[NSRCA-discussion] Cutting CF and FG Panels???

Mon May 19 19:08:59 AKDT 2008

Gray, we have pushed and pushed and all seems strong.  How hard do you flex
the repaired area?  I know "hard" is HARD to define.  Dwayne

-----Original Message-----
From: nsrca-discussion-bounces at lists.nsrca.org
[mailto:nsrca-discussion-bounces at lists.nsrca.org] On Behalf Of Gray E Fowler
Sent: Monday, May 19, 2008 3:59 PM
To: General pattern discussion
Subject: Re: [NSRCA-discussion] Cutting CF and FG Panels???

Dwayne 

Did you "Test Flex" the repaired area? make sure there is no outside skin
buckling before you apply the outside cosmetics. 

Gray Fowler
Senior Principal Chemical Engineer
Radomes and Specialty Apertures
Technical Staff Composites Engineering
Raytheon 

"Dwayne Brown" <dwaynenancy at suddenlink.net> 
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05/19/2008 03:45 PM 

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Re: [NSRCA-discussion] Cutting CF and FG Panels???

Speaking of cutting, Gray, the airplane has had the CF installed.  Now to
microballoon/epoxy the outside, sand, primer and paint.  Thanks again for
the CF.  Dwayne 

-----Original Message-----
From: nsrca-discussion-bounces at lists.nsrca.org
[mailto:nsrca-discussion-bounces at lists.nsrca.org] On Behalf Of Gray E Fowler
Sent: Monday, May 19, 2008 8:24 AM
To: General pattern discussion
Subject: Re: [NSRCA-discussion] Cutting CF and FG Panels??? 

Larry 

It never gets dull, but here at work we break them on occasion...probably
set up wrong. You are set for your entire pattern life...as a matter of fact
people could send stuff to you to cut and you could charge them 50 cents an
inch or so......after 10 years you will break even, just like everyone else
who offers pattern services.

Gray Fowler
Senior Principal Chemical Engineer
Radomes and Specialty Apertures
Technical Staff Composites Engineering
Raytheon 

"Lisa & Larry" <lld613 at psci.net> 
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05/17/2008 12:49 AM 

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Re: [NSRCA-discussion] Cutting CF and FG Panels???

Gray, 

I did get a Tungsten Carbide band saw blade. Mc Master Carr doesn't seem to
carry it. I bought mine at Industrial Carbide Saw out of Louisville, KY.
Custom length and had it in three days. Used it tonight and all I can say is
smooth easy cutting.Very impressive. Thanks for the tip. 

Was a bit pricy, but the weld is guaranteed for life and I don't see me
wearing this blade out. 

Larry Diamond 

  _____  

From: nsrca-discussion-bounces at lists.nsrca.org
[mailto:nsrca-discussion-bounces at lists.nsrca.org] On Behalf Of Gray E Fowler
Sent: Thursday, May 08, 2008 12:34 PM
To: General pattern discussion
Subject: Re: [NSRCA-discussion] Cutting CF and FG Panels??? 

Keith 

Makes sense especially to increase stifness, but I ponder the weight savings
after adding the resin and fiber especially is you are laminating with the
5.7oz 3K plain weave (most standard stuff). It is real easy to get over
strong, and landing gear usually needs a load distribution into the fuse
more than super strong gear plates.  On my firewall, built out of lite ply
by Lance, I used 2oz glass to "Strengthen" the ply..it is a waffle design so
very stiff. The idea being that the fiberglass will help keep the lite ply
from fractures-or waffle delams-disbond. Cannot get 2oz CF and the 1K CF
(4.2 oz)  that we make or canopies and chin cowls out of would be overkill. 
Have you compared weights? that would be interesting. I never have but alway
worried about it. 

How's that Guitar hero frustration game coming along for you? Any cyber
groupies yet or have you not made it to that level...like your son has...or
did you not realize your son was "involved" so to speak.

Gray Fowler
Senior Principal Chemical Engineer
Radomes and Specialty Apertures
Technical Staff Composites Engineering
Raytheon 

"Keith Black" <tkeithblack at gmail.com> 
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05/08/2008 12:17 PM 

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Re: [NSRCA-discussion] Cutting CF and FG Panels???

I often laminate lite ply in situations where I don't think the lite ply
will be strong or stiff enough and I don't want the weight penalty of
aircraft ply. I also have laminated regular aircraft ply to give extra
strength to things like landing gear plates. This allows me to use a thinner
aircraft ply (in my mind anyways). 

Keith Black 
----- Original Message ----- 
From: Gray E Fowler <mailto:gfowler at raytheon.com>  
To: General <mailto:nsrca-discussion at lists.nsrca.org>  pattern discussion 
Sent: Wednesday, May 07, 2008 4:21 PM 
Subject: Re: [NSRCA-discussion] Cutting CF and FG Panels??? 

While at work I find these blades on the machine. Somehow they magically
show up. Where you would get them??? perhaps McMaster Carr 

And what is you application that requires carbon fiber laminated on plywood?

Gray Fowler
Senior Principal Chemical Engineer
Radomes and Specialty Apertures
Technical Staff Composites Engineering
Raytheon 

"Keith Black" <tkeithblack at gmail.com> 
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05/07/2008 03:15 PM 

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Re: [NSRCA-discussion] Cutting CF and FG Panels???

This doesn't sound like something one would find at the local hardware
store. Where can these blades be found? 

BTW, what if you have aircraft ply laminated with carbon fiber? I would
think in this case one would need a blade with teeth. 

Keith Black 
----- Original Message ----- 
From: Gray E Fowler <mailto:gfowler at raytheon.com>  
To: General <mailto:nsrca-discussion at lists.nsrca.org>  pattern discussion 
Sent: Wednesday, May 07, 2008 8:31 AM 
Subject: Re: [NSRCA-discussion] Cutting CF and FG Panels??? 

Larry 

The proper bandsaw blade for composites does not have any teeth on it at
all.  The blade consists of a coating of tungsten carbide bits like rough
sandpaper grit adhered to the leading edge of the band. The blade cuts by
abrasion and will break before it wears out. Any blade with teeth is bad for
composites as it will dull and the teeth can grab and delaminate the
sustrate or your bond to the honeycomb.

Gray Fowler
Senior Principal Chemical Engineer
Radomes and Specialty Apertures
Technical Staff Composites Engineering
Raytheon 

"Lisa & Larry" <lld613 at psci.net> 
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05/06/2008 08:59 PM 

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[NSRCA-discussion] Cutting CF and FG Panels???

What is the best blade to use on a band saw? It has 2 speeds, what is the
best speed (1,450 / 3,000 rpm)?

I need to cut down two 12 x 24 panels and would like a clean edge ( 1/8"
CF/Nomex/CF panel, and a FG/Nomex/FG panel) .

Nope, don't use the band saw much..

Thanks, 

Larry Diamond_______________________________________________
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