Interestingly, the "C," for chloride, is the part of the compound with the most negative environmental impact. Other vinyls like EVA (ethylene vinyl acetate) or PVB (polyvinyl butyral) - ones without that "C" component - are much better for the environment. But all of them are plastic.

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Operators need to keep in mind that a solid-carbide drill is less forgiving than an indexable insert drill when it comes to deflection and vibrations.

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Beyond the traditional solid-carbide and indexable insert drills, some angled hole applications can be done using a modular drill.

"Consider machine setup, then decide whether a milled flat is necessary, or if feed reductions will be most reliable and efficient," said McEachern.

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Feed Rates and Speeds: A good rule of thumb for plastic is to use high spindle speeds and low feed rates. This will reduce heat.

Depth of Cut: Shallow depths of cut can also help prevent heat buildup. Two shallow passes are cooler than one deep pass.

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Is Formica® plastic? Yes. Manufacturers of Formica® swear it's made mostly from layers of kraft paper, which is true. What they don't tell you, is that the paper is layered between sheets of melamine resin, a thermoplastic.

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Start with a Spiral O Single Flute, Plastic Cutting Up-Cut Router Bit. The Spiral ‘O’ flute sharpening/finishing process increases feed rates, allowing for more linear feet routed in less time.

According to McEachern, solid-carbide drills also provide the best positional and diameter tolerance because of the chisel point centring capabilities, combined with symmetrical cutting edges and circular land. Surface finishes can be controlled with corner radii on the geometry, as well as feed rate.

Ultimately, the best approach is to plan the process carefully and choose a drill best-suited for the hole diameter and tolerance.

Don't be confused by the manufacturer's stated "melting points." That is the temperature at which plastic literally becomes a liquid; like, it flows. Most durable plastics will melt at temperatures below 500 degrees Fahrenheit, but will begin to soften -- and deform -- well before that.

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Beyond that, the hole and part specifications will help determine whether a solid-carbide, indexable, or modular (exchangeable-tip) drill should be used.

When it comes to working with angled surfaces, depending on the severity of the grade of the angle, creating a flat surface can be an effective way to ensure a high-quality hole.

This is why McEachern cautioned that solid-carbide drills are a great option for parts with an angled surface of 10 degrees or less. If an operator insists on using a solid-carbide drill on a surface angle greater than 10 degrees, McEachern recommends milling a flat surface before drilling.

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"Indexable insert drills have a steel body and multitude of geometries and grades to work with, so they can be adapted to withstand the punishment of angled entries," said McEachern.

Although using a flat-bottom drill may be the most efficient option, it’s not always a viable option. Generally, a shop will have a multitude of end mills available in its tool crib to get the job done. This is not always the case with flat-bottom drills and may require a shop to special-order one specifically for the job. In situations where timing is tight, it may be easier to choose the end mill option. However, Pilger noted that if a shop can anticipate and plan for its angled holemaking operations, a flat-bottom drill is preferable.

"If an operator needs to work in tight tolerances with a slanted entry or exit situation, it’s better to work with a solid-carbide drill," said Schmitt. "This is especially true when it comes to a non-perpendicular hole exit because this type of drill has a lot of contact to the hole surface, making it much more stable upon exit than indexable or modular drills that may require guideways for stabilization."

Not to sound like a commercial, but you can't go wrong with the Solid Carbide Spektra™ Extreme Tool Life Coated, Plastic Cutting CNC Router Bits, made with the highest quality sub-micrograin carbide, with nACo® nanocomposite coating for less friction and heat buildup.

For the most part, indexable insert drills, which almost always have a flat point angle, are versatile enough to handle almost any type of hole entry, according to McEachern. They can tolerate larger inclination angles than solid carbide and generally offer lower cost per hole. In most cases, with drills up to 5xD, they often remove the need to create a flat surface.

"When drilling non-flat surfaces, use a drill that is as short as possible to reduce tool deflection and vibrations," said Randy McEachern, product and industry specialist, Sandvik Coromant Canada, Mississauga, Ont. "Using a tool that is too long will have more vibrations and lower tool life. Also, in this type of application, using a tool that is too long will reduce the quality of the hole surface within the hole itself, as well as the entrance and exit quality."

Drilling holes on flat surfaces is a common operation many shops perform on a daily basis. Most operators can drill these holes with ease. However, drilling holes on angled or uneven surfaces presents unique challenges. Traditionally drills have been designed with a drilling angle point, whether it’s a 118-degree or 140-degree point, to interact with flat, clean surfaces.

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According to Schmitt, for approaching a slanted surface that has more than a 5-degree angle, as a rule of thumb the operator should decrease the feed rate by 50 per cent. If using a 140-degree point, or even a flat-bottom drill, the operator should reduce the feed by around 30 per cent to make sure that there is low deflection and a safe exit on a slanted surface.

The best blades for plastic are our carbide-tipped no-melt saw blades. The modified triple-chip grind and 2° negative hook angle produce less heat than a standard blade, leaving a crisp, smooth edge.

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Schmitt noted that for slanted entries and exits that require superior hole quality and straightness, operators should choose a modular or indexable drill that has four margin lands rather than two. Four margin lands will help maximize the resting surface of the tool on the wall of the hole, making it easier to exit at a slanted surface.

Is Corian® plastic? Technically, no, corian is not plastic per se. But, it is made from about 1/3 acrylic, which is a plastic. (The other 2/3 is mostly natural material.)

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Polycarbonate, like Lexan™, is a soft plastic widely used in signmaking. It softens at about 297°F, and flows above 311°F. So; higher temperatures, but a very short window between "soft" and goo.

"With a modular drill, a solid-carbide tip is attached to a steel body," said Pilger. "This type of drill is not an indexable drill with inserts that are replaceable. But what it does is gives the operator the same penetration rates as the carbide piece to cut and the steel body gives a little bit more flex than the solid-carbide drill for some challenging applications."

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"The most common way to do this is through using a solid end mill with multiple flutes," said Steve Pilger, NA product manager, holemaking, YG-1 USA, Vernon Hills, Ill. "Operators can create a flat surface by milling it. A solid end mill will circular interpolate a pilot bore for the drill to effectively enter the material."

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"If the drill is long enough, it can drill straight through, basically limiting the operator to one operation rather than having to mill the surface then drill the hole," said Pilger. "It’s done all in one shot. Running a flat-bottom drill instead of a solid end mill to create that surface is at least three to five times faster as far as cycle time."

On an angled or uneven surface, this point angle could potentially push the drill point to one side, affecting the true position of the hole location and overall straightness of the hole. Cutting tool manufacturers have some tips and tricks to produce quality holes in the most challenging surface configurations. Here are a few different options that they recommend.

Best Blades and Bits for Cutting Plastic Router Bits | Saw Blades September 8th, 2023 6 minute read Listen to article 1x 00:00 Audio generated by DropInBlog's Blog Voice AI™ may have slight pronunciation nuances. Learn more Here's the thing about cutting plastic:  It melts. Cutting requires friction. Friction generates heat. And heat melts plastic.  If your material melts a lot, it will re-bond behind the cutting tool in a process known as "chip-weld." If it melts a little bit, you'll end up with rough, uneven edges. Neither option is pretty.  So, you need specialized router bits and saw blades to cut plastic. Watch LED Acrylic Sign Making full screen What Do We Mean by "Melt"? Don't be confused by the manufacturer's stated "melting points." That is the temperature at which plastic literally becomes a liquid; like, it flows. Most durable plastics will melt at temperatures below 500 degrees Fahrenheit, but will begin to soften -- and deform -- well before that.  High-Density Polyethylene (HDPE), a hard plastic used to make park benches, pipes, industrial & commercial windows, and other building materials, starts to melt at 257°F, but it begins to soften at between 110-120°. Acrylic, or Polymethyl Methacrylate (PMMA), a.k.a. Lucite® or Plexiglas®, is also considered a hard plastic. It's translucent, making it a good substitute for glass, at half the weight. It melts at around 320°F. It softens at around 120°F. You can actually bend the stuff with a hair dryer.  Polycarbonate, like Lexan™, is a soft plastic widely used in signmaking. It softens at about 297°F, and flows above 311°F. So; higher temperatures, but a very short window between "soft" and goo. High Density Urethane (HDU Board) is a closed-cell foam board, also commonly used in signmaking. It is rated for up to 200°F continuous exposure. In contrast, wood will begin to char at between 450°F to 500°F. Moral of the story: Plastic melts.  Watch How to Make: CNC LED Holiday Sign full-screen Other Things to Know About Plastic Feed Rates and Speeds: A good rule of thumb for plastic is to use high spindle speeds and low feed rates. This will reduce heat. Adjust speeds and feeds according to chip formation. Ideally, the chips should be small and consistent. Depth of Cut: Shallow depths of cut can also help prevent heat buildup. Two shallow passes are cooler than one deep pass. Chip Clearing: Plastics can produce long, stringy chips. Regular chip clearing can prevent these from getting entangled and affecting the machining process. Clamping: Plastics are softer and more flexible than metals, so avoid over-clamping, which can cause deformation or breakage. Use soft jaws or fixtures to prevent marring the surface. Cooling and Lubrication: Many plastics can be machined dry, but for some, a coolant or air blast can help prevent melting and improve surface finish. When using coolants, make sure they're compatible with the plastic. Some plastics might absorb the coolant, leading to dimensional changes or degradation. Surface Finish: If a smooth surface finish is required, use a finishing pass with a fine tool and slower feed rate.  Safety: Some plastics can release toxic fumes when machined. Always ensure proper ventilation and use protective equipment like masks and goggles. Watch How to Make a CNC Alphabet Piggy Bank full-screen Get the plans here Best Saw Blades for Cutting Plastic The best blades for plastic are our carbide-tipped no-melt saw blades. The modified triple-chip grind and 2° negative hook angle produce less heat than a standard blade, leaving a crisp, smooth edge.  The negative hook angle greatly reduces the tendency of chip-welding or melting of Acrylic Sheets, Plexiglas®, Lexan®, Corrugated Polypropolyene, HDPE, Polycarbonates, Coroplast®* and other plastics. Additionally, blades coated with Amana Tool's Electro-Blu™ Non-Stick Coating prevent resin build-up. Best Router Bits for Cutting Plastic Not to sound like a commercial, but you can't go wrong with the Solid Carbide Spektra™ Extreme Tool Life Coated, Plastic Cutting CNC Router Bits, made with the highest quality sub-micrograin carbide, with nACo® nanocomposite coating for less friction and heat buildup. Spektra bits have a special proprietary edge processing system and feature a super high polished cutting edge with a unique “mirror finish”, resulting in clean cuts, superior surface finish and a longer tool life. Benefits of Mirror-Finish: Razor sharp cutting edge Effortless chip removal Helps prevent chip re-welding Dissipates heat well and prevents melting Extends tool life Exceptional cut quality Start with a Spiral O Single Flute, Plastic Cutting Up-Cut Router Bit. The Spiral ‘O’ flute sharpening/finishing process increases feed rates, allowing for more linear feet routed in less time.  These can also be purchased without the nACo® coating, but the coating does extend the life of your bit up to 2.5 times. For profiling and carving, get a 3-piece or 4-piece Spektra Extreme Tool Life Coated 2D/3D Carving Set. For fine lettering and engraving, try a 30 Degree Engraving 0.005 Tip Width bit. And a Spiral Finisher leaves an extra high surface finish. People Also Ask: Is Corian® plastic? Technically, no, corian is not plastic per se. But, it is made from about 1/3 acrylic, which is a plastic. (The other 2/3 is mostly natural material.) It is prudent to treat Corian® like a plastic, taking all the precautions you would with actual plastic.  Is vinyl plastic? Absolutely, yes. "Vinyl" usually means PVC (polyvinyl chloride). The "V" is for vinyl.  Interestingly, the "C," for chloride, is the part of the compound with the most negative environmental impact. Other vinyls like EVA (ethylene vinyl acetate) or PVB (polyvinyl butyral) - ones without that "C" component - are much better for the environment. But all of them are plastic. Is Formica® plastic? Yes. Manufacturers of Formica® swear it's made mostly from layers of kraft paper, which is true. What they don't tell you, is that the paper is layered between sheets of melamine resin, a thermoplastic.  Treat all laminates like plastic. See our full set of free downloadable safety posters here. « Back to Articles Related Articles Dovetail Joints: 5 Different Types and Their Uses 4 minute read September 5th, 2023 Dado Saw Blades - The Ultimate Guide 9 minute read September 1st, 2023 Best Aluminum Cutting Saw Blades 3 minute read September 15th, 2023

High-Density Polyethylene (HDPE), a hard plastic used to make park benches, pipes, industrial & commercial windows, and other building materials, starts to melt at 257°F, but it begins to soften at between 110-120°.

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FORMULAS FOR MILLING ; Formula. vc (SFM): :Cutting Speed; D1 (inch): :Cutter Diameter ; Formula. fz (IPT): :Feed per Tooth; z: :Insert Number ; Formulate. vf(inch/ ...

Chip Clearing: Plastics can produce long, stringy chips. Regular chip clearing can prevent these from getting entangled and affecting the machining process.

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High Density Urethane (HDU Board) is a closed-cell foam board, also commonly used in signmaking. It is rated for up to 200°F continuous exposure.

Clamping: Plastics are softer and more flexible than metals, so avoid over-clamping, which can cause deformation or breakage. Use soft jaws or fixtures to prevent marring the surface.

Because of its design, the indexable insert drill tends to be more forgiving on an irregular surface than other drill options. And although solid-carbide drills are preferable for holes with tight tolerances, some indexable drills offer wiper technology on the corner of the peripheral insert for improved surface finishes.

When using coolants, make sure they're compatible with the plastic. Some plastics might absorb the coolant, leading to dimensional changes or degradation.

So how do you find the Cutting Speed and Chip Load for your tool? · Aluminum: 300SFM, 0.7% of the diameter (for example fz = 0.5"dia x 0.007 = 0.0035in/tooth)

"A lot of challenges can be solved by opting for a flatter drill point," added Alexander Schmitt, director of holemaking product management, Kennametal, Latrobe, Pa. "A flat-bottom drill with a 180-degree point angle limits the deflection forces, making it much easier to enter a slanted surface."

The negative hook angle greatly reduces the tendency of chip-welding or melting of Acrylic Sheets, Plexiglas®, Lexan®, Corrugated Polypropolyene, HDPE, Polycarbonates, Coroplast®* and other plastics.

"With solid-carbide drills, these applications generate uneven and excessive forces acting on the cutting edges while intermittent cutting as the drill enters and exits the workpiece," said McEachern. "This increases the chance of vibration and can distort the drilling profile, causing more tool wear than conventional drilling. Premature wear or breakage can occur, which drives up the cost per hole."

Opting for a flat-bottom drill, operators can drill a hole completely through if the hole is within a certain range, typically 2xD or 3xD. Photo courtesy of YG-1.

"Exiting a hole also with a slanted surface might be a bit easier with a solid-carbide drill because the drill is already resting in the hole," said Schmitt. "However, this may be a bit more of a challenge for indexable and modular drills, which cannot rest on the hole as much. The tool body of an indexable or modular drill is normally not touching the whole surface. Depending on the slanted exit situation, a custom holder using guide pads may be a suitable option."

A modular drill option, like the Kennametal KenTIP™ FS, combines the benefits of a solid-carbide and indexable drill in one tool. Photo courtesy of Kennametal.

Spektra bits have a special proprietary edge processing system and feature a super high polished cutting edge with a unique “mirror finish”, resulting in clean cuts, superior surface finish and a longer tool life.

Lindsay Luminoso, sr. editor/digital editor, contributes to both Canadian Metalworking and Canadian Fabricating & Welding. She worked as an associate editor/web editor, at Canadian Metalworking from 2014-2016 and was most recently an associate editor at Design Engineering.

Sandvik’s CoroDrill® DS20 enables reliable drilling of deep holes up to 7xD with less demanding hole tolerances in both inclined surfaces and exits. Photo courtesy of Sandvik Coromant.

Operators should use the shortest drill possible to minimize vibration tendencies and decrease the effects of drill deflection. An operator also can decrease the feed rate to limit deflection.

Luminoso has a bachelor of arts from Carleton University, a bachelor of education from Ottawa University, and a graduate certificate in book, magazine, and digital publishing from Centennial College.

One of the biggest determinants of which drill option to choose is the hole diameter to be made. For projects requiring a very small hole diameter, a solid-carbide drill is the best option as it tends to come in a much smaller diameter range.

According to Pilger, this type of drill should easily enter uneven surfaces up to a 30-degree angle. This will also create a nice flat surface for a longer drill with a point angle to then be used if the hole requires it. Opting for a flat-bottom drill, operators can drill the hole completely through if the hole is within a certain range, typically 2xD or 3xD.

Safety: Some plastics can release toxic fumes when machined. Always ensure proper ventilation and use protective equipment like masks and goggles.

Pilger outlined a second, often overlooked option. He suggested that operators can use a flat-bottom solid-carbide drill, or a 180-degree point drill.

Once this flat surface has been created, depending on the hole specifications, the operator can then use the necessary drill and continue drilling the hole.

When it comes to drilling angled surfaces, there are some limitations that will help determine which type of tool is the best option.

Acrylic, or Polymethyl Methacrylate (PMMA), a.k.a. Lucite® or Plexiglas®, is also considered a hard plastic. It's translucent, making it a good substitute for glass, at half the weight. It melts at around 320°F. It softens at around 120°F. You can actually bend the stuff with a hair dryer.

If your material melts a lot, it will re-bond behind the cutting tool in a process known as "chip-weld." If it melts a little bit, you'll end up with rough, uneven edges. Neither option is pretty.

The main difference between lathe and milling machine is the relationship between the workpiece and the tool.

Cooling and Lubrication: Many plastics can be machined dry, but for some, a coolant or air blast can help prevent melting and improve surface finish.

One of the advantages of the modular drill is that many diameters can be drilled using one drill body, which is especially helpful in situations where many hole diameters need to be drilled on an angled surface. The operator just needs to change the carbide drill point to produce various hole sizes and specifications.

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