By Dravis - 8/14/2012 10:17:06 PM
Hi,
I have just ordered a piece of the smallest cell honeycomb, but for one of my projects I would really like to have the material as this as 4 - 5 mm ..
Do you have any suggestions as to how I might machine it thinner?
I was considering cutting out a small section of the un-expanded stock, and then making a jig to told the piece compressed, while milling it thinner on my mill.
Does that sound like a feasible method?
Also, do you have any experience with how titanium bonds to (and into) Epoxy based composites, are you aware of any "pitfalls" with this metal?
I have successfully bonded aluminium before, using West Systems Resins, and Ti should be similar, but I'm wondering about your High Temp resin?
Cheers
Dravis
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By Dravis - 8/29/2013 12:01:59 PM
Hi,
I have been doing some testing on the Alu honeycomb --
Results so far:
I have successfully cut smaller un-expanded pieces of the small cell honeycomb into two layers 4 mm in thickness, by using an ordinary fine toothed hacksaw .. I simply clamp a short piece in my vice (in the direction of expansion) and allow about 5 mm to stick out, then cut this lenght, and move the piece up another 5 mm, and so on.. as soon as about 5 mm i free above the hacksaw blade, I put a small c-clamp on above the hacksaw blade.
This produces two pieces of thinner honeycomb, but with an uneven, rough finish on one side... i then clamp the piece flat in the vice and simply sand it nice and flat on the rough hacksaw cut side..
For precision parts I use my milling machine, to ensure perfectly even thickness.
A 4 mm test piece bonded between two layers of 3x 200 g carbon supported a weight of more than 60 kg per square cm, with no deformation
Permanent deformation did not occur until the load surface was reduced to less than 1 square cm with 70+ kg on one point.
The 6 cm long piece did not crack or deform permanently when clamped by 1 cm at one side and loaded with 70 kg+ clamped to 1 cm on the other end.
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