Which Tool Offers the Highest Performance When Machining Fiber-Reinforced Composites?

 

The Leitz Diamond Router bits are included in the 2019 CNC Machining Year End Promotion. Learn more about the special pricing and offer details here. Contact the Leitz Customer Service Team direct at 616.431.4096 or email insidesales@leitz.org for more info.

When you combine machining and fiber-reinforced composite materials, such as carbon fiberboard and glass fiberboard, it can be difficult to achieve accurate and repeatable results. These materials present additional challenges to maximizing tool life and cut quality. Composite materials can wear down tools quickly. As tools become dull, they catch the fibers in the material, resulting in tears instead of clean cuts.

The Vienna University of Technology created the Fibercut Benchmark, a large-scale comparison of tooling performance, with the goal of determining which tool is most suitable for machine fiber-reinforced composite materials. The engineers from Vienna University of Technology evaluated the tools on the basis of fraying, delamination, and cracks and splits on the workpiece. In one hundred and twenty-four individual machining tests, they utilized three different workpiece materials: carbon fiberboard, glass fiberboard, and aramid fiberboard.  Eighty-six boring and cutting tools from sixteen different producers in total were tested. In the course of the Benchmark Study, each tool had to perform twelve processing tasks per test.

The tooling from Leitz out-performed the others machining these materials.

In individual tests with carbon fiberboard and glass fiberboard, Leitz submitted a diamond-tipped shank tool with an alternate twist. Andreas Kisselbach, Head of Research and Development at Leitz, explained, “Especially fiberglass being a very abrasive working material, tungsten carbide tools dull and quickly reach the end of their useful life.” In practice, diamond cutting materials are much more suitable when machining glass fiberboard.

Leitz solution with carbon fiber

Diamond tools typically outrun carbide tools by more than 20x and dramatically cut tooling and processing costs. Of course, special consideration must be given to proper application, operation, and service of diamond tools. The best tooling value can only be accomplished through precision service which increases the total service cycles and overall productivity of each tool. Precision tool service will also yield longer service life between sharpening or repair, resulting in fewer tool changes, less machine downtime and improved productivity.

Leitz diamond routers provide longer tool life, greatly improved service life, and high processing speeds to increase productivity and efficiency without compromising quality. Available in diameters as small as 3/8″, 2+2 and 3+3 wing design, and in various cutting lengths.

Leitz diamond tooling is maximized through experienced service technicians who use the finest grinding machinery, precision measuring and inspection equipment, dynamic balancing equipment, and the most current grinding know-how available to keep your cutting tools performing at optimal levels.

Achieve optimal results with Leitz diamond tooling solutions and realize the best return on your investment with expert support services from Leitz.

Contact Leitz at insidesales@leitz.org or (616) 431-4096, or fill out the form below, and we’ll get in touch.

Maximize the Benefits of Diamond Tooling with Continuous Education, Expert Service, and High-Quality Tooling

A premier office furniture manufacturer located in the Midwest increases the benefits of diamond tooling through education, service, and quality tooling.

Diamond tooling offers several benefits over traditional carbide tooling. However, if you are not getting longevity out of your diamond tooling, the cost benefits rapidly diminish.

This is the exact issue a market-leading office furniture manufacturer was experiencing. Unusual amounts of wear and damage to their diamond tooling and exceedingly long turn-around times from their tooling service provider were increasing production expenses and ruining efficiency.

Working with their Leitz representative, the manufacturer was able to identify and implement four areas of strategic improvement.

Tooling Quality

More PCD tip height on a tool’s cutting wing = more serviceable tool life. A taller PCD tip height will allow you to sharpen the tool more times before having to replace the tool. There are currently no industry standards for custom tool tip heights, so it’s important customers understand this significant tooling characteristic. Leitz designs their custom tools with maximum amount of usable tip height more than any other tooling provider and, therefore, provides the customer with more efficient, lowest applied cost tooling solutions.

Continuous Education

Diamond tooling is harder than carbide tooling. As such, it is also much more brittle. Most machine operators lack an understanding of the gravity of the cost difference between diamond and carbide tooling as well as how to properly handle diamond tooling to ensure the longevity of the tools. Leitz is providing ongoing education to teach the operator team how to handle and protect diamond tooling and increase tool life.

These photos show PDC damage due to improper tool handling. There is layered breaking within the PDC layer itself, similar to how shale rock would break. This can only be caused by side impact to the PCD.

Material Improvement

In addition to damage from mishandling, through extensive tool evaluation after running, including high-resolution photographs, the Leitz service team was able to identify and document frontal impact damage to the tool caused by impurities in the materials being cut. The manufacturer was able to return to their material provider and discuss reimbursement for damage and investigate alternative material options.

These photos show PCD damage due to impurities in the material. Damage is straight down through the entire layer of PDC and into the tool body.

Expert Service

Because of the multiple Leitz service centers located around the country, Leitz can provide a faster turn-around time for tool servicing. The manufacturer is now able to carry less tooling in-house with results in cost savings on their overall tooling inventory.

Although the furniture manufacturer was using a quality competitor, Leitz has provided a total tooling solution for the customer that will deliver more efficiency and maximize their investment. By understanding the difference in tooling service and handling, the manufacturer has watched their efficiencies grow and has realized positive downstream effects from the changes implemented during the manufacturing process.

Let’s talk about increasing the benefits of your PCD tooling through better service and education. Contact Leitz at (800) 253-6070 or fill out the form below.

The Top Three Qualities of Precision Tooling Service

Sharpening a tool 5-6 times is relatively easy, but the ability to sharpen the same tool 12-15 times can reduce your overall tooling costs by 50% or more.

Your cutting tools play a vital role in the overall quality and performance of your finished product. Precision servicing of your tools is critical to maximizing the investment you have made in your tooling solution. It’s important to partner with a tooling service provider with the expertise to ensure the longevity of your tooling and, in turn, the ongoing efficiency of your production process and quality of your product. These are the three most important qualities to look for when you select your tooling service partner.

leitz, woodworking tools, wood manufacturing

Consultative Approach

Your tooling service partner should assess your entire production environment and suggest tooling solutions which will optimize your productivity and profitability. This consultative method can be utilized throughout the service cycle as well.  Each time a tool is ready for service your representative should offer ideas to maximize current tool capabilities through usage and servicing options to make certain your tools operate at optimum performance levels for their entire lifecycle.

State-of-the-Art Equipment

Experienced service technicians use the finest grinding machinery, precision measuring and inspection equipment, dynamic balancing equipment, and the most current grinding know-how available to keep your cutting tools performing at optimal levels. Your service provider should make an ongoing investment in the quality of their sharpening and reconditioning equipment.

Experience of Service Technicians

Service technicians should receive continuous qualification updates and training with a special focus on technology and production Service and quality standards should be uniform, consistent, understood and applied by every technician in every company service center. In our rapidly changing industry, the best technicians have up-to-date knowledge on current trends and techniques they can apply to enhance your production success.

The best tooling value can only be accomplished through precision service which maximizes the total service cycles and the overall productivity of each tool. Precision tool service will also yield longer service life between sharpening or repair, resulting in fewer tool changes, less machine downtime and improved productivity.

About Leitz Service >

Leitz has a network of 180+ company-owned service centers around the world, and 8 regional service centers in North America alone. Each service center provides complete tool sharpening and repair services plus convenient pick-up and timely delivery of customer tooling. We continuously upgrade our service center equipment to ensure the most precise tool reconditioning and repair services possible. Our experienced tooling technicians are the best in the world and provide the best possible tooling value to our customers. Our experience allows us to properly service any “safe” tool regardless of original manufacturer.

Let’s talk about your tooling service program and how Leitz can impact your efficiency and productivity >>. 

Tooling Spotlight: Diamond Routers

In our tooling spotlight, we break down what you need to know about our most effective tooling solutions. This MVP is our line of Diamond Routers.

The Tool:

Leitz Diamond Routers perform at high processing speeds, equal to or more than comparable solid carbide tools–offering greatly improved service life.

Recent advancements in tool design and construction have allowed Leitz to expand the small diameter diamond routing and nesting tools to 2+2 and 3+3 wing design.

Available in diameters as small as 3/8″ and in various cutting lengths, Diamond Routers will greatly enhance most CNC nesting and sizing applications.woodworking tools, diamond tooling, routers, tooling, leitz

What makes it better:

  • A wide variety of specifications available
  • Technical and economic superiority in critical tests with leading machining center manufacturers
  • Significantly longer tool life
  • Fewer tool changes
  • Optimized machine throughput

When to use it:

With CNC and other precision machining. Optimize performance with the Leitz ThermoGrip™ heat shrink tool holding system.

Diamaster PRO Z1+1

 

·       Entry level for lower production requirements

·       Useful for all company sizes

Diamaster PRO Z2+2

 

·       Economic solution for increased performance requirements

·       Optimum price to performance ratio

Diamaster PRO3  Z3+3 – Nesting

 

·        High-performance tool for nesting applications

·       True 3-wing router bits provide continuous cut quality

Diamaster PLUS Z1+1

 

·       Recommended for composite materials

·       Ideal for various non-wood applications

Diamaster QUATTRO Z2+2

 

·       Standard tool for most industrial applications

·       Ideal for both pre- and finish cutting

Diamaster PLUS Z3+3

 

·       Standard for industrial users with high-performance requirements

·       High feed speeds with excellent finish quality

Diamaster PLUS3 Z3+3 ·       The choice for industrial pre- and finish cutting

·       True 3-wing design for continuous cut quality and maximum performance

The results:

All the benefits of Diamond Tooling, including longer tool life, fewer tool changes, and optimized machine throughput, combined with a wide variety of cutting lengths and size options results in increased performance, cost savings, and a tear-free and chip-free finish.

Add this MVP to your line-up:

Download our Diamond Routers brochure.

Take advantage of our current promotion on Diamond Routers and ThermoGrip™, now through the end of 2018.

Contact your local Leitz consultant at (800) 253-6070, or fill out the form below, and we’ll get in touch.

A Year of Tooling Innovation – Looking Back at 2017

What a great year it has been! Thank you to our customers, partners, and employees for making 2017 another banner year for Leitz USA. We’re looking back at our top moments in 2017, the posts and stories that you liked the most, and looking forward to another great year in 2018.

Intelligent Tooling took the stage at Ligna 2017 and will continue to be a factor for innovation in 2018 and beyond. Mike Lind, Leitz CEO, discusses the role of the tool maker in intelligent tooling and how intelligent tooling benefits production with CCI media editor Karl Forth in this webinar originally recorded in June.

Continue reading “A Year of Tooling Innovation – Looking Back at 2017”