bit 4 times, and had to sharpen the broach I used a few times as well. I didn't use my Perry broaches, I used an old shop made one, and another rake tool made from sawzall blades.

I also sprayed the handle down with WD40 while hand sanding it, which I recommend to keep the paper from clogging up, but even moreso, to keep dust down.
 
I prefer natural materials, but man....that's one beautiful knife you've put together.
(Must admit I have several sets of scales made of cf - just haven't made a fitting blade yet)
 
useing hss bits is use less even carbite twist bits wont last long what we use is dagger bits or one shots then reamers to open to full size
 
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