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Machining VYCOM Tool Selection for General Routing In the general machining of Seaboard, Designboard and Playboard, the right tool for the job involves the use of up-cut spiral router bits to evacuate chip and maximize finish. The tools of choice include an Onsrud Cutter 52-080 and 63-725. These 1/4 inch diameter tools tested in 1/2” Seaboard, Designboard and Playboard provided excellent finish in partial, and full depth cuts. The 52-080 performed best in full depth cuts, while the 63-724 was quieter, which translates into less vibration and heat with increased tool life. The feed rate for the material was 100-200 inches per minute at 18,000 RPM, which reflects a chip load range of approximately 0.006” to 0.011” inches. If the user were limited to a single tool selection, the 63-725 would represent the best all around tool for the job. Both of these router tools, unlike end mills, provide the necessary edge sharpness to alleviate the “fuzzing” or “hairing” sometimes associated with machining this material. Drilling In order to prevent chip wrap in soft plastics, and crazing in hard materials, it is recommended that the point angle is set between 90° - 110° degrees (Figure 1c). Onsrud Cutter has developed a drill with a 60° degree point and a flat rake face providing the best plunge point in a wide variety of plastics. The point s style creates a chip in soft plastics that is easily ejected and allows the use of normal drilling routines during programming. Material such as polyethylene required a peck drilling cycle to prevent the formation of long chips that would wrap around the drill. The elimination of pecking drilling procedures in a program can lead to reduced cycle time and can increase cutter life significantly. Figure 1c TIP For best results, drill bits should be kept sharp at all times. Avoid straight plunge cuts into the material. Program the tool path to ramp into or enter the material from the side providing a path for the chips to be ejected. Maximize dust collection to evacuate gummy chip produced by softer plastics. Chapter 1 Copyright 2013 Vycom 09PDF Image | FABRICATION MANUAL HDPE
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