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

"Sapere Aude"... Dare to KNOW!

The written word is the only truly efficient vehicle for transmitting a complex concept from mind to mind...

103% of all people do not understand statistics...

Do not adjust our mind, theres a fault in reality :-)

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.

"Sapere Aude"... Dare to KNOW!

The written word is the only truly efficient vehicle for transmitting a complex concept from mind to mind...

103% of all people do not understand statistics...

Do not adjust our mind, theres a fault in reality :-)