Machining Plastics: Avoid Melt and Chip Damage

When machining plastics, the main challenges are melting from heat and chipping from brittle fracture. The solution lies in controlling temperature and using the right tool geometry.

Always use sharp tools with polished flutes. Carbide or polycrystalline diamond (PCD) tools are ideal. A negative rake angle helps shear the material instead of tearing it. This reduces heat generation and prevents chipping.

To manage heat, use high feed rates and moderate spindle speeds. Avoid dwelling in one spot. Apply coolant as a mist or air blast to keep the cutting zone cool. For deep cuts, peck drilling or chip breakers help evacuate chips and prevent rewelding.

Different plastics require adjustments: Acrylic is brittle and needs very sharp tools and low feed rates. Nylon can melt easily, so keep speeds low and use plenty of coolant. Always test a small area first.

By following these practices, you can achieve clean, accurate parts without melting or chipping.

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