Why are Carbon fiber materials difficult to process?

Carbon fiber materials are widely used in aerospace, automotive and other fields due to their high specific strength, high temperature resistance, friction resistance, electrical conductivity, thermal conductivity and corrosion resistance. However, the processing of carbon fiber materials is difficult. Traditional rotary files are easily worn during processing and have a short lifespan. Frequent tool replacement not only increases costs but also affects processing efficiency. At the same time, carbon fiber materials are prone to defects such as delamination and tearing during processing, which has an adverse effect on the quality of the processed surface.

PCD rotary file

PCD rotary file is made of PCD material, which has good hardness, toughness and fatigue resistance, ensuring stable power transmission during high-speed rotation. Special welding process connection ensures the firmness of the connection and stable dynamic balance performance.

Moresuperhard PCD (Polycrystalline Diamond) Rotary File is a high-performance cutting tool designed for precision machining of carbon fiber-reinforced plastics (CFRP) and other advanced composite materials. Engineered with ultra-hard diamond cutting edges, this rotary file offers exceptional wear resistance, ultra-smooth finishes, and extended tool life—especially important in aerospace, automotive, and sporting goods industries where carbon fiber is widely used.

Advantages of PCD roray file for machining Carbon fiber materials

1. Improve tool life: The use of PCD material, combined with optimized cutting edge design, can significantly reduce tool wear when processing carbon fiber, improve tool life, reduce tool replacement frequency, and reduce processing costs.

2. Improve processing surface quality: The unique design effectively reduces defects such as delamination and tearing of carbon fiber materials during processing, improves the flatness and finish of the processed surface, and meets the requirements of high-precision processing.

3. Enhance processing efficiency: The optimized cutting edge design and chip groove structure enable the rotary file to maintain a high cutting speed and feed rate when processing carbon fiber, significantly improving processing efficiency.

What are the advantages of PCD rotary files compared to carbide rotary files?

While tungsten carbide rotary files are commonly used, PCD rotary files outperform them significantly in carbon fiber applications. Here's why Moresuperhard PCD rotary files are the superior choice:

1. Extreme Hardness & Wear Resistance

PCD is second only to natural diamond in hardness. This results in much slower wear rates and longer tool life, especially when working with highly abrasive carbon fiber materials. One PCD tool can replace several tungsten carbide files in heavy-use environments.

2. Superior Surface Finish

The PCD rotary file maintains a razor-sharp cutting edge throughout its service life, delivering precise cuts with minimal fraying or delamination. This is crucial when working with multi-layer composite materials.

3. Improved Efficiency & Cost Saving

Though initially more expensive than carbide tools, PCD rotary files offer a much lower cost per part thanks to fewer tool changes and reduced rework. This leads to higher productivity in both manual and automated machining.

4. Reduced Heat Generation

PCD tools minimize friction and heat buildup, protecting the integrity of composite materials and ensuring safer operations—especially in high-speed, dry-machining environments.