I have a bunch of molded parts made out of HDPE to do some machining on for a customer. The work on them is pretty simple. Drill some holes and do a slot. The slot is giving me a few problems however.
This product has 2 molded parts that fit together and lock in with a bar of aluminum. The slot has to be cut so that both of the parts get slotted at the same time so they are a perfect match. I have it locked down as much as is possible, and the part doesn't move or chatter if I machine at 3000 rpms and 20 IPM with about a .202" DOC. However the fuzzies (caused by the plastic melting) get way down into the inner moldings of the part, and I can't get them cleaned up decently. A deburring tool leaves an ugly cut mark on the material because the plastic is so dang soft.
I ran the feeds/speeds past GWizard, and it's telling me I should be running around 38(HSS)-70(Carbide) IPM at the same DOC and RPM. I can't do that because the little part of the piece that sticks into the other piece will deflect (even tho I am clamping it as best I can) and will chatter causing a bad cut and a bad match on the 2 pieces that have to lock together.
Is there a cutter I can use to do these cuts that will eliminate some of the burrs? If anyone has any suggestions I'd appreciate it. I have hundreds of each part to do and trying to deburr the fuzzies I am getting is nearly impossible and way too time consuming.
Thanks,
Wade
This product has 2 molded parts that fit together and lock in with a bar of aluminum. The slot has to be cut so that both of the parts get slotted at the same time so they are a perfect match. I have it locked down as much as is possible, and the part doesn't move or chatter if I machine at 3000 rpms and 20 IPM with about a .202" DOC. However the fuzzies (caused by the plastic melting) get way down into the inner moldings of the part, and I can't get them cleaned up decently. A deburring tool leaves an ugly cut mark on the material because the plastic is so dang soft.
I ran the feeds/speeds past GWizard, and it's telling me I should be running around 38(HSS)-70(Carbide) IPM at the same DOC and RPM. I can't do that because the little part of the piece that sticks into the other piece will deflect (even tho I am clamping it as best I can) and will chatter causing a bad cut and a bad match on the 2 pieces that have to lock together.
Is there a cutter I can use to do these cuts that will eliminate some of the burrs? If anyone has any suggestions I'd appreciate it. I have hundreds of each part to do and trying to deburr the fuzzies I am getting is nearly impossible and way too time consuming.
Thanks,
Wade