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Tool Talk Discussion Forum

fly-cutting acrylic plastic

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Eric

03-29-2004 23:09:33




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I need to surface panels of acrylic plastic. They are made up of thousands of pieces laminated together, so they are rough with glue squeeze-out and a generally uneven surface. They're about 16" wide by 96" long. They need to be finished to a complete polish. I've been doing this using a rotary wet sander, but I'd like to machine the surface past the rough stage so that I have less sanding to do. I was thinking that a fly cutter would be the proper tool for the job. Am I correct? If so, what speed should it run at. I'm thinking of about a 2" diameter cutter, and I'll have to remove about 3/32" depth. I'll buy a motor and build a carriage/jig to run the cutter over the material. I'd appreciate any pertinent advice anyone might have. Thanks!

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DL

04-03-2004 15:32:03




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 Re: fly-cutting acrylic plastic in reply to Eric, 03-29-2004 23:09:33  
In our shop, we routinely cut a variety of plastics... using a variety of cutters. I've had good results using a fly cutter... depending on material, RPM can vary... 1000, 1500 ... we normally just select a speed, observe the cut & adjust as necessary. When heat is a problem, we use coolant... you can put some in a spray bottle and apply as needed. I agree with a previous post... make sure you have positive control over the FEED of this jig... if you're not careful, it'll eat your lunch!!!

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RP

03-30-2004 17:33:24




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 Re: fly-cutting acrylic plastic in reply to Eric, 03-29-2004 23:09:33  
How about using a jointer or a belt sander to get it close?



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Davis In SC

03-30-2004 15:16:13




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 Re: fly-cutting acrylic plastic in reply to Eric, 03-29-2004 23:09:33  
I have machined lots of different plastics. The 2 main considerations on the acrylic are melting of the plastic from cutting heat, & chipping at the edges where the cutter exits the workpiece. A sharp carbide fly cutter with positive rake & generous clearance should minimize these problems. If you build this jig, be careful cutting, that 2 inch cutter can walk away from (or toward you)in a hurry !!!

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ray

03-31-2004 06:46:20




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 Re: Re: fly-cutting acrylic plastic in reply to Davis In SC, 03-30-2004 15:16:13  
I agree heat will be your worst enemy here. It has a narrow tranisition temperature -- solid to molten -- careful with the flycutter.
You might want to bring a piece to local machine shop and ask there opinion. They might be able to help you out with the cutter selection. Good luck



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kraigWY

03-30-2004 07:53:57




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 Re: fly-cutting acrylic plastic in reply to Eric, 03-29-2004 23:09:33  
I'm a fan of fly cutters in a millling machine but the job you mention is gonna be slow but possible if you get your jig built properly.

I think people may be tired of me spouting about this book but the Machinery's Handbook, would give you the speeds and feeds for the fly cutter for the desired effect on the meteraly you are using.



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