Milling Experiences
Here we collect our experiences with CNC milling or routing different materials. Please add more information if you try something new (whether it's a success or not)!
Wood & Engineered Woods
MDF
| operation | mill | spindle speed | feedrate | pass depth | plunge rate | results | comments |
|---|---|---|---|---|---|---|---|
| 2D contour | 8 mm flat endmill, Z=2 (Sorotec UNI) | 16000 rpm ("1" on DeWalt 611) | 2000 mm/min | 3 mm | excellent | black (Bauhaus)
| |
| 2D contour | 8 mm flat endmill, Z=3 (cheap "VHM") | 21000 rpm ("3-4" on DeWalt 611) | 1000 mm/min | 2 mm | terrible | Bauhaus
| |
| pocket clearing | 8 mm flat endmill, Z=2 (Sorotec UNI) | 16000 rpm ("1" on DeWalt 611) | 2000 mm/min | 3 mm | excellent | black (Valchromat) | |
| 2D chamfer | 8 mm chamfer mill, Z=4 | 16000 rpm ("1" on DeWalt 611) | 2000 mm/min | excellent | black (Valchromat) | ||
| pocket operation | 1 mm flat endmill | 16000 rpm ("1" on DeWalt 611) | 400 mm/min | 2 mm | excellent | black (Bauhaus) | |
| drilling holes, pocket | 1/4 inch Kyocera 1620 - 2500.500 flat endmill, 2 flute | 16000 rpm ("1" on DeWalt 611) | 1000 mm/min | 2.5 mm | 333 mm/min |
Plywood
Most kinds of plywood should work, but of course you only get out what you put in - Micha has had bad experiences with pine plywood as it is much too soft and likes to warp.
Plastics
Polycarbonate works better than acrylic glass.
Acrylic Glass
| operation | mill | spindle speed | feedrate | pass depth | plunge rate | results | comments |
|---|---|---|---|---|---|---|---|
| pocket operation | 3 mm flat endmill, 4 flute | 17000 rpm ("1-2" on DeWalt 611) | 660 mm/min | 0.4 mm | quite good |
|
Polycarbonate
| operation | mill | spindle speed | feedrate | pass depth | plunge rate | results | comments |
|---|---|---|---|---|---|---|---|
| pocket operation & contur | 3 mm flat endmill, 4 flute | 17000 rpm ("1-2" on DeWalt 611) | 900 mm/min | 0.8 mm | 660 mm/min | quite good |
POM
Bits
tested with 2 and 3 sided HSS Bits 4mm-6mm but no indication against any other diameters
RPM, Speeds, etc.
Spindle on level 1 (=16 000rpm)
- Schnittvorschub: 500mm/min +
- Einfahrvorschub: 500mm/min +
- Ausfahrvorschub: 500mm/min +
- Helixvorschub: 200mm/min +
- Eintauchvorschub: 30mm/min
- Depths: 2-3mm
Strongly advise a horizontal Rohteilaufmaß and a final finishing cut to remove any "layer" marks.
Cooling
Not neccessary with the current settings but might increase the cutting speeds drastically
Metals
Aluminum
Possible with a lot of patience and the correct bits, but check if it's millable aluminum
- different alloys of aluminum containing Cu, Si, Pb
Bits
maximum two cutting sides carbide is more rigid than HSS and advised by some online guides Tested 4mm 2-sided pointy-end bit with acceptable success
RPM, Speeds, etc.
Values are only the tested ones, faster CAN be possible as well
- slow RPM: 16 000 is our minimum but e.g. for a 4mm bit, 6000 RPM would be better
- different mill or PID-ing?
- Feed Rate/Schnittvorschub: ~200 mm/min
- Einfahrvorschub: 15-20 mm/min
- Ausfahrvorschub: 200 mm/min
- Helixvorschub: 15-25 mm/min
- Eintauchvorschub: 15 mm/min
- Depths: 0.25mm per pass
Milling directions (to be tested): Conventional/Up-Cut (Gleichlauf) milling milling for the basic different passes with a finish using Climb-milling/Down-Cut milling (= Gegenlauf)
Cooling
Not yet tested
- any sort of lubricant or coolant will increase the efficiency of aluminum milling
- there are suggestions ranging from cutting fluid over WD-40 to candle wax for lubing
- As coolant, a water or alcohol mist seems unsuitable with our pressboard
- instead, using the air compressor might be a possiblity
