It's critical to choose the right cutting tools, feeds, and speeds when CNC machining nylon to get the best results and avoid issues like tool wear, uneven surface finishes, and even part damage. Here's a breakdown of some key factors to consider:
Cutting Tools:
Material: High-speed steel (HSS) is a good place to start for most nylons because it balances performance and cost. For improved wear resistance and quicker machining when working with glass-filled nylons or higher production volumes, take into consideration Carbide Tipped (TCT) or Diamond-coated tools.
Geometry: While end mills with two or four flutes are typically utilized for general milling, ball nose end mills are ideal for curved surfaces. Consider chip flute angles of 10 to 15 degrees to guarantee smooth chip evacuation.
Diameter: Choose tool diameters that match the dimensions of your features; avoid using very thin tools that could deflect or vibrate.
Feeds and Speeds:
Cutting Speed (VC): Generally speaking, nylon is more resilient to cutting speeds than certain metals, withstanding up to 200–300 feet per minute (61–91 meters per minute). Start at slower speeds and adjust depending on the specific material, type of tool, and shape of the part.
Feed Rate (F): Maintaining moderate feed rates will ensure optimal chip formation and prevent excessive heat buildup. Aim for 0.002 to 0.008 inches (0.05 to 0.20 mm/tooth) as a starting point.
Depth of Cut (DOC): To minimize tool deflection and ensure optimal chip evacuation, make shallow incisions. Start with DOCs ranging from 0.5 to 1.3 mm (0.020 to 0.050 inches), and then modify based on the tool diameter and material properties.
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