I use standard end mills for cutting carbon fibre sheets. Generally the cutters are 2 to 3 mm diameter, with a flute length of about 8 mm. I use 3- and 4-flute end mills. These work quite well if they are surfaced (TiN) or solid carbide. Uncoated or HSS tooling becomes dull very quickly.
Now I need to work with an aramid composite, where the core is carbon fibre and the outer layers are Kevlar. Overall thickness is 2.5 to 5.0 mm.
The surface layers are not cutting cleanly - leaving a fine fuzz that is a pain to remove.
The cutter is cooled by airjet, spindle speed is at the maximum setting of 10,000 RPM. I have tried feed rates from 5 mm/sec to 25 mm/sec at various cutting depths without any significant improvement.
How could I improve the quality of the cut? I would like to try alternative types of cutters or machining strategies.