machining plastic parts
DESCRIPTION
Machining Plastic Parts. Luke Kwisnek Patrick Slater Matt Jackson. Objective. Differences between metal and plastic Materials Advantages Disadvantages. Outline. Why Machine Plastics Process Considerations Material Considerations. Why Machine Plastic?. Cost Effective - PowerPoint PPT PresentationTRANSCRIPT
Machining Machining Plastic PartsPlastic Parts
Luke KwisnekLuke Kwisnek
Patrick SlaterPatrick Slater
Matt JacksonMatt Jackson
ObjectiveObjective
Differences between metal and Differences between metal and plasticplastic
Materials Materials AdvantagesAdvantages DisadvantagesDisadvantages
OutlineOutline
Why Machine PlasticsWhy Machine Plastics Process ConsiderationsProcess Considerations Material ConsiderationsMaterial Considerations
Why Machine Plastic?Why Machine Plastic?
Cost EffectiveCost Effective Low Volume ProductionLow Volume Production Secondary OperationsSecondary Operations
Material LimitationsMaterial Limitations ThermosetsThermosets CompositesComposites Ultra-High Mw MaterialsUltra-High Mw Materials
Machining Plastics vs Machining Plastics vs MetalsMetals
Ventilation ConcernsVentilation Concerns AnnealingAnnealing
To Avoid WarpageTo Avoid Warpage Robust FixturingRobust Fixturing Tooling ConsiderationsTooling Considerations
SharperSharper More Clearance (“Rake”)More Clearance (“Rake”)
Factors Affecting Cutting Factors Affecting Cutting Action In PlasticsAction In Plastics
HeatHeat Thermal Conductivity < MetalThermal Conductivity < Metal
Resists Compressive FractureResists Compressive Fracture Factors Promoting Tensile Fracture:Factors Promoting Tensile Fracture:
Sharp ToolsSharp Tools Large Rake AnglesLarge Rake Angles
Factors Affecting Cutting Factors Affecting Cutting Action In PlasticsAction In Plastics
Chip FormationChip Formation Want Continuous Flow TypeWant Continuous Flow Type
Smooth and ContinuousSmooth and Continuous High Elastic DeformationHigh Elastic Deformation
Lathe CuttingLathe Cutting
ToolingTooling Standard Tool MaterialsStandard Tool Materials High Rake AngleHigh Rake Angle
Water Soluble CoolantsWater Soluble Coolants Close Chucking and Follow RestsClose Chucking and Follow Rests
Prevent chatterPrevent chatter
MillingMilling
ToolingTooling Standard Tool MaterialsStandard Tool Materials High ClearanceHigh Clearance
Water Soluble CoolantsWater Soluble Coolants Slower Cutting FeedsSlower Cutting Feeds Same as Metal OtherwiseSame as Metal Otherwise
Drilling/ReamingDrilling/Reaming
ToolingTooling Wide, Highly Polished FlutesWide, Highly Polished Flutes Large Helix AnglesLarge Helix Angles Point angles of 60-90° (included)Point angles of 60-90° (included)
120° for PMMA and PVC120° for PMMA and PVC
Dimensional Concerns Dimensional Concerns Thermal ExpansionThermal Expansion Drill OversizeDrill Oversize
Tapping/ThreadingTapping/Threading
ToolingTooling Same Tools as MetalSame Tools as Metal Blunt Withdrawal Edges Blunt Withdrawal Edges
SpeedsSpeeds 50 ft/min Most Plastics50 ft/min Most Plastics 25 ft/min Filled Materials25 ft/min Filled Materials
New Cutting New Cutting TechnologiesTechnologies
Water JetWater Jet UltrasonicUltrasonic Laser-assisted turningLaser-assisted turning
Machining Neat PlasticsMachining Neat Plastics
Teflon, Acetal, AcrylicsTeflon, Acetal, Acrylics Generous RakeGenerous Rake Low Cutting Speeds (< 1m/min)Low Cutting Speeds (< 1m/min)
NylonNylon Continuous ChipsContinuous Chips Rake, Depth and SpeedRake, Depth and Speed
AnnealingAnnealing StandardStandard Double Anneal (Teflon)Double Anneal (Teflon)
Machining ThermosetsMachining Thermosets
Base Resin MixturesBase Resin Mixtures Phenolic, Urea, Melamine, SiliconePhenolic, Urea, Melamine, Silicone
Most similar to metalMost similar to metal High speeds and feeds High speeds and feeds Finishing requiredFinishing required
Machining Reinforced Machining Reinforced PlasticsPlastics
Fiber-Reinforced Plastics (FRPs)Fiber-Reinforced Plastics (FRPs) Base MaterialsBase Materials
Polyesters, Polyamides, Expoxy ResinsPolyesters, Polyamides, Expoxy Resins Matrix (Filler) MaterialsMatrix (Filler) Materials
Glass, Carbon, Aramid FibersGlass, Carbon, Aramid Fibers
Machining Reinforced Machining Reinforced Plastics Plastics cont.cont.
Usage LimitationsUsage Limitations Chip/Dust ProductionChip/Dust Production Surface DetailsSurface Details
Unique Modes of FailureUnique Modes of Failure Different Fracture CharacteristicsDifferent Fracture Characteristics
Machining Reinforced Machining Reinforced Plastics Plastics cont.cont.
ToolingTooling Longer Life With K-CarbideLonger Life With K-Carbide
Cutting Speed 38 m/minCutting Speed 38 m/min Single Crystal Diamond ToolingSingle Crystal Diamond Tooling
Better LifeBetter Life Cutting Speed 426 m/minCutting Speed 426 m/min
ConclusionConclusion
Cost EffectiveCost Effective Low VolumeLow Volume Difficult to Mold MaterialsDifficult to Mold Materials
Promote Tensile FracturePromote Tensile Fracture Continuous Flow ChipsContinuous Flow Chips Generous RakeGenerous Rake Sharp ToolsSharp Tools
Low Cutting SpeedsLow Cutting Speeds