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Machinists Toolkit

The World's Leading Manufacturer of Plastic Stock Shapes

Plastic increasingly replace traditional materials such as bronze, stainless steel, cast iron and ceramics. They are chosen for improved performance and cost reduction. Plastic can:

  • Reduce Weight
  • Eliminate Corrosion
  • Improve Wear Performance in Unlubricated Conditions
  • Reduce Noise
  • Increase Part Life
  • Insulate & Isolate, Both Thermally and Electrically

Typical applications for engineering plastics range from semiconductor processing equipment components to heavy equipment wear parts, to food processing industry components.

Machinable plastic stock shapes (sheet, rod, and tubular bar) are now available in more the 50 grades, spanning the performance/price randge of both ferrous and non-ferrous metals to specialty ceramics. Plastics capable of long term service up to 800° F (425° C), with short term exposures to 1,000° F (540° C) are now available. As the number of material options has increased, so has the difficulty of selecting the right material for a specific application.

  • keyboard_arrow_downGeneral

    When machining plastic stock shapes, remember...

    • Thermal expansion is up to 10 times greater with plastics than metals
    • Plastics lose heat more slowly than metals, so avoid localized overheating
    • Softening (and melting) temperatures of plastics are much lower than metals
    • Plastics are much more elastic than metals

    Because of these differences, you may wish to experiment with fixtures, tool materials, angles,speeds and feed rates to obtain optimum results.

    Getting Started

    • Positive tool geometries with ground peripheries are recommended
    • Carbide tooling with ground top surfaces is suggested for optimum tool life and surface finish. Polycrystalline diamond tooling provides optimum surface finish when machining Duratron® PBI.
    • Use adequate chip clearance to prevent clogging
    • Adequately support the material to restrict deflection away from the cutting tool
  • keyboard_arrow_downCoolants

    Coolants
    Coolants are generally not required for most machining operations (not including drilling and parting off). However, for optimum surface finishes and close tolerances, non-aromatic, water soluble coolants are suggested. Spray mists and pressurized air are very effective means of cooling the cutting interface. General purpose petroleum based cutting fluids, although suitable for many metals and plastics, may contribute to stress cracking of amorphous plastics such as Quadrant® PC 1000, Quadrant® PSU, Duratron® U1000 PEI, and Quadrant® PPSU.

    Machining Tips

    • Coolants are strongly suggested during drilling operations, especially with notch sensitive materials such as Ertalyte® PET-P, Duratron® PAI, Duratron® PBI and glass or carbon reinforced products.
    • In addition to minimizing localized part heat-up, coolants prolong tool life. Two (flood) coolants suitable for most plastics are Trim E190 and Tim Sol LC SF (Master Chemical Corporation-Perrysburg, OH).
  • keyboard_arrow_downThreading & Tapping

    Threading and Tapping

    Threading should be done by single point using a carbide insert and taking four to five 0.001" passes at the end. Coolant usage is suggested. For tapping, use the specified drill with a two flute tap. Remember to keep the tap clean of chip build-up. Use of a coolant during tapping is also suggested.

  • keyboard_arrow_downMilling

    Milling

    Sufficient fixturing allows fast table travel and high spindle speeds when end milling plastics. When face milling, use positive geometry cutter bodies.

    Milling Tips

     

    Climb milling is recommended over conventional milling (see Diagrams).

     

    End Milling / Slotting Guidelines

    TIVAR® UHMW-PE, Nylatron® PA6, and Acetron® POM-H based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Proteus® PP, Quadrant® PC 1000, Quadrant® PSU, Quadrant® PPSU & Duratron® PEI based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Ertalyte® PET-P based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Symalit® PVDF and ECTFE based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Ketron® PEEK based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Fluorosint® PTFE based materials (1)

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    (1) For Fluorosint MT-01 PTFE contact Quadrant's Technical Service team

    Techtron® PPS based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Duratron® PAI and Duratron® PI based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Duratron® PBI based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.015

    Speed Feet / Min.

    250-350

    Feed In./ Tooth

    0.002


    Face Milling
    (C-2, Carbide Tool)


    TIVAR® UHMW-PE, Nylatron® PA6, and Acetron® POM-H based materials

    Depth of Cut

    0.150
    0.060

    Speed Feet / Min.

    1300-1500
    1500-2000

    Feed In./ Tooth

    0.020
    0.005

    Proteus® PP, Quadrant® PC 1000, Quadrant® PSU, Quadrant® PPSU & Duratron® PEI based materials

    Depth of Cut

    0.150
    0.060

    Speed Feet / Min.

    1300-1500
    1500-2000

    Feed In./ Tooth

    0.020
    0.005

    Ertalyte® PET-P based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Symalit® PVDF and ECTFE based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.250
    0.050

    Speed Feet / Min.

    270-450
    300-500

    Feed In./ Tooth

    0.002, 0.003, 0.005
    0.008, 0.001, 0.002, 0.004

    Ketron® PEEK based materials

    Depth of Cut

    0.150
    0.060

    Speed Feet / Min.

    500-750

    Feed In./ Tooth

    0.020
    0.005

    Fluorosint® PTFE based materials (1)

    Depth of Cut

    0.150
    0.060

    Speed Feet / Min.

    500-700
    550-750

    Feed In./ Tooth

    0.010
    0.005

    (1) For Fluorosint MT-01 PTFE contact Quadrant's Technical Service team

    Techtron® PPS based materials

    Depth of Cut

    0.150
    0.060

    Speed Feet / Min.

    1300-1500
    1500-2000

    Feed In./ Tooth

    0.020
    0.005

    Duratron® PAI and Duratron® PI based materials

    Depth of Cut

    0.035

    Speed Feet / Min.

    500-800

    Feed In./ Tooth

    .006-.035

    Duratron® PBI based materials

    Recommend Carbide

    1/4", 1/2", 3/4", 1", 2"
    1/4", 1/2", 3/4"

    Depth of Cut

    0.015

    Speed Feet / Min.

    250-350

    Feed In./ Tooth

    0.002

  • keyboard_arrow_downSawing

    Sawing

    Band sawing is versatile for straight, continuous curves or irregular cuts. Table saws are convenient for straight cuts and can be used to cut multiple thicknesses and thicker cross sections up to 4" with adequate horsepower. Saw blades should be selected based upon material thickness and surface finish desired.

    Sawing Tips

    • Rip and combination blades with a 0° tooth rake and 3° to 10° tooth set are best for general sawing in order to reduce frictional heat.
    • Hollow ground circular saw blades without set will yield smooth cuts up to 3/4" thickness.
    • Tungsten carbide blades wear well and provide optimum surface finishes.

    TIVAR® UHMW-PE, Nylatron® PA6, and Acetron® POM-H based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 3,000 2,500 2,000 1,500
    Pitch Teeth/In. 10-14 6 3 3
    Tooth Form

    Precision

    Butress

    Proteus® PP, Quadrant® PC 1000, Quadrant® PSU, Quadrant® PPSU & Duratron® PEI based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 4,000 3,500 3,000 2,500
    Pitch Teeth/In. 10-14 6 3 3
    Tooth Form

    Precision

    Butress

    Ertalyte® PET-P based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 3,000 2,500 2,000 1,500
    Pitch Teeth/In. 10-14 6 3 3
    Tooth Form

    Precision

    Butress

    Symalit® PVDF and ECTFE based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 3,000 2,500 2,000 1,500
    Pitch Teeth/In. 10-14 6 3 3
    Tooth Form

    Precision

    Butress

    Ketron® PEEK based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 4,000 3,500 3,000 2,500
    Pitch Teeth/In. 8-14 6-8 3 3
    Tooth Form

    Precision

    Butress

    Fluorosint® PTFE based materials (1)

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 3,000 2,500 2,000 1,500
    Pitch Teeth/In. 8-14 6-8 3 3
    Tooth Form

    Precision

    Butress

    (1) For Fluorosint MT-01 PTFE contact Quadrant's Technical Service team

    Techtron® PPS based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 3,000 2,500 2,000 1,500
    Pitch Teeth/In. 8-14 6-8 3 3
    Tooth Form

    Precision

    Butress

    Duratron® PAI and Duratron® PI based materials

    Material Thickness <.5" .5"-1.0" 1.0"-3.0" >3.0"
    Band Speeds Ft./Min. 5,000 4,300 3,500 3,000
    Pitch Teeth/In. 8-14 6-8 3 3
    Tooth Form

    Precision

    Butress

    Duratron® PBI based materials

    Material Thickness

    <.375"-1.0"

    1.0"-2.0"

    Band Speeds Ft./Min.

    3,000

    1,500

    Pitch Teeth/In.

    10

    10

    Tooth Form

    Precision

    Butress

  • keyboard_arrow_downDrilling

    Drilling

    The insulating characteristics of plastics require consideration during drilling operations, especially when hole depths are greater than twice the diameter.

    Small diameter holes
    (1/32" to 1" diameter)

    High speed steel twist drills are generally sufficient for small holes. To improve swarf removal, frequent pullout (peck drilling) is suggested. A slow spiral (low helix) drill will allow for better swarf removal.

    Large diameter holes
    (1" diameter and larger)

    A slow spiral (low helix) drill or general purpose drill bit ground to a 118° point angle with 9° to 15° lip clearance is recommended. The lip rake should be ground (dubbed off) and the web thinned.

    It is generally best to drill a pilot hole (maximum 1/2" diameter) using 600 to 1,000 rpm and a positive feed of 0.005" to 0.015" per revolution. Avoid hand feeding because of the drill grabbing which can result in microcracks forming. Secondary drilling at 400 to 500 rpm at 0.008 to 0.020" per revolution is required to expand the hole to larger diameters.

    A two step process using both drilling and boring can be used on notch sensitive materials such as Ertalyte® PET-P and glass reinforced materials. This minimizes heat build-up and reduces the risk of cracking.

    1. Drill a 1" diameter hole using an insert drill at 500 to 800 rpm with a feed rate of 0.005" to 0.015" per revolution.

    2. Bore the hole to final dimensions using a boring bar with carbide insert with 0.015" to 0.030" radii at 500 to 1,000 rpm and a feed rate of 0.005 to 0.010" per revolution.

    Drilling Guidelines

    Nominal Hole Diameter

    Feed In./Rev.

    TIVAR® UHMW-PE, Nylatron® PA6, and Acetron® POM-H based materials

    1/16" to 1/4"
    1/2" to 3/4"
    1" to >2"

    .007 - .015
    .015 - .025
    .020 - .050

    Proteus® PP, Quadrant® PC 1000, Quadrant® PSU, Quadrant® PPSU & Duratron® PEI based materials

    1/16" to 1/4"
    1/2" to 3/4"
    1" to >2"

    .007 - .015
    .015 - .025
    .020 - .050

    Ertalyte® PET-P based materials

    1/16", 1/8", 1/4"
    1/2", 3/4"
    1", 1-1/2", 2", >2"

    002 - .005
    .015 - .025
    .020 - .050
    Symalit PVDF & ECTFE

    1/16" to 1/4"
    1/2" to 3/4"
    1" to >2"

    .002 - .005
    .015 - .025
    .020 - .050

    Ketron® PEEK based materials

    1/16", 1/8", 1/4"
    1/2", 3/4"
    1", 1-1/2", 2", >2

    .007 - .015
    .015 - .025
    .020 - .050

    Fluorosint® PTFE based materials (1)

    1/16", 1/8", 1/4"
    1/2", 3/4"
    1", 1-1/2", 2", >2"

    .007 - .015
    .015 - .025
    .020 - .050

    Techtron® PPS based materials

    1/16", 1/8", 1/4"
    1/2", 3/4"
    1", 1-1/2", 2", >2"

    .007 - .015
    .015 - .025
    .020 - .050

    Duratron® PAI and Duratron® PI based materials

    1/16", 1/8", 1/4"
    1/2", 3/4"
    1", 1-1/2", 2", >2"

    .007 - .015
    .015 - .025
    .020 - .050

    Duratron® PBI based materials

    1/2" or larger

    .015 - .025

    (1) For Fluorosint MT-01 PTFE contact Quadrant's Technical Service team

  • keyboard_arrow_downTurning

    Turning

    Turning operations require inserts with positive geometries and ground peripheries. Ground peripheries and polished top surfaces generally reduce material build-up on the insert, improving the attainable surface finish. A fine grained C-2 carbide is generally best for turning operations.

    Turning Tips

    Inserts with positive geometries and ground peripheries.

    • Use recommended Turning Tooling Geometry (see Diagrams).

    Turning Guidelines
    (C-2, Carbide Tool)

    TIVAR® UHMW-PE, Nylatron® PA6, and Acetron® POM-H based materials

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    500-600
    600-700

    Feed In./ Tooth

    .010-.015
    .004-.007

    Proteus® PP, Quadrant® PC 1000, Quadrant® PSU, Quadrant® PPSU & Duratron® PEI based materials

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    500-600
    600-700

    Feed In./ Tooth

    .010-.015
    .004-.007

    Ertalyte® PET-P based materials

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    500-600
    600-700

    Feed In./ Tooth

    .010-.015
    .004-.007

    Syamlit® PVDF and ECTFE based materials

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    500-600
    600-700

    Feed In./ Tooth

    .010-.015
    .004-.007

    Ketron® PEEK based materials

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    350-500
    500-600

    Feed In./ Tooth

    .010-.015
    .003-.008

    Fluorosint® PTFE based materials (1)

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    600-1000
    600-700

    Feed In./ Tooth

    .010-.016
    .004-.007

    (1) For Fluorosint MT-01 PTFE contact Quadrant's Technical Service team

    Techtron® PPS based materials

    Depth of Cut

    0.150" deep cut
    0.025" deep cut

    Speed Feet / Min.

    100-300
    250-500

    Feed In./ Tooth

    .010-.020
    .005-.010

    Duratron® PAI and Duratron® PI based materials

    Depth of Cut

    0.025" deep cut

    Speed Feet / Min.

    300-800

    Feed In./ Tooth

    .004-.025

    Duratron® PBI based materials

    Depth of Cut

    0.025" deep cut

    Speed Feet / Min.

    150-225

    Feed In./ Tooth

    .002-.006

  • keyboard_arrow_downAnnealing

    Annealing

    When should parts be annealed after machining to ensure optimum part performance?

    Experience has shown us that very few machined plastic parts require annealing after machining to meet dimensional or performance requirements.

    All Quadrant stock shapes are annealed using a proprietary stress relieving cycle to minimize any internal stresses that may result from the manufacturing process. This assures you that the material will remain dimensionally stable during and after machining.

    Machined-in stress can reduce part performance and lead to premature part failure. To prevent machined-in stress, it is important to identify the causes.

    Machined-in stress is created by:

    • Using dull or improperly designed tooling
    • Excessive heat - generated from inappropriate speeds and feed rates
    • Machining away large volumes of material -usually from one side of the stock shape

    To reduce the potential for machined-in stress, review the fabrication guidelines for the specific material. Recognize that guidelines change as the material type changes.

    Post Maching
    Benefits of Post-Machining Annealing

    Improved Chemical Resistance
    Polycarbonate, polysulfone, and Ultem® PEI, like many amorphous (transparent) plastics may be annealed to minimize stress crazing. Duratron® PAI also benefits from post machining annealing. Annealing finished parts becomes more important as machining volume increases. Annealing after machining reduces "machined-in" stresses that can contribute to premature failure.

    Better Flatness and Tighter Tolerance Capability
    Extremely close-tolerance parts requiring precision flatness and nonsymmetrical contour sometimes require intermediate annealing between machining operations. Improved flatness can be attained by rough machining, annealing and finish machining with a very light cut. Balanced machining on both sides of the shape centerline can also help prevent warpage.

    Improved Wear Resistance
    Extruded or injection molded Duratron® PAI parts that require high PV's or the lowest possible wear factor benefit from an additional cure after machining. This curing process optimizes the wear properties. Only PAI benefits from such a cycle.

    Annealing Tips

    • Ensure parts are fixtured to desired shape or flatness.
    • Do not unfixture until parts have completed entire cycle and are cool to the touch.
    • Do not take short-cuts.

    Finish machining of critical dimensions should be performed after annealing.

    Important: Annealing cycles have been generalized to apply to a majority of machined parts. Changes in heat up and hold time may be possible if cross sections are thin. Parts should be fixtured during annealing to prevent distortion.

    Post Machining Air Annealing Guidelines

    Material

    Heat Up

    Hold

    Cool Down

    Environment

    Type 6 Nylons

    4 hours to 300° F

    30 minutes per 1/4" thickness

    50° F per hour

    Oil or Nitrogen

    Type 6/6 Nylons 4 hours to 350° F

    30 minutes per 1/4" thickness

    50° F per hour

    Oil or Nitrogen

    Ertalyte® PET-P 4 hours to 350° F

    30 minutes per 1/4" thickness

    50° F per hour

    Oil or Nitrogen

    Acetron® GP POM-C

    4 hours to 310° F

    30 minutes per 1/4" thickness

    50° F per hour

    Nitrogen or Air

    Acetron® POM-H

    4 hours to 320° F

    30 minutes per 1/4" thickness

    50° F per hour

    Nitrogen or Air

    Quadrant® PC 100  4 hours to 275° F

    30 minutes per 1/4" thickness

    50° F per hour

    Nitrogen or Air

    Quadrant® PSU

    4 hours to 330° F

    30 minutes per 1/4" thickness

    50° F per hour

    Nitrogen or Air

    Quadrant® PPSU

    4 hours to 390° F

    30 minutes per 1/4" thickness

    50° F per hour

    Nitrogen or Air

    Duratron® PEI

    4 hours to 390° F

    30 minutes per 1/4" thickness

    50° F per hour

    Air

    Techtron® PPS

    4 hours to 350° F

    30 minutes per 1/4" thickness

    50° F per hour

    Air

    Ketron® PEEK

    4 hours to 300° F
    4 hours to 375° F

    60 minutes per 1/4" thickness
    60 minutes per 1/4" thickness

    50° F per hour

    Air

    Duratron® PAI

    4 hours to 300° F
    4 hours to 420° F
    4 hours to 470° F
    4 hours to 500° F

    1 day
    1 day
    1 day
    3 to 10 days

    50° F per hour

    Air

    Duratron® PI

    4 hours to 300° F
    4 hours to 450° F
    4 hours to 600° F

    60 minutes per 1/4" thickness
    60 minutes per 1/4" thickness

     

    50° F per hour

    Air

Drilling Troubleshooting
Difficulty Common Cause
Tapered Hole
1.  Incorrectly sharpened drill 
2.  Insufficient clearance 
3.  Feed too heavy
Burnt or Melted Surface
1.  Wrong type drill
2.  Incorrectly sharpened drill
3.  Feed to light
4.  Dull drill
5.  Web too thick
Chipping of Surfaces
1.  Feed too heavy
2.  Clearance too great
3.  Too much rake (thin web as described)
Chatter
1.  Too much clearance
2.  Feed to light
3.  Drill overhang too great
4.  Too much rake (thin web as described)
Feed Marks or Spiral Lines on Inside Diameter
1.  feed too heavy
2.  Drill not centered
3.  Drill ground off-center
Oversize Holes
1.  Drill ground off-center
2.  Web too thick
3.  Insufficient clearance
4.  Feed rate too heavy
5.  Point angle too great
Undersize Holes
1.  Dull drill
2.  Too much clearance
3.  Point angle too small
Holes Not Concentric
1.  Feed too heavy
2.  Spindle speed too slow
3.  Drill enters next piece too far
4.  Cut-off tool leaves nib, which deflects drill
5.  Web too thick
6.  Drill speed too heavy at start
7.  Drill not mounted on center
8.  Drill not sharpened correctly
Burr at Cut-off
1.  Dull cut-off tool
2.  Drill does not pass completely through piece
Rapid Dulling of Drill
1.  Feed too light of drill
2.  Spindle speed too fast
3.  Insufficient lubrication from coolant
Turning and Boring Troubleshooting
Difficulty Common Cause
Melted Surface
1.  Tool dull or heel rubbing
2.  Insufficient side clearance
3.  Feed rate too slow
4.  Spindle speed too fast
Rough Finish
1.  Feed too heavy

2. 

Incorrect clearance angles
3.  Sharp point on tool (slight nose radius required)
4.  Tool not mounted on center
Burrs at Edge of Cut
1.  No chamfer provided at sharp corners
2.  Dull tool
3.  Insufficient side clearance

4. 

Lead angle not provided on tool (tool should ease out of cut gradually, not suddenly)
Cracking or Chipping of Corners
1.  Too much positive rake on tool
2.  Tool not eased into cut (tool suddenly hits work)
3.  Dull tool
4.  Tool mounted below center
5.  Sharp point on tool (slight nose radius required)
Chatter
1.  Too much nose radius on tool
2.  Tool not mounted solidly
3.  Material not supported properly
4.  Width of cut too wide (use 2 cuts)
Cutting Off
Difficulty Common Cause
Melted Surface
1.  Dull tool
2.  Insufficient side clearance
3.  Insufficiant coolant supply
Rough Finish
1.  Feed too heavy
2.  Tool improperly sharpened
3.  Cutting edge not honed
Spiral Marks
1.  Tool rubs during its retreat
2.  Burr on point of tool
Concave or Convex Surfaces
1.  Point angle too great
2.  Tool not perpendicular to spindle
3.  Tool deflecting
4.  Feed too heavy
5.  Tool mounted above or below center
Nibs or Burrs at Cut-off Point
1.  Point angle not great enough
2.  Tool dull
3.  Feed too heavy
Burrs on Outside Diameter
1.  No chamber before cut-off diameter
2.  Dull tool
  • keyboard_arrow_downMachining Tips

    • Coolants are strongly suggested during drilling operations, especially with notch sensitive materials such as Ertalyte® PET-P, Duratron® PAI, Duratron® PBI and glass or carbon reinforced products.
    • In addition to minimizing localized part heat-up, coolants prolong tool life. Two (flood) coolants suitable for most plastics are Trim 9106CS (Master Chemical Corporation - Perrysburg, OH) and Polycut (Tulico - Savannah, GA). A generally suitable mist coolant is Astro-Mist 2001A (Monroe Fluid Technology - Hilton, NY).

  • keyboard_arrow_downMilling Tips

    Climb milling is recommended over conventional milling (see Diagrams).

  • keyboard_arrow_downTurning Tips

    Inserts with positive geometries and ground peripheries

     

    • Use recommended Turning Tooling Geometry (see Diagrams).

  • keyboard_arrow_downSawing Tips

    • Rip and combination blades with a 0° tooth rake and 3° to 10° tooth set are best for general sawing in order to reduce frictional heat.
    • Hollow ground circular saw blades without set will yield smooth cuts up to 3/4" thickness.
    • Tungsten carbide blades wear well and provide optimum surface finishes.

  • keyboard_arrow_downDrilling Tips

    Smaller diameter holes

     

    • High speed twist drills
    • Peck drill suggested

     

    Larger diameter holes

     

    • Drill pilot hole
    • Use slow speed spiral drills or inserted drills

  • keyboard_arrow_downAnnealing Tips

    • Ensure parts are fixtured to desired shape or flatness.
    • Do not unfixture until parts have completed entire cycle and are cool to the touch.
    • Do not take short-cuts.
Climb Milling vs. Conventional Milling
Recommended Turning Tooling Geometry

Machinability

Machinability
MaterialRelative Machinability
(1 to 10, 1 = easiest)
Acetron® GP POM-C1
Acetron® POM-H1
Acetron® AF1
Acetron® AF Blend1
Duratron® CU60 PBI10
Duratron® T4203 PAI5
Duratron® T4301 PAI5
Duratron® T4501 PAI6
Duratron® T4503 PAI6
Duratron® T5530 PAI8
Duratron® U1000 PEI7
Duratron® U2300 PEI7
Ertalyte® PET-P2
Ertalyte® TX PET-P2
Fluorosint® MT-01 PTFE3
Fluorosint® 500 PTFE1
Fluorosint® 207 PTFE1
Fluorosint® HPV PTFE1
Ketron® 1000 PEEK5
Ketron® GF30 PEEK7
Ketron® HPV PEEK6
Nylatron® MC901 PA61
Nylatron® MC907 PA61
Nylatron® GS PA661
Nylatron® GSM PA61
Nylatron® GSM Blue PA62
Nylatron® NSM PA62
Quadrant Nylon 101 PA661
Quadrant PC 10002
Quadrant PSU3
Quadrant PPSU3
Techtron® PSBG PPS5
Techtron® PPS3
Techtron® PPS3
Techtron® HPV PPS6
Semitron® MTLS

Follow guidelines for most similar base resins

Base Resin
225POM-C1
410CPEI7
420PEI7
420VPEI7
480PEEK6
490 HRPEEK6
500 HRPTFE1
520 HRPAI6
CMP LL5PET2
CMP XL20PAI10

 

 

Conversions

Fractions

Decimal

MM

1/64

.0156

0.396

1/32

.0312

0.793
3/64

.0468

1.190
1/16 .0625 1.587
5/64

.0781

1.984
3/32 .0937 2.381
7/64

.1093

2.778
1/8

.125

3.175
9/64

.1406

3.571
5/32

.1562

3.968
11/64

.1718

4.365
3/16 .1875 4.762
13/64 .2031 5.159
7/32 .2187 5.556
15/64 .2343 5.953
1/4 .250 6.350
17/64 .2656 6.746
9/32 .2812 7.143
19/64 .2968 7.540
5/16 .3125 7.937
21/64 .3281 8.334
11/32 .3437 8.731
23/64 .3593 9.128
3/8 .375 9.525
25/64 .3906 9.921
13/32 .4062 10.318
27/64 .4218 10.715
7/16 .4375 11.112
29/64 .4531 11.509
15/32 .4687 11.906
31/64 .4843 12.303
1/2 .500 12.700
33/64 .5156 13.096
17/32 .5312 13.493
35/64 .5468 13.890
9/16 .5625 14.287
37/64 .5781 14.684
19/32 .5937 15.081
39/64 .6093 15.478
5/8 .625 15.875
41/64 .6406 16.271
21/32 .6562 16.668
43/64 .6781 17.065
11/16 .6875 17.462
45/64 .7031 17.859
23/32 .7187 18.256
47/64 .7343 18.653
3/4 .750 19.050
49/64 .7656 19.446
25/32 .7812 19.843
51/64 .7968 20.240
13/16 .8125 20.637
53/64 .8281 21.034
27/32 .8437 21.431
55/64 .8593 21.828
7/8 .875 22.225
57/64 .8906 22.621
29/32 .9062 23.018
59/64 .9218 23.415
15/16 .9375 23.812
61/64 .9531 24.209
31/32 .9687 24.606
63/64 .9843 25.003
1 1.000

25.400

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