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By Michael JacksonMethods for making holes andcutouts in non-metallic enclosuresW h e n I t ’ sMetal Halide,Make SureIt’sVentureDrilling composite glass fiber material can be difficultand, for some, a mystery. In fact, the ability toaccurately drill holes in this material has been thesubject of numerous articles and How-To demonstrations.Composites offer the benefits of part integration and minimizationalong with substantial savings in weight. Alongwith this is a reduction in the requirements for machiningoperations that need to be performed to complete anassembly.However, not all drilling and cutting operations can becompletely avoided, but there are several types of machiningoperations that can be performed on composites, suchas turning, drilling, routing, trimming, sanding and milling.Most of these operations are similar to metal removaltechniques but some differences need to be addressed tomake clean, high-quality holes and cutouts in composites.Delamination of the outer surface and glass fibers directlybelow the surface are the main failure modes when holesor cutouts are improperly drilled or cut out. Most timesexcessive edge chipping around the perimeter of the cutoutor hole is due to improper tools used and methods applied.Other times excessive fiber pulls or attached fibers notsheared off during the cutting or turning process can alsocause delamination failure from the tearing action duringmaterial removal. Improper tools used and/or methodsare also a culprit of this failure mode. All these can lead todownstream assembly and functionality problems, and anaesthetically unappealing result when taken to the extreme.The most common source of failure when making holes inan enclosure is a dull cutting tool. Dull tools tend to rip ortear the material rather than cut or shear the material and glassfibers. In fact, it is the glass fibers themselves that are often theculprit, as they are very abrasive and can dull a tool quickly.This is why a little planning and understanding of the propermethods for machining composites upfront can make all thedifference in the final outcome of the operation.Now, let’s take a look at some of the following methodsfor making holes or cutouts in non-metallic enclosures.Hole Saw. The easiest and least complex method providingan opening in a composite enclosure is to use a fine-toothedhole saw. You must first layout the size and location of thecutout, pre-drill a small hole in the centre within the cutoutarea for the hole saw to start, then carefully cut out thearea to be removed. This is more time consuming and theleast accurate method of the ones we’ll discuss, but can beaccomplished in almost any environment.Keeping the saw perpendicular to the cutting surface,maintaining a consistent sawing acting and using a diamondimpregnatedhole saw or fine-toothed saw will provide thehighest-quality cutout with minimal edge chipping.Drilling, Boring. Putting round holes in enclosure wallsor through the enclosure door is the most common type ofcutout used to provide entry into an enclosure and accessto the components housed within. The most common toolused is the standard twist drill. A recommended tool wouldbe a carbide-tipped or PCD diamond-tipped tool that willmaintain a sharp cutting edge. (HSS tools will also workbut they become dull very quickly, resulting in excessiveedge chipping and a poor-looking hole.) Use high RPMsand low feed rates with your drill, as this reduces the chippingaround the cutout. The single-most important factor,though, is keeping your tool very sharp.Drill geometry and feed rates are the largest contributingfactors when drilling composites. Using a drill with a positiverake angle and thin/split points can help reduce cutting pressureand, thus, delamination at both entrance and exit. Feedrates must also be constant and may even be reduced uponexiting from a hole to reduce flexing of the part when the drillexits. Using a solid back surface to support the part when drillingcan also aid in reducing delamination and chipping.Routing. A third method is to use a carbide router bit androuter. This method produces very clean holes and cutoutsbut also requires the holes and cutouts to be manually laidout beforehand, as well as a steady hand to stay within thelayout lines. The use of a jig or fixture to help guide therouter is helpful for keeping straight edges and clean cutouts.The use of diamond-impregnated router bits is preferredfor longevity, but carbide bits will work just as well.Similar to routing, jigsaws can also be used. Again, diamond-impregnatedcutters are preferred, but fine-toothedcutters can also be used.Punching. A fourth method is to use a standard hole punchsimilar to what you would use with metal boxes. This producesa good clean hole but can leave chipped edges whenthe punch is dull. Again, maintaining sharp tools is essentialto producing clean cutouts. A pilot hole is required beforeusing a standard hole punch. Manual or hydraulic punchactuators can both be used with composite materials. Punchpress-type manufacturing equipment can be employedwhen production volumes warrant. Proper support andsharp tools are necessary to produce chip-free, clean holes.Alternative methods. Some additional methods sometimesused to machine composites are waterjet and laser cutting.Both methods produce very accurate, clean holes orcutouts, but also require a high capital investment in bothequipment and employee training.In waterjet cutting, a high velocity stream of waterand abrasive material is forced through a small diameter(0.010-in.) jet. The stream of water quickly erodes the materialwith water pressures up to 60,000 psi and 2600 ft/s.Laser cutting uses a concentrated raw light beam focusedonto the part being cut. The cutting operation takes placeby local melting as in thermoplastics, and vaporization andchemical degradation as in composites and thermosets.That’s the hole storyWhile there are several suitable ways of producing holesand cutouts in non-metallic enclosures, not every one maybe right for you or the application at hand. Ultimately, letthe work—and your own comfort level—dictate the mostappropriate cutting method.ReferencesMazumdar, Sanjay K., Ph.D., (2002). CompositesManufacturing, CRC Press, Boca Raton, Fla.Michael Jackson has been actively involved in product developmentfor electrical applications at Stahlin Enclosures over the last eightyears. He possesses a Bachelors degree in Industrial & ManufacturingEngineering Technology and an Associates Degree in MechanicalEngineering. He currently serves on NEMA’s 5EN Enclosures Sectiontechnical committee (NEMA 250), as well as ANSI/IEC 60529 TC70(U.S.) International Committee for Industrial <strong>Electrical</strong> Enclosures.The World Leaderin Metal Halide Technology VentureLighting.comVenture_1_EB_Jan08.indd 1www. mag.com • MARCH 2008 • 1512/21/07 9:51:19 AM

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