The Benefits of CoreHog’s Assembly Style Tooling in Composites
Harvey Performance Company brand CoreHog, which focuses on the manufacturing of the world’s most advanced composite and honeycomb core cutting tools, fully stocks an array of “Assembly Style Cutting Tools,” which allow a machinist to build the perfect solution for their specific application’s needs. In doing so, a cutting tool can be optimized for specific materials, densities, and manufacturing styles to increase efficiency, decrease costs, and provide unbelievable machining flexibility.
How Does Assembly Style Tooling Work?
CoreHog’s Assembly Style Tooling works by taking multiple pieces and tool components, and assembling them together to create one finished cutting tool. The concept of assembling a completed tool allows machinists greater flexibility in choosing cutting edges that are best suited for their application or material type. Further, this type of tooling is often utilized by machinists because it’s often a less expensive alternative to solid round, non-assembled tooling, as a machinist would only need to replace the cutting end components when they begin to dull, and not the arbors or shank pieces.
CoreHog’s offering of Assembly Style Tooling includes Small Size, Medium Size, and Large Size Finishing Tools, as well as Valve Cutters and Modular Rebating Tools. The way in which each system is built varies by tool type.
Finishing Tools for Composites
Small Size Finishing Tools
Optimized to machine small, closed features in composites, such as pockets, joggles, and closed walls, Small Size Finishing Tools are engineered for the superior finishing of honeycomb core materials. This configuration includes a Small Coreslicer with three different edge options: Smooth, Sawtooth, or Staggered Tooth, and an optional Small CoreHogger. The right edge style for the Coreslicer depends largely on the material you’re working in. While a Smooth edge style works well in lighter density honeycomb core materials such as Kevlar®, Nomex®, and Aluminum, Sawtooth and Staggered Tooth options work best for honeycomb core materials with densities of 6 pounds or higher, such as aluminum core, Kevlar®, or Nomex®.
Key Benefits: Eliminating the risk of material wrapping around the spindle by disintegrating them as they approach the face of the slicer.
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Medium Size Finishing Tools
Designed for finishing honeycomb core materials, this assembly style CNC tooling is engineered for shaping smaller complex surfaces, bevels, and external radii. For this configuration, a Medium CoreHogger and a Medium Coreslicer must be utilized and fastened with a screw. Similar to the Small Size Finishing Tool options, this assembly can be used with a Smooth, Sawtooth, or Staggered Tooth Coreslicer edge.
Key Benefits: This Medium Size Finishing Tool offering includes both carbide and high speed steel options. The carbide version is uncoated, whereas the high speed steel version is TiCN coated for extended tool life and improved wear resistance.
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Large Size Finishing Tools
Designed to vastly reduce cycle times while finishing honeycomb core materials, this assembly style tooling removes large volumes of material quickly, while providing excellent surface finish and keeping tool pressure and heat low.
Large Size Finishing Tools require a slightly more complex configuration. This type of modular tool features an Arbor, which includes a washer and screw; Large CoreHogger; and Large Coreslicer. For this assembly, four types of Coreslicer edge options are available: Smooth, Sawtooth, Staggered Tooth, or Wavy. Wavy style options are best utilized in heavier density types of Kevlar®, Nomex®, and Aluminum Core, and are engineered to be useful when machining parts that contain bond lines.
Key Benefits: The Arbors in this configuration are heat treated and finish ground for extremely tight tolerances in runout, concentricity, and perpendicularity. With tighter tolerances, harmonics are minimized while longer tool life and better part finish are observed.
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Different from CoreHog’s Finishing Tools, Valve Cutters are assembly tooling engineered for machining honeycomb core materials and finishing thin features, such as bevels and knife edge parts. To build a Valve Cutter, utilize an Arbor, a Valve Stem Slicer, and a screw to fasten the two together. Similar to Small and Medium Size Finishing Tools, the Valve Stem Slicer can feature a Smooth, Sawtooth, or Staggered Tooth edge profile.
Key Benefits: The Stem design of CoreHog’s Valve Stem Arbors is optimized for free flowing applications, eliminating grabbing when machining Honeycomb Core Materials.
Modular Rebating Tools
Machinists may opt to use a Modular Rebating Tool if they are aiming to reduce setup, minimize cost per cutter, and obtain flexibility with varying sandwich panel configurations. For this configuration, an Arbor connects to a Core Insert, Skin Insert, and is fastened with a screw. Here, the Arbor, which features a .500” shank diameter and a 3” overall length, can be paired with multiple sizes of Core Inserts. As of September 2022, CoreHog’s offering of Core Inserts range in diameter from .875” to 1”, with a length of cut spanning from .160” to .312”. All Inserts feature TiAlN coating, which provides high hardness and high temperature resistance. Finally, the Skin Insert features a ½” diameter, and provides a machinist with the option of DLC or CVD Coating. While DLC coating provides optimal performance, true crystalline CVD diamond coating works to significantly extend tool life.
Key Benefits: The complex geometry of Sandwich Panel Cutters – Arbors helps to reduce tearing, flagging, and fuzz, while providing a rebated area to allow for edge filling or fasteners, later on.
For more information on CoreHog’s Assembly Style Tooling, visit its website at corehog.com.