Joe,
We have one job that is EPOXY CONSTRUCTION and is extremely abrasive.
The material is layered with epoxy and glass and it looks a lot
like a chuck of fiber glass and is a pale greenish colour.
I have no idea what the official name of this stuff is
but we use it as a quench block for its heat resistance qualities.
We get the material supplied to us in 4' x 4' x 1" thick sheets.
The material leaves grooves in our HSS and solid carbide tooling.
When the cutters become grooved and dull they exert too much tool
pressure causing the material to chip.
As far as using inserted cutters they simply chip the material too much.
We run the job with coolant to keep the air borne particles down.
Below is the first op of five ops for this job.
We hold the part in the throat of the vice where permissible to
support the sides as we make pockets because the part cracks
easily. Its like trying to cutter a wafer cookie.
We run 1788 rpm because that is the top rpm on our
22 year old manual tool changer Bosotmatic.
Job Setup File = W:\BO1000\BO0547A.jsf
Date Created = 04/04/94
Created by = Michael Senack
Machine Type= Mill Units= Inch
Part Description = #S1=/G120X
Material Description = EPOXY CONSTRUCTION - 3.63L X 1.72W X .75T
Notes = BLOUNT CANADA LTD - PRO-BAR DEPARTMENT
#S4=E2-211549-030202 REV.AB OP.1
#S1=/G120X
MILL AND DRILL QUENCH BLOCK
EPOXY CONSTRUCTION - 3.63L X 1.72W X .75T
TO MAKE R.H. PART:
-CLAMP PART IN VICE STOPPING AGAINST L.H. STOP
-SET X0Y0 TO BACK L.H. CORNER and SET Z HEIGHT TO 2.0 INCHES
-TURN BLOCK DELETE ON TO MAKE R.H. PART
TO MAKE L.H. PART:
-CLAMP PART IN VICE STOPPING AGAINST R.H. STOP
-SET X0Y0 TO BACK R.H. CORNER and SET Z HEIGHT TO 2.0 INCHES
-TURN BLOCK DELETE OFF TO MAKE L.H. PART REFER TO SETUP SHEET
T32 = 3/16 FINISH END MILL H Speed Code: 1788 RPM Feed: 1.00 IPM
T1 = NO.11 C/DRILL 1/8 X 3/64 H Speed Code: 1788 RPM Feed: 1.40
IPM
T31 = NO.45 DRILL(.082) H Speed Code: 1788 RPM Feed: 1.86 IPM
T5 = NO.14 C/DRILL 5/16 X 7/64 H Speed Code: 492 RPM Feed: 2.10
IPM
T30 = 13/32 DRILL(.406) H Speed Code: 766 RPM Feed: 2.26 IPM
We also have 3 or 4 phenolic jobs that are used on our adduction
hardening machines.
We use only HSS and solid Carbide tooling and run 80 sfm for both the
milling and drilling.
Inserted cutters chip or push up large burrs.
On a 1/2 hss e/m we use .0035"/rev.
On a 7/8 hss e/m we use .0045"/rev.
On a 1.0 hss e/m we use .0050"/rev.
We use coolant to keep the stuff from becoming air borne.
It's messy but effective. The operators wear masks when they
machine phenolic or epoxy construction mat'l.
Hope this is of some help.
Regards,
Michael Senack
-----Original Message-----
From: John Gent [mailto:[EMAIL PROTECTED]
Sent: Tuesday, March 30, 2004 2:02 PM
To: [EMAIL PROTECTED]
Subject: RE: [mfg-smartcam] G-10 anyone?
Hi Joe,
I've machined G-10 Epoxy (yellow and green). Others have accurately
pointed
out speeds and cutters. One thing that we would do is use a mister with
light water only. The dust from that stuff is really abrasive and the
water
would help keep it out of the air (and off the other equipment). It's a
mess
at the end, but at least it's all in one place.
There's also the blue stuff (phenolic, I think), but I only punched that
stuff.
HTH,
- John Gent
McKenzie River Software
Your Exclusive Source for SmartCAM
-----Original Message-----
From: [EMAIL PROTECTED]
[mailto:[EMAIL PROTECTED] On Behalf Of JOE MEDEIROS
Sent: Monday, March 29, 2004 3:38 PM
To: [EMAIL PROTECTED]
Subject: [mfg-smartcam] G-10 anyone?
i am wondering if anyone has any experience machining G-10 phenolic or
any
similar "fiberglass" material. i have machined several parts with great
difficulty, and would like to know if maybe i am doing it the
bass-ackward
way as far as feeds and speeds go. i am using pcd end mills. any
suggestions
would be greatly appreciated. thanks.
JOE MEDEIROS
PRECISION PLASTICS
SACRAMENTO, CA
916-568-5284
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