Carbon Fiber Plate Processing
The carbon fiber model comes white as standard, but can be produced in any colour to meet your requirements.
The colour samples are indicative and not intended as an exact replica of the actual colour of the product. Due to variations in monitor settings and colour balances, colours are representative only and should not be construed as an exact colour match of the listed product. We advise you to request actual material samples before ordering.
Carbon fiber plate is one of the main application forms of carbon fiber composite materials. Carbon fiber plate used in the field of building reinforcement adopts the traditional wet extrusion process mainly with unidirectional fibers, and the carbon fiber board used in the fields of industry, transportation, medical treatment and the like adopts prepreg curing process, which is more designed in mechanical properties.
The raw material used in carbon fiber plate processing is carbon fiber prepreg. According to the size of carbon fiber bundle in prepreg material, it can be divided into 1k, 3k, 6k and 12k, etc. According to the surface grain of the carbon fiber sheet, it can be divided into plain grain and twill pattern. And according to the surface treatment effect, it can be divided into bright light and matte. The specific processing process includes prepreg cutting, layering, curing, cutting and post-processing and other procedures.
The prepreg material should be cut according to the length and width of the sheet, and prepreg material’s thickness is determined based on the thickness of carbon fiber plate. The conventional thickness of carbon fiber plates are: 0.2mm, 0.3mm, 0.5mm, 0.8mm, 1.0mm, 1.5mm, 2.0mm, 3.0mm, 4.0mm, 6.0mm and 10.0mm, etc. We have rich professional experience in manufacturing carbon fiber plates, and customization service offered according to customers’ different requirements. The bigger the carbon fiber plate’s thickness is, the more prepreg layers are needed to be stacked. Generally speaking, carbon fiber plate with 3mm thickness needs prepreg material with more than 10 layers. The width of the raw material of the prepreg is fixed, and if the original size is not enough , the splicing of the material is concerned. For the carbon fiber plate with unconventional size, the prepreg material should be designed before tailoring. With the optimization of design, the prepregmaterial will be used to reduce the margin and production cost.
According to the demands on tensile force, shear force and strength of carbon fiber sheet, the orientation and sequence of prepreg are determined. The orientation includes: 0°, 45°, 90°and -45°. In order to make greater use of fiber axial performance, laying order should be selected according to the type of load in actual operation. The laying direction of the fiber should be set according to the main direction of the load. In the stress state of the point, the laying with 0 °angle corresponds to the normal stress, and the layer with ±45 °angle corresponds to the shear stress. The layer with an angle of 90 °is used to ensure that there is enough positive pressure in the radial direction of composite material. If the load of composite plate is mainly tension and compression. Then the direction of laying should choose the direction of tension and compression load. If the main load of composite parts is shear load, then the laying in pairs of 45 °and -45 ° should be main. If the load of composite parts is complex and includes multiple loads, the laminates are laid in 0 °, ±45 °or 90 °multi-directional mixed laying. In the specific laying, the general composite parts layer are symmetrical balanced, whose characteristics are that among the overall layer, the upper and lower layer are in the middle face. If the design is necessary to be asymmetric balanced, the unbalanced or asymmetric layer should be arranged near the middle of the whole layer, which can effectively avoid the tension-bending coupling of composite materials and warping after pull-shear coupling.
In a word, the stacking sequence not only influences initial load, matrix crack propagation rate, fracture toughness, and also has a significant impact on the saturation of matrix crack and crack density. For example, for the cross-ply laminate, the fracture toughness has a corresponding relationship with the crack growth rate under the same applied load. However, for the advantages and disadvantages of different layering order, the composite material’s advantage of designability should be made full use according to different application requirements.
After cut and stacked, the prepreg will enter the curing process. The prepreg material is placed in a pressure-heated mould at the predertermined temperature. And then the hot pressing die is closed, the laminated material gradually solidifies under hot pressing and reaches a certain degree of solidification. The mould is opened and the drawing device is pulled away from the hot pressing die to complete the solidification. In the whole curing process, the curing time and temperature should be adjusted in stages according to the performance requirements of the sheet. Different temperature and heating time will affect the properties of carbon fiber sheet. In the actual production process, the time of hot pressing stage should be shortened as far as possible on the premise of keeping the dimension stable in the curing stage after the workpiece is satisfied.
After solidification, carbon fiber sheet needs cutting, drilling and other post-processing for the accuracy requirements or assembly. With the same cutting process parameters, cutting depth and other conditions, knifes and drills with different materials, sizes, and dimensions have various effects. Besides, the force, direction, time and temperature of cutting tool and drill will affect the machining effect.
During the post-processing, the sharp cutting tool with diamond coating and solid carbide are preferred to be chosen. The wear resistance of cutting tool and drill determines the quality of machining and the service life of the tool. If the cutting tools and bits are not sharp enough or not used properly, it will accelerate weariness, increase processing costs, and cause damage to plate, affects the shape, size and the stability of machining parts, such as holes and grooves. What’s worse, it can lead to lamellar tearing, block caving, and even scrapping of the whole plate.
In the drilling of carbon fiber sheet, the faster the speed is, the better is the result. As for the drill bit selection, PCD8 surface edge drill point is more suitable for the unique design of carbon fiber sheet, which has better penetration of the sheet and reduces the stratification risk. When cutting thick carbon fiber plate, it is recommended to use left and right double spiral blade design of the compression type milling cutter.