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Polystyrene Machining

Anonymous

Polystyrene Machining

Anonymous
Not applicable

Hi everyone,

I was hoping if someone could help me in selecting good tools for machining polysyrene foam (expanded) in Fusion and also how can i minimise the machining time. And how can i justify those slected parameters as from the manufactrure module i also have to machine it in real. So i am open to ideas. As of now am going crazy about the rpm and feed that i could use because higher spindle speed or feed rate might burn the foam.

thanks in advance....

Cheers!!!!!

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Mattxer
Advocate
Advocate

Hello, can you give us a rough estimate of the size of the work piece, machine type, max rpm?

Matt Smith
Software Engineer - MSmithDev - https://msmithdev.com/
CAD/CAM/CNC - Micro Insert Inc. - https://microinsertinc.com/
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Anonymous
Not applicable

Hey Matt,

My design deals with a 150 mm x 150 mm with thickness 80 mm. I can go upto 15000 rpm. Any ideas with this????

I hope the design (screenshot) gives you a better idea..

Thanks

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Mattxer
Advocate
Advocate

From what I've found online, you should run 15K rpm, use like a 2 flute HSS (something very sharp) and you want to be pretty fast with your feeds. Is it like solid foam or like the bead type? (XPS/EPS)

 

I found this chart online:

cap.PNG

 

I hope this helps!

Matt Smith
Software Engineer - MSmithDev - https://msmithdev.com/
CAD/CAM/CNC - Micro Insert Inc. - https://microinsertinc.com/
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Anonymous
Not applicable

i am working with high density EPS. my machien has restriction of 3600 mm/min feed rate so i have to use spindle speed accordingly. I found the exact same PDF of that screenshot :grinning_face_with_big_eyes:.

But i have to justify it my supervisor too. 

You have been a great help thanks. Do message me if found anything.  

Cheers!!!!!

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Mattxer
Advocate
Advocate

if you max out at 51 in/min then your RPM would be around 2K to keep the same feed/tooth

Matt Smith
Software Engineer - MSmithDev - https://msmithdev.com/
CAD/CAM/CNC - Micro Insert Inc. - https://microinsertinc.com/
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daniel_lyall
Mentor
Mentor

Try with a single flute or 0 flute 


Win10 pro | 16 GB ram | 4 GB graphics Quadro K2200 | Intel(R) 8Xeon(R) CPU E5-1620 v3 @ 3.50GHz 3.50 GHz

Daniel Lyall
The Big Boss
Mach3 User
My Websight, Daniels Wheelchair Customisations.
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Anonymous
Not applicable

hey,

Even i am thinking to work with single flute mill. I have two kins of surface plane and one curved surface. So iwas thinking single 1/8" flute end mill and 6mm ball nose for curved surface. 

But i was thinking if i can use ball use for whole process..//Will that sam eme some time ?????

Cheers!!

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Anonymous
Not applicable

Thats sounds good and it maches with what i have reseacrhed....I may have to experiment with some other speed and measure the surface finish.....

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daniel_lyall
Mentor
Mentor

Have a look at the chip load this is more important than anything else using an 0 flute gives you the slow feed high RPM option as you can move slower and get the same chip load, with routers you have to think more about chip load as you can eat plastics or melt it in under a second.


Win10 pro | 16 GB ram | 4 GB graphics Quadro K2200 | Intel(R) 8Xeon(R) CPU E5-1620 v3 @ 3.50GHz 3.50 GHz

Daniel Lyall
The Big Boss
Mach3 User
My Websight, Daniels Wheelchair Customisations.
Facebook | Twitter | LinkedIn

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