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Guidelines for machining   ensinger
Guidelines for machining   ensinger
Guidelines for machining   ensinger
Guidelines for machining   ensinger
Guidelines for machining   ensinger
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Guidelines for machining ensinger

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  • 1. ENSINGER essentials.Technical know-how for plastic applications. ASK. THINK. SUCCEED.
  • 2. I MP PAProcessing of ls* T D ,P PB OR ,A ria E FE, E PPPlastics ma d AT AH te P, T, S ER fille ET AB PE EC E, TR I S, ,P RM EP ON / EK ,T DF ON SI ced TF R N NMachining guidelines T L ID ID CA ID EL ® I DU NA ID NY RA SO FIN FO PE PE TR ST ,P PV FL M IM TE AM EN or NG TIM CA CA CA CA CA CA CA CA CA CA SP CA CA inf NT C SIN VE TE TE TE TE TE TE TE TE TE TE TE TE Re TE SI beads, carbon fibres, graphite, mica, talcum. etc. Sawing * Reinforcing materials/fillers: glass fibre, glass 20 20 20 15 15 15 15 15 20 15 15 15 15 5 5 5 15 α - - - - - - - - - - - - - - - - - 30 30 30 30 30 30 30 30 30 30 30 30 30 10 10 10 30 t 2 2 0 5 5 5 5 0 5 0 0 0 0 0 0 0 10 γ - - - - - - - - - - - - - - - - - 5 5 5 8 8 8 8 5 8 4 4 5 5 3 3 3 15 α 500 500 500 800 800 800 200 γ V 500 500 - 300 300 300 300 300 300 500 500 - - - - - - 800 800 800 900 900 900 300 α Clearance angle (°) γ Rake angle (°) 3 3 2 3 3 3 3 2 2 2 2 3 3 10 10 10 3 V t Cutting speed Pitch m/min mm t - - - - - - - - - - - - - - - - - 8 8 5 8 8 8 8 8 5 5 5 5 5 14 14 14 5 Drilling 5 5 5 5 8 8 8 8 10 3 3 5 5 5 5 5 α - - - - - - - - - - - - - - - - 6 15 15 10 10 10 10 10 12 16 10 10 10 10 10 10 10 10 10 15 10 10 10 10 10 5 10 10 10 10 5 5 5 5 ϕ γ - - - - - - - - - - - - - - - - - 20 20 30 20 20 20 20 30 20 20 20 30 30 10 10 10 10 γ 90 α ϕ 90 90 90 90 90 90 90 90 130 90 90 90 90 120 120 - 120 120 α Clearance angle (°) 50 50 50 50 50 50 50 50 150 20 20 50 50 80 80 80 80 γ Rake angle (°) V - - - - - - - - - - - - - - - - - ϕ Point angle (°) 150 150 200 100 100 100 100 200 200 80 80 200 200 100 100 100 100 V Cutting speed m/min S Feed mm/rev 0,1 0,1 0,1 0,2 0,2 0,2 0,2 0,2 0,1 0,1 0,1 0,1 0,1 0,02 0,02 0,05 0,1 The twist angle β of the drill bit S - - - - - - - - - - - - - - - - - should be approx. 12° to 16° 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,1 0,1 0,15 0,3 Milling 10 10 5 5 10 10 10 5 5 2 2 5 5 2 2 2 15 α - - - - - - - - - - - - - - - - - α 20 20 15 15 20 20 20 10 15 10 10 15 15 5 5 5 30 γ 5 5 5 5 5 5 5 0 5 1 1 6 6 0 0 0 6 α Clearance angle (°) γ - - - - - - - - - - - - - - - - - γ Rake angle (°) 15 15 15 15 15 15 15 10 15 5 5 10 10 5 5 5 10 χ Side angle (°) V Cutting speed m/min 250 250 250 300 250 250 250 250 250 90 90 90 80 The feed can be up to V - - - 300 300 300 300 - - - - - - - - - - 0.5 mm / tooth 500 500 500 500 500 500 500 500 500 100 100 100 100 Turning 6 6 6 5 5 5 5 5 6 6 2 2 2 6 α - - - - - - - - 10 6 6 - - - - - - 10 10 8 10 10 10 10 15 8 8 5 5 5 8 0 0 0 0 6 6 6 25 5 0 0 0 0 0 2 χ α γ - - - - - - - - - 0 0 - - - - - - α 5 5 5 5 8 8 8 30 8 5 5 5 5 5 8 γ 45 45 45 45 45 45 45 45 45 45 45 7 7 7 45 χ - - - - - - - 15 10 - - - - - - - - α Clearance angle (°) 60 60 60 60 60 60 60 60 60 60 60 10 10 10 60 γ Rake angle (°) χ Side angle (°) V Cutting speed m/min 250 250 300 300 200 150 350 350 250 250 100 100 100 150 S Feed mm/rev V - - - - 300 300 300 - - - - - - - - - - 500 500 600 400 500 500 400 400 500 500 120 120 120 200 0,1 0,1 0,1 0,2 0,1 0,1 0,1 0,2 0,1 0,1 0,1 0,1 0,1 0,05 0,05 0,05 0,1 The nose radius r must be at least 0.5 mm S - - - - - - - - - - - - - - - - - 05 05 0,4 0,4 0,5 0,5 0,5 0,5 0,3 0,3 0,3 0,5 0,5 0,08 0,08 0,25 0,5 Special Heat before sawing: from 60 mm diameter TECAPEEK GF/PVX, TECATRON Heat before drilling in the centre: from 60 mm diameter TECAPEEK GF/PVX, TECATRON GF/PVX measures from 80 mm diameter TECAMID 66 GF, TECADUR PET/PBT from 80 mm diameter TECAMID 66 MH, 66 GF, TECADUR PET/PBT from 100 mm diameter TECAMID 6 GF, 66, 66 MH from 100 mm diameter TECAMID 6 GF, 66, TECAM 6 Mo, TECANYL GF Caution when using coolants: Preheat material to susceptible to 120 °C Use carbide-tipped tools stress cracking14
  • 3. | General information* 2. Milling Non-reinforced thermoplastic polymers can be machined For plane surfaces, end-milling is more economical than peri- using high speed tools. For reinforced materials, carbide- pheral milling. For circumferential and profile milling the tools tipped tools are necessary. should not have more than two cutting edges so that vibrati- ons caused by the cutters can be kept low and the gaps bet- In all cases, only correctly sharpened tools should be used. ween the chips is sufficiently large. Due to the poor thermal conductivity of plastics, good heat Optimum cutting performance and surface finish are obtai- flow must be ensured. The best form of cooling is heat ned with single-cutter tools. dissipation via the chips. 3. Drilling| Dimensional stability Twist drills can generally be used; these should have an Dimensionally accurate parts presuppose the use of angle of twist of 12° to 16° and very smooth spiral grooves stress relieved semi-finished products. Heat from machi- for good removal of cuttings. ning will otherwise unavoidably result in the release of Larger diameters should be pre-drilled or should be produced machining stresses and distortion of the part. If large using hollow drills or by cutting out. Particular attention material volumes are to be machined, intermediate tem- should be paid to using properly sharpened drills when drilling pering may be necessary after rough machining to relieve into solid material, as otherwise the resulting compression the resulting thermal stresses. Specific temperatures and stresses can increase to the extent that the material splits. times to be used according to material can be obtained from us upon request. Reinforced plastics have higher residual processing stresses and a lower impact resistance than non-reinforced plastics Materials with high moisture absorption (e.g. polyamides) and are therefore particularly susceptible to cracking. Where may have to be conditioned before processing. possible, they should be heated to around 120 °C before dril- ling (heating time approx. 1 hour per 10 mm cross-section). Plastics require higher production tolerances than metals. This method is also recommended for polyamide 66 and Furthermore, the very much higher thermal expansion polyester. needs to be taken into consideration. 4. Sawing| Machining methods Unnecessary heat generation caused by friction must be 1. Turning avoided, as generally thick-walled parts are cut with relatively Guide values for tool geometry are given in the table. For thin tools during sawing. Well-sharpened and strongly offset surfaces with particularly high quality requirements, the saw blades are therefore recommended. cutting edge must be designed as a broad smoothing tool as shown in Figure 1. 5. Thread cutting Threads are best cut using thread chasers; burring can be For cutting off, the lathe tool should be ground as shown avoided by using twin-toothed chasers. in Figure 4 to prevent the formation of burrs. Die cutters are not recommended as re-cutting can be For thin-walled and particularly flexible workpieces, on the expected during removal of the cutter. other hand, it is better to work with tools that are ground to a knife-like cutting geometry (Figures 2 and 3). A machining allowance (dependent on material and diameter; guide value: 0.1 mm) must frequently be taken into account when using tap drills. 6. Safety precautions Failure to observe the machining guideli- nes can result in localised overheating which can lead to material degradation. Decomposition products which may be released, e.g. from PTFE fillers, should1 Secondary cutter Grinding prevents burr be removed using extraction facilities.2 Lathe tool Figure 1 formation Figure 4 In this respect, tobacco products should be kept out of the production area due Stress produced with a blunt drill to the risk of poisoning.Cutting off flexible pla-stics Figure 2 Figure 5 *Our application engineering advice, provided both written and orally, is intended to help you in Stress produced with a sharp drill your work. It must be regarded as a recommen- dation without obligation, also with respect to possible third-party property rights. We can assu- me no liability for any possible damage which ari- ses during processing.Parting off flexible pla- Figure 3stics Figure 6 15
  • 4. Annealing specificationsWhen processing plastic semi-finished goods usingmachining processes it is recommended under certaincircumstances, an annealing process is carried out afterrough machining, in order to achieve the best dimensio-nal stability and resistance.Annealing is a temperature treatment, which serves the The parameters given in the following annealing specifi-following purposes: cation are approximate values and apply up to a wall thickness of 50 mm. For larger wall thicknesses pleaseI Increase the crystallinity to improve the contact our technical marketing department. strength and chemical resistance.I Reduces inner tension, which can arise by extrusion or machining.I Increases the dimensional stability over a broad range of temperatures. Material DIN specification Heating-up phase Maintaining phase ** Cooling down phase VESPEL® PI 2 h to 160 °C 1h at 20 °C/h to 40 °C 2 h to 300 °C per cm wall thickness SINTIMID PI 2 h to 160 °C 2 h at 160 °C at 20 °C/h to 40 °C 6 h to 280 °C 10 h at 280 °C TECAPEEK PEEK 3 h to 120 °C 1,5 h at 20 °C/h to 40 °C 4 h to 220 °C per cm wall thickness TECATRON PPS 3 h to 120 °C 1,5 h at 20 °C/h to 40 °C 4 h to 220 °C per cm wall thickness TECASON E PES 3 h to 100 °C 1h at 20 °C/h to 40 °C 4 h to 200 °C per cm wall thickness TECASON P PPSU 3 h to 100 °C 1h at 20 °C/h to 40 °C 4 h to 200 °C per cm wall thickness TECASON S PSU 3 h to 100 °C 1h at 20 °C/h to 40 °C 3 h to 165 °C per cm wall thickness TECAFLON PVDF PVDF 3 h to 90 °C 1h at 20 °C/h to 40 °C 3 h to 150 °C per cm wall thickness TECANAT PC 3 h to 80 °C 1h at 20 °C/h to 40 °C 3 h to 130 °C per cm wall thickness TECADUR PET PET 3 h to 100 °C 1h at 20 °C/h to 40 °C 4 h to 180 °C per cm wall thickness TECADUR PBT GF 30 PBT 3 h to 100 °C 1h at 20 °C/h to 40 °C 4 h to 180 °C per cm wall thickness TECAMID 6 PA 6 3 h to 90 °C 1h at 20 °C/h to 40 °C 3 h to 160 °C per cm wall thickness TECAMID 66 PA 66 3 h to 100 °C 1h at 20 °C/h to 40 °C 4 h to 180 °C per cm wall thickness TECAFORM AH POM-C 3 h to 90 °C 1h at 20 °C/h to 40 °C 3 h to 155 °C per cm wall thickness TECAFORM AD POM-H 3 h to 90 °C 1h at 20 °C/h to 40 °C 3 h to 160 °C per cm wall thickness** at maximum temperature, unless otherwise specified.16
  • 5. | Headquarters and European Stock | France | Italy ENSINGER GmbH ENSINGER France SARL ENSINGER Italia S.R.L. Postfach 11 61 · PLZ 71150 3, Chemin de la Vierge Via Franco Tosi 1/3 Rudolf-Diesel-Straße 8 B.P. 614 20020 Olcella di Busto Garolfo 71154 Nufringen 95196 Goussainville Telephone +39 - 03 31 / 56 83 48 Telephone +49 (0) 70 32 / 8 19-0 Telephone +33 (0) 1 / 39 33 92 50 Fax +39 - 03 31 / 56 78 22 Fax +49 (0) 70 32 / 8 19-100 Fax +33 (0) 1 / 39 88 45 75 home@ensinger.it www.ensinger-online.com contact@ensinger.fr info@ensinger-online.com | Japan Info-Line: +49 (0) 1 80 / 3 81 98 19 | Germany ENSINGER Japan Co., Ltd. ENSINGER GmbH Shibakoen Denki Bldg. 7F| Austria Postfach 15 24 · PLZ 93405 1-1-12, Shibakoen, Minato-ku ENSINGER Sintimid GmbH Thierlsteiner Straße 14 Tokyo 105-0011 Werkstraße 3 93413 Cham Telephone +81 (0) 3 - 54 02- 44 91 4860 Lenzing Telephone +49 (0) 99 71 / 3 96-0 Fax +81 (0) 3 - 54 02- 44 92 Telephone +43 (0) 76 72 / 7 01 28 00 Fax +49 (0) 99 71 / 3 96-5 20 y.okada@ensinger.jp Fax +43 (0) 76 72 / 9 68 65 info@ensinger-online.com office@ensinger-sintimid.at | Poland | ENSINGER GmbH ENSINGER Polska Sp. z o.o.| ENSINGER TECARIM GmbH Postfach 11 54 · PLZ 59603 ul. Spóldzielcza 2a Floetzerweg 184 Borsigstraße 7 64-100 Leszno 4030 Linz 59609 Anröchte Telephone +48 (0) 65 / 5 29 58 10 Telephone +43 (0) 7 32 / 38 63 84-0 Telephone +49 (0) 29 47 / 97 22-0 Fax +48 (0) 65 / 5 29 58 11 Fax +43 (0) 7 32 / 38 63 84-10 Fax +49 (0) 29 47 / 97 22-77 info@ensinger.pl office@ensinger.at info@ensinger-online.com | Singapore| Brazil | ENSINGER GmbH ENSINGER International GmbH ENSINGER Ltda. Mooswiesen 13 (Singapore Branch) Av. São Borja 3185 88214 Ravensburg 63 Hillview Avenue # 04-07 93.032-000 São Leopoldo-RS Telephone +49 (0) 7 51 / 3 54 52-0 Lam Soon Industrial Building Telephone +55 (0) 51 / 5 79 88 00 Fax +49 (0) 7 51 / 3 54 52-22 Singapore 669569 Fax +55 (0) 51 / 5 88 28 04 Internet: www.thermix.de Telephone +65 - 65 52 41 77 ensinger@ensinger.com.br info@thermix.de Fax +65 - 65 52 51 77 info@ensinger.com.sg| Canada | Great Britain ENSINGER Plastifab ENSINGER Limited | Spain 8115 Lafrenaie Street Llantrisant Business Park ENSINGER S.A. Montréal. Québec H1P 2B1 Llantrisant, Pontyclun Girona, 21-27 Telephone +1 (5 14) 3 25 - 98 40 Mid Glamorgan CF72 8LF 08120 La Llagosta Fax +1 (5 14) 3 25 - 52 22 Telephone +44 (0) 14 43 / 23 74 00 Barcelona e-mail: infoprod@plastifab.ca Fax +44 (0) 14 43 / 23 73 42 Telephone +34 9 35 74 57 26 http://www.ensinger.ltd.uk Fax +34 9 35 74 27 30| China sales@ensinger.ltd.uk info@ensinger-plastics.com ENSINGER International GmbH Further Factories in GB: Rm 2301.23/F Waterlooville, Hampshire | Sweden Nanzheng building No. 580 PO7 7XX ENSINGER Sweden AB Nanjing Road (W) Irlam, Manchester Box 185 Shanghai 200041 M44 6GD Kvartsgatan 2C Telephone +86- 21- 52 28 51 11 Bridgwater, Somerset 74523 Enköping Fax +86- 21- 52 28 52 22 TA6 6TS Telephone +46 (0)1 71 47 70 50 info@ensinger-china.com Bishop’s Stortford, Herts Telephone +46 (0)1 71 44 04 18 CM23 5PE info@ensinger.se| Czech Republic East Kilbride, Glasgow ENSINGER s.r.o. G74 4QZ | USA º Prumyslová 991 Birmingham, West Midlands ENSINGER Inc. P.O. Box 15 B7 4SN 365 Meadowlands Boulevard 33 441 Dobrany Washington, PA 15301 Telephone +420 (0) 37 / 7 97 20 56 Telephone +1 (7 24) 7 46 - 60 50 Fax +420 (0) 37 / 7 97 20 59 Fax +1 (7 24) 7 46 - 92 09 ensinger@ensinger.cz ensinger@ensinger-ind.com Your specialist dealer: 08/05 267 ASK. THINK. SUCCEED.

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