Re: Carbon fibre threading improvements?
always slightly de-laminate the top skin
just delam the fibers rather then cut them.
hy k-turner warenb's idea about the countersink seems nice; even so, a countersink could lead to same delamination; carefull with not visible delamination
is one thing to plunge a countersink/tap, and another to interpolate the chamfer/thread, thus there is a balance between cutting forces and time
to make that tap work with less delamination, it has to be more sharp, have longer entrance ( conical zone ) and less calibration teeth ( cilindrical zone ); you could take a tap and grind it so to have a single helix, thus it's cutting force will be as low as possible, but you may not be able to guide it if there is overhang
to make your process work, you simply need to find a tool that has cutting force as close as your actual method of intepolation you will have to test many taps
Also puts all the pressure on the machinist to keep adjusting cutter comp as you know one digit wrong and the part is scrap
i suggest :
... checking the consistency of the process, and mapping things as needed, so to identify & eliminate time waste
... avoid error related to inputs, by using a macro that checks offset deviation, and an incremental aproach for final finishes, that simply increases the toolpath radius, without requiring the operator to always modify ++++ then ---- at a new part; if process is stable, is possible to bound it's corections, and speed up or at least partially replace operator's actions
such actions can ease the operator, and works as long as deviations follow a previsible pattern; there may be burs, lack of thread rigidity
some with around 80 tapped holes blind and through in a range of sizes
One of our ops is around 30 mins to run the whole thread milling program, then adjust and re-run, hours of work...
at 1st glance, time seems fine
you can boost feed by adding one more tooth, thus instead of experimenting with taps, simply use denser threadmills, at least for orughing
consider also finish with different tool / kindly
Ladyhawke - My Delirium, https://www.youtube.com/watch?v=X_bFO1SNRZg