Drilling through multimaterial complex holes


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Jones
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I'm looking to join two matching 3d shaped carbon fiber sheets together with M4 screws and threaded inserts (the threaded insert can't stick out on either side) and I need a few hundred of those holes...

The stack I will drill through is:
one sheets is 1mm carbon and glass and the other is 1.5mm carbon, 5mm solid epoxy (core), 1.5mm glass.

The shape is not flat so a drillpress is not an option. The space for a drill cup is also probably to small. But on the other hand perfect 90 degree holes are not necessarily needed. It might also be hard/inconvenient to strap a waste board on the backside to prevent chip-out/blowouts because of the shape

So my question is how do I tackle this the best possible way?
I guess making a jig to locate and clamp down the two pieces in place.
Find a suitable M4 drillbit that lasts, ideally one that doesn't produce blow-outs and is self starting
Drill through both sheets.
Enlarge the hole in the thicker carbon piece and find a suitable threaded insert.
Hum...

 






Edited 6 Years Ago by Jones
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Steve Broad
Steve Broad
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Jones - 1/22/2019 9:56:06 AM
I'm looking to join two matching 3d shaped carbon fiber sheets together with M4 screws and threaded inserts (the threaded insert can't stick out on either side) and I need a few hundred of those holes...

The stack I will drill through is:
one sheets is 1mm carbon and glass and the other is 1.5mm carbon, 5mm solid epoxy (core), 1.5mm glass.

The shape is not flat so a drillpress is not an option. The space for a drill cup is also probably to small. But on the other hand perfect 90 degree holes are not necessarily needed. It might also be hard/inconvenient to strap a waste board on the backside to prevent chip-out/blowouts because of the shape

So my question is how do I tackle this the best possible way?
I guess making a jig to locate and clamp down the two pieces in place.
Find a suitable M4 drillbit that lasts, ideally one that doesn't produce blow-outs and is self starting
Drill through both sheets.
Enlarge the hole in the thicker carbon piece and find a suitable threaded insert.
Hum...

 






Some photos would be very useful :-)

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