Cutting Lexan

[Silver03SRT]

I am trying to cut .028" slots in a 1/4" lexan sheet. I can cut through it no problem but the shavings melt in the slot making it difficult to insert the steel in teh slot. Anyone know a way to get them not to stick in the slot or a way to get the shavings out of the slot easy. We are using a Gerber Profile router.

[DurtyKurty]

Decrease the RPM or speed up the feedrate and you won't melt the chips.

[Silver03SRT]

I tried that. I guess I could go a little slower. We had the RPMs at 18500. Im just worried if I go to slow it will break the bit since its only .028 wide.

[juicedimpss]

I tried that. I guess I could go a little slower. We had the RPMs at 18500. Im just worried if I go to slow it will break the bit since its only .028 wide.

thats what i would be worried about also

[SLOWC5]

Everyone loves broken Carbide :)

[Silver03SRT]

Everyone loves broken Carbide :)

Haha its not my money but eventually it effects me. Lots of broken bits no raise:durr
I may have figured it out.

[Silver03SRT]

Maybe I didnt figure it out. Broke another bit.

[SLOWC5]

Whats your depth of cut?

[DurtyKurty]

how many flutes? and yeah, you may have to take multiple cuts.

[SLOWC5]

coolant, air blast

[fly5150]

thats a tiny bit. The RPM is too fast for that small of a bit. slow the RPM down, and you may have to slow the feed rate just a little.

[Al]

thats a tiny bit. The RPM is too fast for that small of a bit. slow the RPM down, and you may have to slow the feed rate just a little.

Then again, dental drills spin at 500,000 rpm and won't break in lexan (ive tried it).

I'll second the slower feed rate.

You might also want to make multiple passes at different depths. I've snapped a few router bits in wood because my initial pass was too deep.

[fly5150]

Then again, dental drills spin at 500,000 rpm and won't break in lexan (ive tried it).

I'll second the slower feed rate.

You might also want to make multiple passes at different depths. I've snapped a few router bits in wood because my initial pass was too deep.

Most dental drills are 60,000 rpm. The bit wont break at the high rpm, but it melts the lexan. you need a slower rpm to keep from melting. The problem is a bit that small will break before you get a nice clean perfect cut.

[lilws6]

to keep the lexan from melting yes it has to be almost crawling i've tried many times cutting this stuff with a dremel and the slowest sped ont he dremel isn't slow enough. If your trying to drill it it needs to have a slow feed rate as well as rpm. to fast it will heat the lexan and melt. goober up your bit and the lexan can warp a little

[SSLEVO]

I would recommend a fast feedrate with a light depth of cut.

[Silver03SRT]

We have been using 2 flute bits. I have some 4 flute bits on the way.
We have a cold air gun but the thing is our compressor cannot keep up with all our machines running when that is on. I appreciate all the imput. I am still in the testing stages and need all the help I can get. If this doesnt work I will have to stick with laser cutting.

[Want_Notch]

hammer......