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Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic...

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Quadrant’s Machinist Handbook You inspire … we materialize ®
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Page 1: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Quadrant’sMachinist Handbook

You inspire … we materialize®

Page 2: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

The World

’s Leading M

anufacturer of Plastic S

tock Shap

esP

lastics increasingly replace traditional materials such as bronze, stainless

steel, cast iron and ceramics. They are chosen for im

proved performance and

cost reduction. Plastics can:

• R

educe W

eight

• E

liminate C

orro

sion

• Im

pro

ve Wear P

erform

ance in Unlub

ricated C

ond

itions

• R

educe N

oise

• Increase P

art Life

• Insulate, bo

th Therm

ally and E

lectrically

Typical applications

for engineering

plastics range

from

semiconductor

processing equipment com

ponents to heavy equipment w

ear parts, to food processing industry com

ponents.M

achinable plastic stock shapes (sheet, rod, and tube) are now available in

more than 50 grades, spanning the perform

ance/price range of both ferrous and non-ferrous m

etals to specialty ceramics. P

lastics capable of long term

service up to 300°C, w

ith short term exposures to 500°C

are now available. A

s the num

ber of material options has increased, so has the difficulty of selecting

the right material for a specific application.

TAB

LE O

F CO

NT

EN

TS

Coolants. . . . . . . . . . . . . . . . . . . . . .

5

Annealing

. . . . . . . . . . . . . . . . . . . . . 6

Machinability. . . . . . . . . . . . . . . . . . .

9

Drilling . . . . . . . . . . . . . . . . . . . . . . . 10

Saw

ing. . . . . . . . . . . . . . . . . . . . . . . 16

Milling

. . . . . . . . . . . . . . . . . . . . . . . . 19

Turning. . . . . . . . . . . . . . . . . . . . . . . 21

2 Yo

u inspire …

we m

aterialize®

Page 3: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

The World

’s Leading M

anufacturer of Plastic S

tock Shap

esThe follow

ing guidelines are presented for those m

achinists not

familiar

with

the m

achining characteristics of plastics. They are intended as guidelines only, and m

ay not represent the most

optimum

conditions for all parts. The trouble-shooting quick reference guides in this booklet should be used to correct undesirable surface finishes or m

aterial responses during machining

operations. All Q

uadrant materials are stress

relieved to ensure the highest degree of machi-

nability and dimensional stability. C

ompared to

metals, how

ever, the higher coefficient of thermal

expansion, lower stiffness and higher elasticity

as well as eventual sw

elling due to moisture

absorption (m

ainly w

ith nylons)

and possible

deformations caused by internal stress-relieving

during and after machining, generally result in

greater difficulty

maintaining

tight tolerances

during and

after m

achining. A

good

rule of

thumb for m

achining tolerances on plastics is 0.1 to 0.2% of the nom

inal size although tighter tolerances are possible w

ith very stable, reinforced materials.

Quadrant Engineering P

lastic Products’ stock shapes can be easily m

achined on ordinary m

etalworking and in som

e cases on woodw

orking machines. H

owever,

there are some points w

hich are worth noting to obtain im

proved results.

In view of the poor therm

al conductivity, relatively low softening and m

elting tem

peratures of thermoplastics, generated heat m

ust be kept to a minim

um

and heat

build up

in the

plastics part

avoided. This

is in

order to

prevent deform

ations, stresses, colour changes or even melting.

Therefore:• Tools m

ust be kept sharp and smooth at all tim

es (ground cutting edges),• Feed rates should be as high as possible, • Tools m

ust have sufficient clearance so that the cutting edge only comes in

contact with the plastic m

aterial, • A

good swarf rem

oval from the tool m

ust be assured, • C

oolants should be applied for operations where plenty of heat is generated

(e.g. drilling).

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Page 4: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

When m

achining Quad

rant stock shapes, rem

emb

er...• Therm

al expansion is up to 20 times greater w

ith plastics than with m

etals.

• Plastics lose heat m

ore slowly than m

etals, so avoid localized overheating.

• Softening (and m

elting) temperatures of plastics are m

uch lower than those of

metals.

• Plastics are m

uch more elastic than m

etals.

Because of these differences, you m

ay wish to experim

ent with fixtures, tool

materials, angles, speeds and feed rates to obtain optim

um results.

GE

TTING

STA

RTE

D• A

s engineering plastics are not as rigid as

metals,

it is

essential to

support the w

ork adequately during machining

in order

to prevent

deflection or

deform

ation.

• High speed steel tools w

ork well w

ith m

any plastics.

• For long runs, use tungsten carbide, ceram

ic or

polycrystalline diam

ond

tooling.

• Polycrystalline

diamond

tooling pro-

vides optim

um

surface finish

when

machining celazole

® pbi or torlon® pai.

4 Yo

u inspire …

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aterialize®

Page 5: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Coolants

• Exept for drilling and parting, coolants are not typically necessary for therm

oplastic machining operations.

• Keeping the cutting area cool generally im

proves surface finish and tolerances.

• When coolants are required, w

ater-soluble coolants generally do very well. They should, how

ever, not be used when m

achi-ning am

orphous thermoplastics, such as P

C 1000, R

AD

EL

® PP

SU

1000, ULTE

M® P

EI 1000, P

SU

1000 and SE

MITR

ON

® E

Sd 410C

, because these materials are susceptible to environm

ental stress-cracking. The most suitable coolants for these

materials are pure w

ater or compressed air.

• When the use of w

ater-soluble coolants or general purpose petroleum based cutting fluids cannot be avoided during the

machining of am

orphous thermoplastics (e.g. during drilling of large diam

eters and/or deep holes or during tapping operations), the parts should im

mediately after m

achining be thoroughly cleaned with isopropyl alcohol first and rinsed w

ith pure water

afterwards in order to reduce the risk of stress-cracking.

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Page 6: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Annealing

Quadrant E

ngineering Plastic P

roducts’ stock shapes are annealed using a proprietary stress-relieving cycle to minim

ise any internal stresses that m

ay result from the m

anufacturing process.

This annealing procedure generally assures optimum

dimensional stability during and after m

achining. How

ever, when m

achining parts that have to m

eet stringent requirements w

ith respect to dimensional stability (tolerances, distortion, w

arpage,...) and/or w

hen machining causes asym

metric and/or heavy section changes, it is recom

mended to apply an interm

ediate annealing procedure after pre-m

achining and prior to final machining of the part.

Annealing can be done in an air or preferably a nitrogen circulating oven, or in an oil bath.

6 Yo

u inspire …

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aterialize®

Page 7: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Recom

mend

ed annealing

T1: heat-up time (heating rate: 10 – 20°C

/hour)T2:

hold-time

(depends on

the w

all thickness:

10 minutes per m

m part thickness)

T3: cool-down tim

e (cooling rate: 5 – 10°C/hour)

T4: additional

time

required to

establish norm

al room

tem

perature (depends

on the

wall

thickness: 3 minutes per m

m part thickness)

TIPS

FOR

AN

NE

ALIN

G• W

hen pre-machining, leave enough oversize to

allow m

achining to final sizes after annealing.• Fixturing

parts to

desired shape

or flatness

during the

entire annealing

cycle often

proves

advantageous.• D

o not unfixture until parts have completed entire

annealing cycle and are cool to the touch.• M

ake sure that temperatures are uniform

and within

+/- 3°C all over the oven or the oil bath at all tim

es during the annealing cycle.

• Do not take short-cuts.

THRT

T1 T2 T3 T4

Temp

erature in the centre of the plastic p

art

Oven or oil tem

perature

RT : room

temp

erature - TH : hold

-temp

erature

Time

(1)

(2)

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Page 8: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Annealing guid

elines

M

aterials H

eat up

Ho

ld tem

perature

Ho

ld-tim

e (T2)

Co

ol D

ow

n E

nvironm

ent(*)

PA

10-20 °C

/h 150°C

10 m

in/mm

5-10°C

/h air, nitrogen or oil

P

OM

10-20 °C

/h 150°C

10 m

in/mm

5-10°C

/h air, nitrogen or oil

P

ET

10-20 °C/h

150°C

10 min/m

m

5-10°C/h

air, nitrogen or oil

PE

-(U)H

MW

10-20 °C

/h 80°C

10 m

in/mm

5-10°C

/h air, nitrogen or oil

P

C

10-20 °C/h

130°C

10 min/m

m

5-10°C/h

air or nitrogen

PE

EK

10-20 °C

/h 250°C

10 m

in/mm

5-10°C

/h air, nitrogen or oil

P

PS

10-20 °C

/h 200°C

10 m

in/mm

5-10°C

/h air, nitrogen or oil

P

PS

U

10-20 °C/h

200°C

10 min/m

m

5-10°C/h

air or nitrogen

PE

I 10-20 °C

/h 200°C

10 m

in/mm

5-10°C

/h air or nitrogen

P

SU

10-20 °C

/h 170°C

10 m

in/mm

5-10°C

/h air or nitrogen

P

VD

F 10-20 °C

/h 140°C

10 m

in/mm

5-10°C

/h air, nitrogen or oil

(*): when annealing in air, a m

ore or less pronounced colour change of the outer surface is to be expected (particularly with nylons) – the thin oxidised surface-layer involved, how

ever, is m

ost of the time rem

oved during further machining operations.

8 Yo

u inspire …

we m

aterialize®

Page 9: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

12

34

56

Machinab

ility

Relative M

achinability (1 to 6 ; 1 =

easiest)

1. TIVAR

/ ER

TAC

ETA

L 2. E

RTA

LON

& N

YLATR

ON

GR

AD

ES

/ SY

MA

LIT PV

DF 1000 / FLU

OR

OS

INT 207 &

5003. E

RTA

LYTE

/ ER

TALY

TE TX / K

ETR

ON

PE

EK

-1000 / TOR

LON

4203 & 4503 PA

I / PC

1000 / RA

DE

L PP

SU

1000 / U

LTEM

PE

I 1000 / PS

U 1000

4. ER

TALO

N 66-G

F30 / TEC

HTR

ON

HP

V P

PS

/ KE

TRO

N P

EE

K-H

PV

/ TOR

LON

4301 & 4501 PA

I5. K

ETR

ON

PE

EK

-GF30 / K

ETR

ON

PE

EK

-CA

30 / TOR

LON

5530 PAI

6. CE

LAZO

LE P

BI

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Page 10: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Drilling

Plastics can build up heat very easily during drilling operations, especially w

hen hole depths are greater than twice the diam

eter. Therefore a cooling liquid is generally recom

mended.

• Sm

all diameter holes (0.5 - 25 m

m diam

eter)

High speed steel tw

ist drills generally work w

ell. In order to improve heat and sw

arf removal, frequent pull-outs (peck-drilling)

are necessary. A slow

spiral (low helix) drill w

ill allow for better sw

arf removal.

• Large diameter holes (25 m

m diam

eter and larger)

It is advised to use drills with a thinned w

eb (dubbed drill) in order to reduce friction and hence heat generation.

Drill large holes stepw

ise: a bore diameter of 50 m

m e.g. should be m

ade by drilling successively with Ø

12 mm

and

Ø 25 m

m, then by expanding the hole further w

ith large diameter drills or w

ith a single point boring tool.

10 Yo

u inspire …

we m

aterialize®

Page 11: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Drilling

For the following m

aterials it is recomm

ended to bore holes in round rods on a lathe, using “insert drills” or a rigid, flat boring tool w

ith its cutting edge perfectly set on centre-height (see draw

ing on the right).

• Rods >

50 mm

diameter:

C

ELA

ZOLE

® P

BI,

TOR

LON

® PA

I, K

ETR

ON

® P

EE

K-H

PV,

KE

TRO

PE

EK

-GF30,

KE

TRO

PE

EK

C

A30,

TEC

HTR

ON

® H

PV

P

PS

and

SEM

ITRO

ESD

410C.

• Rods >

100 mm

diameter:

E

RTA

LON

® 66-GF30, E

RTA

LYTE

®, ER

TALY

TE® TX and

K

ETR

ON

® PE

EK

-1000.

• Rods >

200 mm

diameter:

E

RTA

LON

® and NY

LATRO

N®.

No

te: for these materials, som

e machinists prefer to heat the stock shapes up

to about 120 - 150°C prior to drilling.

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Page 12: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Drilling

α : relief angle

(°)γ : rake angle

(°)φ

: top angle (°)

v : cutting speed (m

/min)

s : feed (m

m/rev.)

�S

ection AB

A

B

12 Yo

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aterialize®

Page 13: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Drilling

α

γ

φ

s v

ER

TALO

N / N

YLATR

ON

• TIVAR

• SY

MA

LIT PV

DF 1000

10-15 3-5

90-120 0.1-0.3

50-100

ER

TAC

ETA

L • SE

MITR

ON

ES

d 225 5-10

3-5 90-120

0.1-.03 50-100

ER

TALY

TE • TO

RLO

N 4203 / 4503 PA

I 5-10

3-5 90-120

0.1-0.3 50-80

KE

TRO

N P

EE

K-1000

PC

1000 • RA

DE

L PP

SU

1000 • ULTE

M P

EI 1000 • P

SU

1000 5-10

3-5 90-120

0.1-0.3 50-100

ER

TALO

N 66-G

F30 • TOR

LON

4301 / 5-10

3-5 90-120

0.1-0.3 50-80

4501 / 5530 PAI • K

ETR

ON

PE

EK

-HP

V /

GF30 / C

A30 • TE

CH

TRO

N H

PV

PP

S •

SE

MITR

ON

ES

d 410C / 520 H

R

CE

LAZO

LE P

BI

5-10 3-5

90-120 0.1-0.3

25-50

FLUO

RO

SIN

T 207 / 500 • SE

MITR

ON

5-10

3-5 90-120

0.1-0.3 50-100

ES

d 500 HR

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Page 14: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Difficulty

Co

mm

on

Cause

Difficulty

Tapered

H

ole

1. Incorrectly sharp

ened oil

2. Insufficient clearance

3. Feed too heavy

1. Wrong typ

e drill

2. Incorrectly sharp

ened oil

3. Feed too light

4. Web

too thick

1. Feed too heavy

2. Clearance too

great

3. Too much rake

(thin web

as d

escribed

)

1. Too much

clearance

2. Feed too light

3. Drill overhang

too great

4. Too much rake

(thin web

as d

escribed

)

1. Feed too heavy

2. Drill not

centered

3. Drill ground

off-center

Burned

or M

elted

Surface

Chip

ping

of

Surfaces

Chatter

Feed M

arks or

Sp

iral Lines on

Inside D

iameter

Drilling - Troub

leshooting

14 Yo

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aterialize®

Page 15: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Difficulty

Difficulty

1. Drill ground

off-center

2. Web

too thick

3. Insufficient clearance

4. Feed rate too

heavy

5. Point angle too

great

1. Dull d

rill

2. Too much

clearance

3. Point angle too

small

1. Dull cut-off tool

2. Drill d

oes not p

ass comp

le-tely through p

iece

1. Feed too light

2. Sp

indle sp

eed

too fast

3. Insufficient lub

rication from

coolant

1. Feed too heavy

2. Sp

indle sp

eed too slow

3. Drill enters next p

iece too far

4. Cut-off tool leaves nib

, which

deflects d

rill

5. Web

too thick

6. Drill sp

eed too heavy at start

7. Drill not m

ounted on center

8. Drill not sharp

ened correctly

Oversize H

oles

Und

ersize H

oles

Ho

les No

t C

oncentric

Burr at C

ut-off

Rap

id D

ulling

of D

rill

Drilling - Troub

leshooting

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Page 16: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Proper clam

ping of shapes on worktable is required to avoid vibrations and

consequent rough cutting or even rupture.

Band saw

s, circular saws or reciprocating saw

s need to have widely spaced

teeth, to assure good chip removal. They should have enough set to m

inimize

the friction between the saw

and the work and also to avoid close-in behind

the cutting edge, causing excessive heat build-up and even blocking of the saw

.

IMP

OR

TAN

T:

Reinforced m

aterials such as ER

TALO

N® 66-G

F30, TOR

LON

® 4301 PAI,

TOR

LON

® 4501 PAI, TO

RLO

N® 5503 PA

I, KE

TRO

N® P

EE

K-H

PV, K

ETR

ON

® P

EE

K-G

F30, KE

TRO

N® P

EE

K-C

A30, TE

CH

TRO

N® H

PV

PP

S, S

EM

ITRO

ES

d 410C and S

EM

ITRO

N® E

Sd 520H

R are preferably cut w

ith a brand saw

which has a tooth pitch of 4 to 6 m

m (C

ELA

ZOLE

® PB

I: 2-3 mm

). Do not use

circular saws, as this usually leads to cracks.

SA

WIN

G TIP

S• Tungsten

carbide tipped

saw

blades w

ear well and provide optim

um surface

finishes ; particularly alternate top bevel and triple chip grinds yield sm

ooth cuts w

ith little or no chipping or burrs.

Saw

ing

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aterialize®

Page 17: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Saw

ing

c : circular sawb : band saw

α : relief angle

(°)γ : rake angle

(°)t

: pitch (m

m)

v : cutting speed (m

/min)

Circular saw

(carbid

e tipp

ed)

Band

saw

tcXX

X – X

� =

10 – 15

tb

�c

�b

�c�b

Circular saw

(carbid

e tipp

ed)

Band

saw

tcXX

X – X

� =

10 – 15

tb

�c

�b

�c�b

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Page 18: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

α

c γc

tc v

c α

b γb

tb v

b

ERTA

LON

/ NYLATR

ON

• TIVAR

• 10 - 15

0 - 15 8 - 45

1,000-3,000 25 - 40

0 - 8 4 - 10

50 - 500 S

YMA

LIT PVD

F 1000

ERTA

CETA

L • SEM

ITRO

N ES

d 225 10 - 15

0 - 15 8 - 45

1,000-3,000 25 - 40

0 - 8 4 - 10

50 - 500

ERTA

LYTE • TOR

LON

4203 / 4503 PAI

10 - 15 0 - 15

8 - 25 1,000-3,000

25 - 40 0 - 8

4 - 10 50 - 400

KETR

ON

PEEK

-1000

PC

1000 • RA

DEL P

PS

U 1000 • U

LTEM P

EI 1000 • PS

U 1000 10 - 15

0 - 15 8 - 25

1,000-3,000 25 - 40

0 - 8 4 - 10

50 - 400

ERTA

LON

66-GF30 • TO

RLO

N 4301 / 4501 / 5530

10 - 15 0 - 15

8 - 25 1,000-3,000

25 - 40 0 - 8

4 - 6 50 - 200

4501 / 5530 PAI • K

ETRO

N P

EEK-H

PV /

GF30 / C

A30 • TEC

HTR

ON

HP

V PP

S •

SEM

ITRO

N ES

d 410C / 520 H

R

CELA

ZOLE P

BI

10 - 15 0 - 15

8 - 25 1,000-3,000

25 - 40 0 - 8

2 - 3 25 - 100

FLUO

RO

SIN

T 207 / 500 • SEM

ITRO

N ES

d 500HR

10 - 15

0 - 15 8 - 25

1,000-3,000 25 - 40

0 - 8 4 - 6

50 - 200

18 Yo

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Page 19: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Milling

Two flute end m

ills, face mills and shell m

ills with inserts as w

ell as fly cutters can be used for m

illing thermoplastics.

Clim

b milling is recom

mended to help reduce heat by dissipating it into the

chip, and melting and poor surface finishes are m

inimized.

MILLIN

G TIP

• Thin w

orkpieces

are often

fixed onto

the w

ork table

by m

eans of

suctio

n p

lates o

r d

oub

le-sided

adhesive tape.

α

γ

α : relief angle

(°)γ : rake angle

(°)v : cutting speed

(m/m

in)s : feed

(mm

/tooth)

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19

Page 20: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Clim

b M

illing vs. Conventional M

illing

vs.

CU

TTERR

OTATIO

N

TAB

LE FEEDC

LIMB

MILLIN

GTA

BLE FEED

CO

NVEN

TION

AL M

ILLING

CU

TTERR

OTATIO

NC

UTTER

RO

TATION

TAB

LE FEEDC

LIMB

MILLIN

GTA

BLE FEED

CO

NVEN

TION

AL M

ILLING

CU

TTERR

OTATIO

N

20 Yo

u inspire …

we m

aterialize®

Page 21: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Turning

TUR

NIN

G TIP

• The continuous

chip stream

pro-

duced when turning and boring m

any therm

oplastics can

be handled

well

using a compressed air pow

ered suc-tion system

(directly disposing the swarf

onto a container), in this way avoiding

the chip wrapping around the chuck,

the tool or the workpiece.

Typical turning

too

l with tung

sten carbid

e insert

5°5°

3°'0

3

11 °

Insert

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21

Page 22: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Turning & B

oring Troubleshooting

Difficulty

Co

mm

on

Cause

Difficulty

Melted

S

urface

1. Tool dull or

heel rubb

ing

2. Insufficient sid

e clearance

3. Feed rate too

slow

4. Sp

indle sp

eed

too fast

1. Feed too

heavy

2. Incorrect clearance angles

3. Sharp

point

on tool (slight nose rad

ius req

uired)

4. Tool not m

ounted on

center

1. No cham

fer p

rovided

at sharp

corners

2. Dull tool

3. Insufficient side

clearance

4. Lead angle not

provid

ed on tool

(tool should ease

out of cut gradu-

ally, not sudd

enly)

1. Too much p

ositive rake on tool

2. Tool not eased

into cut (tool sud-

denly hits w

ork)

3. Dull tool

4. Tool mounted

b

elow center

1. Too much

nose radius on tool

2. Tool not m

ounted solidly

3. Material not

supported properly

4. Depth of cut

too heavy (use 2 cuts)

Ro

ugh

FinishB

urrs at Ed

ge

of C

ut

Cracking

or

Chip

ping

of

Co

rnersC

hatter

22 Yo

u inspire …

we m

aterialize®

Page 23: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Parting (C

utting-off) - Troubleshooting

Difficulty

Co

mm

on

Cause

Difficulty

Melted

S

urface

1. Dull tool

2. Insufficient sid

e clearance

3. Insufficient coolant sup

ply

1. Feed too

heavy

2. Tool im

prop

erly sharp

ened

1. Tool rubs

during its

retreat

2. Burr on

point of

tool

1. Point angle not

great enough

2. Tool not p

erpend

icular to sp

indle

3. Tool deflecting

4. Feed too heavy

5. Tool mounted

ab

ove or below

center

1. No cham

fer ap

plied

before

cut-off

2. Dull tool

Ro

ugh

FinishS

piral

Marks

Co

ncave or

Co

nvex S

urfaces

Burns o

n O

utside

Diam

eter

Nib

s orB

urrs at C

ut-off

Po

int

1. Point angle

not great enough

2. Dull tool

3. Feed too

heavy

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23

Page 24: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Turning

α : side relief angle

(°)γ : rake angle

(°)η

: side cutting edge angle (°)

v : cutting speed (m

/min)

s : feed (m

m/rev.)

��

g

r = 0.5 – 1 m

m

Section A

B

A

B

24 Yo

u inspire …

we m

aterialize®

Page 25: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Turning

α

γ

η

s v

ER

TALO

N / N

YLATR

ON

• TIVAR

• SY

MA

LIT PV

DF 1000

5-15 0-10

0-45 0.05-0.5

200-500

ER

TAC

ETA

L • SE

MITR

ON

ES

d 225 5-15

0-10 0-45

0.05-.05 200-500

ER

TALY

TE • TO

RLO

N 4203 / 4503 PA

I 5-15

0-10 0-45

0.05-0.5 200-400

KE

TRO

N P

EE

K-100

PC

1000 • RA

DE

L PP

SU

1000 • ULTE

M P

EI 1000 • P

SU

1000 5-15

0-10 0-45

0.05-0.4 200-400

ER

TALO

N 66-G

F30 • TOR

LON

4301 / 5-15

0-10 0-45

0.05-0.3 100-200

4501 / 5530 PAI • K

ETR

ON

PE

EK

-HP

V /

GF30 / C

A30 • TE

CH

TRO

N H

PV

PP

S •

SE

MITR

ON

ES

d 410C / 520 H

R

CE

LAZO

LE P

BI

5-10 3-5

0-45 0.05-0.2

25-100

FLUO

RO

SIN

T 207 / 500 • SE

MITR

ON

8-12

0-5 0-45

0.08-0.4 150-400

ES

d 500 HR

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25

Page 26: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

26 Yo

u inspire …

we m

aterialize®

Page 27: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

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27

Page 28: Quadrant’s Machinist Handbook - alperton.ie · The World’s Leading Manufacturer of Plastic Stock Shapes Plastics increasingly replace traditional materials such as bronze, stainless

Reg

ional H

eadq

uarters

Visit o

ur w

ebsite fo

r add

ition

al info

rmatio

n: w

ww

.qu

adran

tplastics.co

m

EU

RO

PE

Quadrant E

PP

AG

Hardstrasse 5

CH

-5600 LenzburgTel +

41 (0) 62 8858409Fax +

41 (0) 62 8858181e-m

ail: [email protected]

All statem

ents, technical information and recom

mendations contained in this publication are presented in good faith, based upon tests believed to be reliable and

practical field experience. The reader is cautioned, however, that Q

uadrant Engineering P

lastic Products does not guarantee the accuracy or com

pleteness of this inform

ation and it is the customer’s responsibility to determ

ine the suitability of Quadrant’s products in any given application.

ER

TALO

N®, N

YLATR

ON

®, ER

TAC

ETA

L®, E

RTA

LYTE

®, TIVAR

®, KE

TRO

N®, TE

CH

TRO

N®, S

YM

ALIT

® and FLUO

RO

SIN

T® are registered tradem

arks of the Quadrant

Group. TO

RLO

N® and R

AD

EL

® are registered trademarks of S

olvay Advanced P

olymers. U

LTEM

® is a registered trademark of G

E P

lastics.C

ELA

ZOLE

® is a registered trademark of P

BI P

erformance P

roducts Inc. The guide was created by Q

uadrant Engineering P

lastic Products. D

esign and content are protected by copyright law

. © 2006 Q

uadrant Engineering P

lastic Products

Quadrant E

PP

US

A, Inc.

2120 Fairmont A

venueP

O B

ox 14235 - Reading, PA

19612-4235Tel 800 366 0300 / +

1 610 320 6600Fax 800 366 0301 / +

1 610 320 6868e-m

ail: americas.epp@

qplas.com

NO

RT

H A

ME

RIC

A

Quadrant E

PP

Asia P

acific Ltd108 Tai To Tsuen, P

ing Shan

Yuen Long - N.T. H

ong Kong

Tel +852 (0) 24702683

Fax +852 (0) 24789966

e-mail: asia.epp@

qplas.com

AS

IA-PA

CIFIC


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