An Ultimate Guide on the Process of Machining Polycarbonate
Polycarbonate is one of the most popular transparent materials for industry, but most people don’t know how to machine a Polycarbonate Part. This article is to help learn about machining Polycarbonate Parts.
Polycarbonate plastic is a widely used versatile and transparent thermoplastic material. This material is known for its excellent impact resistance, optical clarity, and lightweight nature. And these properties make it a popular choice for industries such as electronics, automotive, aerospace, etc.
To use Polycarbonate in these applications, it is shaped, cut, and manipulated to trigger suitable forms. Here, we detail the process of machining Polycarbonate while elaborating on some relevant aspects like the advantages of Polycarbonate machining, etc. Additionally, we list some tips to deal with the machining challenges of this material.
Advantages of Machining Polycarbonate
Below is a list of advantages of machining Polycarbonate.
Polycarbonate’s machining allows manufacturers to make suitable components of a final product, triggering higher impact resistance in the final production.
Due to having low-density properties, machined Polycarbonate reduces the weight of the main mechanical part or item.
Polycarbonate’s property of enhanced dimension stability ensures that machined parts maintain their intended shape and size over time.
This construction material’s machining processes are relatively straightforward and don’t require extensive tooling.
To enhance the transparency and optical clarity of a product, it is essential to use machined Polycarbonate.
In-depth Discussion of Polycarbonate Machining
In this section, we elaborate on the stepwise processes of Polycarbonate machining.
Turning of Polycarbonate
Below is the stepwise guideline.
Initially, we identify the required type of Polycarbonate for the desired end product.
We also use a pencil or a small knife to mark the spots.
Next, we prepare the turning instrument. We always use only high-speed tool steel.
We set the cutting velocity within the range of 600-900 feet per minute. And, based on the depth of the cutting action, we set a range of 0.025 to 0.015 inches per revolution.
Finally, we start the turning process. And in case there is an excessive amount of heat generation, we use coolant and slow down the cutting speed.
Milling of Polycarbonate Using CNC Machine
The following is the stepwise guideline.
The process begins by designing the required shape and form of Polycarbonate on computer-aided design software. During this phase, we input all the specifications correctly to get a precise outcome.
In the CAD, we also feed the speed within the range of 800-1000 feet per minute. However, it is not a fixed one and we feed speed depending on the type of work we need. Also, for complex milling work, we set the speed at a rate of 20 feet per minute.
Subsequently, we place the respective Polycarbonate in the milling machine.
We start the machine and keep an eye on the work progress. We take out the chips frequently and also use coolant to restrict the impact of heat generation.
Upon the completion of the task, we use sandpapers with a fine grit to make the edges, curves, etc. smoother.
Drilling of Polycarbonate
The following is the process.
We place the respective block, sheet, or roll of Polycarbonate on the workbench using a clamp.
Then, a pencil is used to mark the spots for drilling.
We set the speed of the automatic drill machine at 0.1-0.5 millimeters per revolution. In the case of doing hand drilling, we use gentle pressure on the drill machine’s handle. It is essential to ensure the drill thread penetrates smoothly without the requirement of huge pressure.
We finish the work in multiple stages and perform a close inspection of the work output.
Finally, it is better to rub the holes with fine-grit sandpaper to ensure precise work.
Routing of Polycarbonate
Routing Polycarbonate is the best way to get complex-shaped Polycarbonate pieces. Here is the step-by-step guideline to do Polycarbonate routing.
We make ready the wood milling machine or a router. It is essential to make sure that the cutter is made of carbide.
Then, we place the sheet on the workbench and use a screw clamp to fit it.
In this stage, we create marks on the sheet to do a perfect cutting or trimming job.
The machine gets started to work. Here, we maintain a very slow speed ensuring a perfect finish.
Finally, after the completion of the routing work, we carefully examine the work quality.
Upon requirement, we use fine-grit sandpaper to make the corners and edges smooth and polished.
Bending Polycarbonate
Normally, there are two methods to bend polycarbonate sheets:
Cold bending: Like metal sheet, Polycarbonate sheet can be bent at room temperature;
Hot bending: polycarbonate sheet will be soft if it is heat up to 180 degree centigrade, in this case, it can be bent;
Effective Tips on Machining Polycarbonate
Here are some tips to do a perfect machining job on Polycarbonate.
Polycarbonate has a low melting point. Considering this, maintaining a slow speed and using coolant is essential in machining.
It is required to use well-sharpened tools to minimize the risk of chipping or melting the material.
The clamping of the Polycarbonate piece with the workbench must need to be appropriate to restrict unwanted movement of the material piece.
Work progress at an appropriate feeding rate is very important to maintain.
It is recommended to avoid contact of hand, oil, etc. with the machined Polycarbonate to ensure its transparency level.
Final Words
The unique properties of polycarbonate, such as its impact resistance, optical clarity, and lightweight nature, make it a valuable material for a range of applications. To use this construction material in these applications, the above-mentioned various Polycarbonate machining process is crucially helpful.
Finally, we highly recommend the use of protective gear like safety goggles, gloves, helmets, etc., while performing the machining job of this material.
UVTECO is a leading supplier of polycarbonate plastic and the parts in China, provides sheet, rod, film/roll, tube. If you are looking for a trustworthy supplier, Contact UVTECO now!
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