In the fields of aerospace, new energy vehicles, etc., the efficient and precise cutting of carbon fiber preforms directly affects the performance and production cost of components. When a certain company processed 6mm thick carbon fiber preforms, the cost remained high due to bottlenecks such as large tool loss and poor edge quality in the traditional cutting process.
Processing background and industry pain points
Carbon fiber preforms need to cut complex internal and external contours, and their high strength and high hardness characteristics put forward strict requirements for processing. Traditional mechanical cutting exposes three major defects:
Frequent chipping of the tool: A single tool can only cut 3-5 pieces, and the cost of consumables soars;
Many burrs on the cutting surface: Edge delamination and fiber drawing problems are prominent, and the rework rate exceeds 40%;
Inefficient: To avoid chipping, the feed speed needs to be reduced, and the processing time of a single piece increases by 30%.
MID solutions: Ultrasonic five-axis linkage technology reshapes the process
In view of the characteristics of carbon fiber, MID launched a customized cutting solution:
Multi-purpose ultrasonic gantry five-axis equipment: Through five-axis linkage, complex contours can be formed in one go, reducing repeated positioning errors;
Ultrasonic cutting dagger knife: 20kHz high-frequency vibration reduces cutting resistance and inhibits tearing between fiber layers;
Intelligent full-cut cutting algorithm: Supports 6mm full-thickness cutting, and tool life is increased by 8 times.
A breakthrough in processing efficiency and quality
Actual verification shows that the new solution has achieved three major changes:
Tool zero chipping: The cutting edge remains intact after cutting 50 pieces continuously;
Edge roughness ≤Ra 3.2μm: The cutting surface can be directly used for precision assembly, eliminating the need for secondary polishing;
Efficiency increased by 35%: By optimizing the vibration frequency and feed matching, the single-piece working hours are compressed to the industry-leading level.
About MID
Founded in 2017, MID focuses on advanced material processing technologies for semiconductors, optics, and medical devices. With a research and development center in Shenzhen, the company integrates ultrasonic machining, multi-axis control, and AI-driven process optimization, serving manufacturers in more than 50 countries.
