Master the unmachinable with CoroMill® Plura composite 2P350
Machining composite materials remains one of manufacturing’s toughest challenges. Abrasive fibers, layered structures and sensitivity to heat and vibration often result in unpredictable cutting behavior, delamination, and accelerated tool wear. Their poor thermal conductivity means composites are usually machined dry, making heat even harder to control. So what does it take to machine these materials more efficiently and with greater confidence? Here, our experts in solid carbide end milling tools at Sandvik Coromant explain how.
Composite materials, especially carbon and glass fiber reinforced plastics (CFRP/GFRP), impose unpredictable cutting forces that can vary dramatically depending on fiber direction, resin content and manufacturing method. Conventional tools can dull quickly on hard fibers, while excessive cutting forces or improper geometries often cause delamination or leave uncut fibers. The result is inconsistent performance and elevated scrap rates.
The serrated router, CoroMill® Plura composite 2P350, was developed to address these challenges directly, offering sharper, more durable edges and a geometry optimized for stable, low-defect machining. This is a significant step forward in stability, quality and process security when working in demanding composite applications.
Patented dual cutting mechanism
A crucial feature of CoroMill® Plura Composite 2P350 is its patented serrated geometry, designed to deliver a balanced, scissor-like dual cutting action. This coordinated mechanism effectively clamps and shears the fibers, reducing cutting forces and countering the tendency of composite layers to split and delaminate or produce uncut fibers.
The geometry balances cutting loads across all flutes, preventing any single tooth from taking excessive force. This results in lower and more consistent cutting forces compared to traditional routers, protecting both the tool and the workpiece. Reduced cutting forces also contribute to better surface finish and less risk of delamination or uncut fibers.
By disrupting harmonic vibrations, the geometry also contributes to a more stable and quieter machining process. The controlled cutting action not only improves surface integrity but also enables reliable one-pass machining, supporting both process security and a more comfortable sound level in the workshop.
A grade for abrasive composite environments
The introduction of grade O2AD marks a significant breakthrough for tool life and long-term stability. Composite materials are extremely abrasive, and tools often lose sharpness quickly if not specifically engineered for these conditions. Grade O2AD is developed specifically to combat these challenges, featuring an optimized CVD diamond coating and a tailored substrate that enables strong adhesion between the two. The synergy between the coating and the substrate helps maintain excellent edge-line sharpness for optimal cutting action, ensuring excellent abrasive wear resistance, longer tool life, more predictable performance and less frequent tool changes.
Internal tests and customer evaluations show that grade O2AD can double the tool life compared to the previous grade O12M, delivering clear gains in productivity and cost efficiency.
Performance in aerospace and beyond
CoroMill® Plura composite 2P350 is particularly well-suited for the aerospace industry, where composite components must meet strict structural and dimensional requirements. The tool has shown strong performance when machining fuselage frames, wings, stabilizers, spars, ribs, floor beams and other critical structures. The tool’s reliable behavior across slotting, ramping and edging operations contributes to a more predictable machining process with less scrap and rework, which is especially valuable in high-value production environments. By enabling one-pass machining in these operations, it reduces the need for secondary operations. Simultaneously, the large flute volume enables efficient chip evacuation and high material removal rates, boosting productivity.
Beyond aerospace, industries such as automotive, defense, space and maritime benefit from the tool’s controlled cutting and consistent results, making this tool a versatile option for a broad range of applications.
Beyond aerospace, broader industries such as automotive benefit from the tool’s controlled cutting and consistent results, making this tool a suitable option for a broad range of industry segments and applications.
The full portfolio
CoroMill® Plura composite 2P350 with grade O2AD represents a major advancement in composite machining tooling. Through its patented cutting geometry, optimized diamond coating and proven performance across demanding applications, it provides the process security and productivity needed to machine one of the industry's most challenging materials.
For even more specialized composite operations, CoroMill® Plura composite 2P350 is supported by a wider portfolio. CoroMill® Plura composite 2P460 compression router is ideal for components with woven glass layers on both sides, providing excellent vibration control in thicker materials through its overlapping flute design. For finishing operations, CoroMill® Plura composite 2P050/2P051 low helix routers enable smooth, burr-free edges in composites and CFRPs, with right/left helix options for improved fixture stability and high-feed capability.
Together, these tools form a complete portfolio designed to help manufacturers achieve consistent, high-quality results across the full spectrum of composite machining challenges.
Solid carbide end mill for composite machining
CoroMill® Plura composite
Machining composite materials is a battle of unpredictable forces, heat sensitivity and rapid tool wear. For successful machining, sharp and controlled cutting is required to avoid delamination and vibration.
