Skip to content
Revolutionize Your Tech Journey Today!

Navigating intricacies head-on

Discussion on CFRP drilling and stack material solutions for the aerospace industry, as detailed in a question-and-answer session with Martin Burns, an aerospace expert at Exactaform.

,   and  Administrator
2 min read
Navigating Intricate Matters
Navigating Intricate Matters

In the world of advanced engineering, innovation is the key to pushing boundaries and driving progress. Two companies, Exactaform and Mapal, are making significant strides in the aerospace, automotive, and fluid power sectors.

Exactaform, a pioneer in tooling solutions, is focusing on innovative geometries, advanced coatings, and optimised cutting strategies. Their goal is to deliver solutions that improve hole quality, tool life, and process reliability in aerospace manufacturing.

The aerospace industry is no stranger to challenges when it comes to machining composite materials like carbon fibre-reinforced polymer (CFRP). Excessive thrust force and high-speed drilling can cause delamination, resin burn, fibre pull-out, and degradation of the matrix in CFRP, compromising structural integrity. Exactaform addresses these challenges by combining specialised drill geometries with optimised cutting parameters, and accounting for fibre orientation when drilling.

Meanwhile, Mapal is set to present a range of innovative tooling solutions at Advanced Engineering 2025. Their focus will be on the aerospace, automotive, and fluid power sectors, offering solutions tailored to meet the specific needs of each industry.

The adoption of CFRP in the aerospace manufacturing sector is on the rise due to its lightweight, high-strength properties. However, it's not uncommon for CFRP to be stacked with metals like titanium or aluminium to meet specific strength, weight, and thermal performance criteria. This presents its own set of challenges, as each layer in the stack behaves differently under machining conditions, requiring purpose-built cutting tools for multi-material applications.

Brookhouse Aerospace has recently invested over £500,000 in additional machinery to extend its engineering capabilities. This investment underscores the industry's commitment to innovation and the pursuit of superior manufacturing performance.

In another development, Polycrystalline Diamond (PCD) and nano-grain carbide tools are being adopted more widely for their wear resistance, thermal stability, and ability to maintain sharp cutting edges. These tools are proving invaluable in the machining of CFRP and its stacked counterparts.

Geometry plays a crucial role in modern drills and routers, with variable helix angles, point geometries, and flute designs to reduce thrust force and ensure efficient chip evacuation. These advancements are helping to overcome the challenges posed by CFRP and other composite materials.

On the simulation front, Lockheed Martin is upgrading the Republic of Korea Air Force's F-16 Block 52 flight simulators to mirror the advanced capabilities of its modernised F-16 Viper (F-16V) aircraft. This investment in simulation technology is a testament to the importance of virtual testing and training in the aerospace industry.

Lastly, the National Composites Centre (NCC) has adopted Dassault Systèmes' 3DEXPERIENCE platform on the cloud for innovation centres within the UK High Value Manufacturing Catapult network. This move is expected to accelerate innovation and collaboration in the composites sector, driving the development of even more advanced tooling solutions.

In conclusion, the future of aerospace manufacturing is bright, with companies like Exactaform and Mapal leading the charge in innovation. As the industry continues to push the boundaries of material science and manufacturing performance, we can expect to see even more groundbreaking developments in the years to come.

Read also:

Related

Latest