Hey there! I'm a supplier in the Plastic CNC Machining business. One of the most common headaches we face during plastic CNC machining is dealing with chips. Chips can cause a whole bunch of problems, like clogging up the machine, damaging the workpiece, and even posing safety risks. In this blog, I'll share some tips and tricks on how to deal with chips effectively.
Understanding the Types of Chips in Plastic CNC Machining
First off, it's important to understand the different types of chips that can be generated during plastic CNC machining. There are mainly three types: continuous chips, segmented chips, and discontinuous chips.
Continuous chips are long and stringy. They usually occur when machining plastics with good ductility. While they might seem less of a hassle compared to other types, they can easily get tangled around the cutting tool and the workpiece, causing damage.
Segmented chips are made up of small, semi - connected segments. These chips are often produced when machining plastics with medium ductility. They can clog the flutes of the cutting tool, reducing its cutting efficiency.
Discontinuous chips are small, individual pieces. They are typical when machining brittle plastics. Although they are easier to handle than continuous chips, they can still accumulate in the machining area and cause issues.
Choosing the Right Cutting Tools
The type of cutting tool you use plays a huge role in chip formation and management. For plastic CNC machining, end mills and drills are commonly used.
When it comes to end mills, those with a high helix angle are great for producing continuous chips. The high helix angle helps to evacuate the chips from the cutting area more effectively. For example, a 45 - degree helix angle end mill can do a much better job at chip removal compared to a 30 - degree one.
Drills also need to be carefully selected. High - speed steel (HSS) drills are a popular choice for plastic machining. They can cut through plastics smoothly and produce chips that are relatively easy to manage. However, for more precise and high - volume machining, carbide drills might be a better option. Carbide drills are more wear - resistant and can maintain their cutting edge for longer periods, which is crucial for consistent chip formation.
If you're also interested in metal parts, check out our Metal Turned Parts Components. We offer high - quality metal turned parts for various applications.
Optimizing Cutting Parameters
Cutting parameters such as cutting speed, feed rate, and depth of cut have a significant impact on chip formation.
Cutting Speed: A higher cutting speed generally leads to better chip formation. When the cutting speed is too low, the chips tend to be thicker and more difficult to break. On the other hand, if the cutting speed is too high, it can cause excessive heat generation, which might melt the plastic and make the chips stick to the cutting tool. You need to find the sweet spot based on the type of plastic you're machining. For example, for polycarbonate, a cutting speed of around 100 - 150 m/min is usually a good starting point.
Feed Rate: The feed rate determines how fast the cutting tool moves through the workpiece. A proper feed rate helps in breaking the chips into manageable sizes. If the feed rate is too low, the chips can become long and stringy. If it's too high, it can cause rough surface finishes and even damage the cutting tool. A general rule of thumb is to start with a lower feed rate and gradually increase it while monitoring the chip formation.
Depth of Cut: The depth of cut affects the thickness of the chips. A larger depth of cut produces thicker chips, which can be more difficult to manage. For plastic CNC machining, it's often better to make multiple shallow cuts rather than one deep cut. This helps in keeping the chips thin and easier to evacuate.
Our Cnc Precision Turning Service can provide you with precise control over these cutting parameters, ensuring optimal chip management during the machining process.
Using Chip Removal Systems
In addition to choosing the right tools and optimizing cutting parameters, having an effective chip removal system is essential.
Vacuum Systems: Vacuum systems are one of the most popular ways to remove chips during plastic CNC machining. They work by creating a suction force that pulls the chips away from the cutting area. You can install a vacuum attachment directly on the machine or use a standalone vacuum unit. Vacuum systems are especially useful for removing small, discontinuous chips.
Air Blowers: Air blowers can also be used to blow the chips away from the cutting area. They are simple and cost - effective. However, they might not be as effective as vacuum systems for removing fine chips. You need to adjust the air pressure carefully to avoid blowing the chips into unwanted areas.
Chip Conveyors: For large - scale plastic CNC machining operations, chip conveyors can be a great solution. They can continuously remove the chips from the machining area and transport them to a collection bin. This helps in keeping the machining area clean and reducing the risk of chip - related problems.
If you're dealing with large - scale projects, our Large Part CNC Machining Services come with advanced chip removal systems to ensure smooth and efficient machining.
Safety Considerations
Dealing with chips also involves some safety considerations. Plastic chips can be sharp and can cause cuts if not handled properly. When cleaning the chips, always wear appropriate personal protective equipment (PPE), such as gloves and safety glasses.
Also, make sure to keep the machining area well - ventilated. Some plastics can release fumes when machined, especially if there is excessive heat generation. Inhaling these fumes can be harmful to your health.
Regular Maintenance
Regular maintenance of the CNC machine is crucial for effective chip management. Check the cutting tools regularly for wear and tear. Dull cutting tools can produce poor - quality chips and increase the risk of clogging. Replace the cutting tools as soon as they start to show signs of wear.
Clean the chip removal systems regularly to ensure they are working efficiently. A clogged vacuum system or air blower won't be able to remove the chips effectively.
Conclusion
Dealing with chips during plastic CNC machining is a multi - faceted challenge. By understanding the types of chips, choosing the right cutting tools, optimizing cutting parameters, using effective chip removal systems, considering safety, and performing regular maintenance, you can significantly reduce the problems associated with chips.
If you're in the market for high - quality plastic CNC machining services, we're here to help. We've got the expertise and the equipment to handle all your plastic machining needs. Whether it's a small - scale project or a large - scale production run, we can provide you with top - notch results. Don't hesitate to reach out to us for a quote and let's start a great partnership!
References
- "CNC Machining Handbook"
- "Plastic Materials and Their Applications"
- Industry - specific research papers on plastic CNC machining