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

Tue May 20 05:04:12 AKDT 2008

If it is gonna flex you do not have to push real hard...sounds like it is 
fixed.

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

"Dwayne Brown" <dwaynenancy at suddenlink.net> 
Sent by: nsrca-discussion-bounces at lists.nsrca.org
05/19/2008 10:13 PM
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Re: [NSRCA-discussion] Cutting CF and FG Panels???

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 
To: General 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 
To: General 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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