In the world of machining, the choice of cutting tools plays a pivotal role in determining the quality and efficiency of the process. One such advanced tool is the DLC coated end mill. As a supplier of DLC Coated End Mills, I often encounter questions about the suitability of these tools for machining plastics. In this blog post, I will delve into the characteristics of DLC coated end mills and explore whether they can be effectively used for machining plastics.
Understanding DLC Coated End Mills
Diamond-Like Carbon (DLC) coating is a thin-film coating that has gained popularity in the machining industry due to its exceptional properties. DLC coatings are composed of carbon atoms arranged in a structure similar to that of diamond, which gives them many of the desirable characteristics of diamond, such as high hardness, low friction, and excellent wear resistance.
When applied to end mills, DLC coatings offer several advantages. Firstly, the high hardness of the DLC coating helps to maintain the sharpness of the cutting edge for a longer period, reducing the need for frequent tool changes. This not only improves productivity but also ensures consistent machining quality. Secondly, the low friction coefficient of the DLC coating reduces the heat generated during the cutting process, which can prevent thermal damage to the workpiece and the tool. Additionally, the excellent wear resistance of the DLC coating protects the underlying substrate from abrasion, extending the tool life.
Machining Plastics: Challenges and Requirements
Plastics are a diverse group of materials with a wide range of physical and chemical properties. When machining plastics, several challenges need to be addressed. One of the main challenges is the tendency of plastics to melt or deform under the influence of heat. Since plastics have relatively low melting points compared to metals, excessive heat generated during machining can cause the plastic to melt, smear, or adhere to the cutting tool, resulting in poor surface finish and dimensional accuracy.
Another challenge is the tendency of plastics to produce chips during machining. Unlike metals, which typically produce continuous or segmented chips, plastics can produce long, stringy chips that can wrap around the cutting tool and interfere with the machining process. These chips can also cause clogging in the cutting flutes, reducing the chip evacuation efficiency and increasing the cutting forces.
To overcome these challenges, the cutting tools used for machining plastics need to have certain characteristics. They should be able to cut the plastic with minimal heat generation and provide efficient chip evacuation. Additionally, the cutting tools should have a sharp cutting edge to minimize the cutting forces and prevent the plastic from deforming or tearing.
Can DLC Coated End Mills be Used for Machining Plastics?
The answer to this question is yes, DLC coated end mills can be used for machining plastics. The unique properties of DLC coatings make them well-suited for the challenges associated with machining plastics.
Reduced Heat Generation
As mentioned earlier, the low friction coefficient of the DLC coating reduces the heat generated during the cutting process. This is particularly beneficial when machining plastics, as it helps to prevent the plastic from melting or deforming due to excessive heat. By maintaining a lower cutting temperature, the DLC coated end mills can ensure a better surface finish and dimensional accuracy of the machined plastic parts.
Excellent Chip Evacuation
The smooth surface of the DLC coating also promotes better chip evacuation. The low adhesion properties of the DLC coating prevent the plastic chips from sticking to the cutting tool, reducing the risk of chip clogging in the cutting flutes. This allows the chips to flow freely out of the cutting zone, improving the chip evacuation efficiency and reducing the cutting forces.
Sharp Cutting Edge
The high hardness of the DLC coating helps to maintain the sharpness of the cutting edge for a longer period. A sharp cutting edge is essential for machining plastics, as it can cut the plastic cleanly with minimal deformation or tearing. The sharp cutting edge of the DLC coated end mills also reduces the cutting forces, which further helps to prevent the plastic from melting or deforming.
Types of Plastics Suitable for Machining with DLC Coated End Mills
DLC coated end mills can be used to machine a wide range of plastics, including thermoplastics and thermosetting plastics. Some of the common thermoplastics that can be machined with DLC coated end mills include acrylics, polycarbonates, polyesters, and polyvinyl chlorides (PVC). These plastics are widely used in various industries, such as automotive, electronics, and medical, due to their excellent mechanical, electrical, and optical properties.
Thermosetting plastics, such as epoxy resins, phenolic resins, and melamine resins, can also be machined with DLC coated end mills. These plastics are known for their high strength, stiffness, and heat resistance, and are commonly used in applications where high-performance materials are required.
Specific Examples of DLC Coated End Mills for Plastic Machining
For machining plastics, DLC Coating U Slot End Mill for Aluminum and DLC Coating U Slot End Mill For Aluminum can be excellent choices. The U-slot design of these end mills provides efficient chip evacuation, which is crucial for machining plastics. The DLC coating on these end mills further enhances their performance by reducing heat generation and wear.
Machining Parameters for Using DLC Coated End Mills on Plastics
When using DLC coated end mills for machining plastics, it is important to select the appropriate machining parameters to ensure optimal performance. The cutting speed, feed rate, and depth of cut are the three main machining parameters that need to be considered.
The cutting speed should be selected based on the type of plastic being machined and the properties of the DLC coated end mill. Generally, a higher cutting speed can be used for machining softer plastics, while a lower cutting speed is recommended for harder plastics. However, it is important to avoid excessive cutting speeds, as this can generate too much heat and cause the plastic to melt or deform.
The feed rate should be selected to ensure efficient chip evacuation. A higher feed rate can be used when the chip evacuation is good, but it should be adjusted to prevent the plastic from deforming or tearing. The depth of cut should be kept relatively small to minimize the cutting forces and prevent the plastic from melting or deforming.
Conclusion
In conclusion, DLC coated end mills can be effectively used for machining plastics. The unique properties of DLC coatings, such as low friction, high hardness, and excellent wear resistance, make them well-suited for the challenges associated with machining plastics. By reducing heat generation, promoting chip evacuation, and maintaining a sharp cutting edge, DLC coated end mills can provide better surface finish, dimensional accuracy, and productivity when machining plastics.
If you are interested in using DLC coated end mills for your plastic machining applications, I encourage you to contact us for more information and to discuss your specific requirements. Our team of experts can provide you with the technical support and guidance you need to select the right DLC coated end mills for your needs. We are committed to providing high-quality products and excellent customer service to help you achieve the best results in your machining operations.
References
- "Machining of Plastics: A Review" - Journal of Manufacturing Processes
- "Diamond-Like Carbon Coatings for Cutting Tools: Properties and Applications" - Surface and Coatings Technology
- "Cutting Tool Materials and Coatings for Machining Plastics" - International Journal of Machine Tools and Manufacture
