Alexei Volkov
Plastic cutting end mills are used to cut and shape plastics for a variety of applications. The right tool must be chosen for the specific plastic type and desired outcome, as this can mean the difference between an excellent final product and a scrapped job. There are many types of plastic cutting end mills, including one, two, and three-flute mills, as well as variable helix end mills. These mills are used to cut and shape plastics with varying levels of hardness and melting points, and can be used to create products with sharp edges and clean cuts.
| Characteristics | Values |
|---|---|
| Process | A subtractive manufacturing process where layers of plastic material are removed from a workpiece to achieve a desired shape or design |
| Machinery | Specialized milling machines equipped with high-speed rotating cutters |
| Uses | Creating prototypes, parts for consumer products, industrial equipment, aerospace components, medical equipment, automotive parts |
| Advantages | Quieter and faster than metal milling, cheaper, more lightweight, resistant to corrosion |
| Plastic types | Acrylic, polycarbonate, acrylonitrile butadiene (ABS), Acetal, PEEK, PVC, Delrin |
| Plastic properties | Strength, flexibility, resistance to specific conditions, impact strength, toughness, optical clarity, electrical resistance, abrasion resistance, chemical resistance |
| Cutting considerations | Tool speed, feed rates, surface finish, heat generation, material deformation, sharpness of cutting edges, tool material, geometry, coating |
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What You'll Learn
Plastic milling is a subtractive manufacturing process
Subtractive manufacturing is a process that removes material from a workpiece to create the desired shape. It is sometimes referred to as machining and typically involves using a cutting tool to remove material. Other standard subtractive manufacturing processes include turning, thread cutting, sawing, and grinding. The accuracy of subtractive manufacturing depends on the precision of the cutting tools and the skill of the machinist. As a result, there may be some variability in the accuracy of the parts produced.
In contrast, additive manufacturing builds parts by successively adding layers to manufacture a product, with 3D printing being the most associated technology. Additive manufacturing generally has more limited material options, typically relying on plastic derivatives such as thermoplastics, metals, ceramics, resins, and biomaterials. On the other hand, subtractive manufacturing can work with a broader range of materials, including metals, plastics, composites, wood, and glass.
Plastic milling is a versatile process compatible with various plastic types, including acrylic, polycarbonate, and acrylonitrile butadiene (ABS). It is particularly useful for industries that prioritise weight reduction, such as aerospace, as plastic materials are lighter than metal. Additionally, plastics resist corrosion and operate reliably in environments where moisture and chemicals would damage metal parts.
When selecting the right plastic cutting end mill, it is important to consider workholding, the melting point of the material, and potential burr creation. Different types of end mills, such as the 2 Flute Plastic Cutting End Mill and the 3 Flute Plastic Finisher End Mill, can leave distinct swirling patterns or result in a smoother finish, respectively.
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Choosing the right plastic material
Firstly, it is important to understand the properties of plastics and how they can affect the manufacturing process. For instance, the melting point of a plastic material determines the temperature at which it can be melted and moulded. Different plastics have different temperature tolerances, so selecting a plastic that can endure the operating temperature range of your application is vital to ensure reliable performance and avoid product failure.
The transparency of a plastic material is another crucial factor. This property determines the material's ability to transmit light, which is essential for applications that require transparent or translucent products. Additionally, the weight and strength of the plastic material should be considered. Plastics are often chosen over materials like metal, glass, ceramics, and wood due to their lighter weight and comparable strength.
The type of plastic you choose can also impact the maintenance costs of your equipment. Some plastics are more abrasive or corrosive, which can damage processing equipment more quickly. Selecting a less corrosive plastic, such as polyethylene (PE), which is known for its toughness, flexibility, and chemical resistance, can help reduce maintenance expenses.
Furthermore, understanding the specific conditions your product will encounter is essential. If your application demands high impact resistance, electrical properties, or chemical resistance, you should choose a plastic material that suits these requirements. For example, polypropylene (PP) is lightweight, flexible, and resistant to heat and chemicals.
Finally, cost-saving measures can also guide your decision. Using recycled plastic, substituting expensive plastics with cheaper alternatives that offer similar performance, and bulk purchasing are effective ways to reduce costs.
Overall, selecting the right plastic material requires a thorough understanding of your application's requirements and the unique properties of different plastics. By making an informed decision, you can improve the quality of your product, increase its lifespan, enhance its appearance, and ensure its safety and reliability.
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Managing heat during the milling process
Milling processes generate a lot of heat, with temperatures reaching 1500 to 1600 degrees Fahrenheit in the cutting zone. This heat can cause accelerated wear or deformation of the tool, and even damage to the workpiece. Thus, heat management is critical during the milling process.
Techniques to Manage Heat
There are several techniques to manage heat during the milling process. One is to use coolant, which can help manage cutting temperatures. However, introducing coolant can be challenging in high-temperature and high-pressure cutting zones, where it may evaporate instantly. Additionally, while coolant can be beneficial in slot milling, it can cause temperatures to remain too low in side milling applications.
Another technique is to consider the geometry of the cutting edge. Chamfered or rounded edges are stronger but produce more heat, while a sharp edge reduces cutting forces and runs cooler.
The choice of tooling and cutting parameters can also impact heat generation and absorption. For example, the cutter's arc of engagement and the cutting edge angle affect the chip thickness, which in turn influences the amount of heat generated. A smaller portion of the cutting edge in contact with the workpiece results in increased friction and heat, leading to rapid wear. Thus, side milling, where only a small percentage of the cutter is engaged in the workpiece, allows for better heat dissipation.
When working with plastics, proper cooling techniques are crucial due to the thermal properties of plastics. Water-based coolants can be used, especially for materials like ABS, polycarbonate, and PTFE, which are sensitive to temperature fluctuations. Additionally, rotation speed, tool selection, and the use of inserts with positive geometries and ground peripheries are important considerations in heat management for plastics.
Annealing
Annealing is a technique used to manage heat and temperature fluctuations in plastics. It involves slowly heating a polymer part to just below its softening point, holding it there for a specified time, and then allowing it to cool gradually. This process helps to address internal stresses in plastic parts, which can lead to warping, twisting, and dimensional changes. Annealing can be done on raw materials or finished parts, depending on the specific plastic and application requirements.
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CNC machined plastics
There are many different types of plastics available for CNC machining, each with unique properties. ABS, for example, is a versatile and affordable plastic with high impact strength, toughness, and electrical resistance. It is easy to finish and can be painted, glued, or welded. Acrylic is another commonly used plastic in CNC machining, valued for its transparency and lightweight properties, making it an ideal substitute for glass.
Delrin, a trademarked name for a class of semi-crystalline thermoplastic acetal resin, offers excellent dimensional stability, high stiffness, and low friction. Nylon 6/6 is another strong and durable option with high heat and chemical resistance, making it suitable for maintaining its shape and strength under various conditions.
When selecting the right plastic for CNC machining, it is important to consider the specific requirements of your project. Factors such as workholding, melting point, and potential burr creation should be examined to choose the most appropriate tool and plastic type. The right tool selection is crucial to avoid wasting time and resources.
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The benefits of plastic milling
Plastic milling is a critical process in many industries, including aerospace, automotive, and medical manufacturing. It involves shaping solid plastic pieces into precise forms that meet specific requirements. The benefits of plastic milling are numerous:
Precision and Customisation
Plastic milling offers unparalleled accuracy and precision in manufacturing. CNC plastic milling, for example, relies on automated systems to control the milling machine, eliminating guesswork and maximising repeatability. This precision is further enhanced by detailed blueprints, finely tuned hardware, and rigorous post-milling inspections. The customisation afforded by plastic milling allows for the creation of innovative products that meet diverse dimensional and functional needs.
Cost-Effectiveness
Plastic milling is generally quieter and faster than milling other materials due to the softer nature of plastics. This reduced wear on machinery lowers production costs, especially for large-scale projects. Additionally, the lightweight nature of plastics contributes to lower lifetime freight costs compared to heavier metals.
Superior Material Properties
Different types of plastics offer unique benefits such as strength, flexibility, and resistance to specific conditions. For instance, polycarbonate is excellent for impact-resistant parts, while polytetrafluoroethylene (PTFE) handles high temperatures well. Acrylic is favoured for its optical clarity in lenses and displays. CNC machined plastics are also known for their superior impact strength, toughness, corrosion resistance, and resistance to electrical and environmental stresses.
Adaptability and Durability
The remarkable adaptability of plastics allows for a wide range of applications. Millable plastics are chosen based on their mechanical properties, ensuring functionality, appearance, and durability in the final product. Their impact strength, wear resistance, and dimensional stability make them versatile and effective across various temperature and stress conditions.
Tool Selection
Plastic milling requires careful tool selection to avoid issues like overheating or cracking. The availability of specialised tools, such as plastic cutting end mills with upcut and downcut geometries, ensures efficient material removal and minimises swirling marks for a smoother finish.
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Frequently asked questions
Plastic milling is a subtractive manufacturing process where layers of plastic material are removed from a workpiece to achieve a desired shape or design.
Plastic materials are lighter than metal, making them ideal for industries that prioritize weight reduction, such as aerospace. Plastics also resist corrosion and are more cost-effective for large-scale projects.
The choice of the cutting tool depends on the type of plastic being used. Factors such as the hardness, strength, melting point, and heat tolerance of the plastic will determine the appropriate cutting tool. For example, single-flute tools are used for low melting point plastics, while multi-flute tools are used for plastics with higher heat tolerance.
