AXYZ Technical Tip: Are you using the right speeds and feeds?

When it comes to routing Precision Board HDU with a CNC machine, we often get asked questions about proper settings for speeds and feeds.  We came across this excellent article from AXYZ, a global manufacturer of CNC router systems and CNC knife systems.  They do a great job explaining what feeds and speeds are as well as ways to calculate the correct parameters.  Check it out!

axyz

From the AXYZ website:

There are certain parameters that must be considered, before setting up any job for processing if you are to achieve the finish and accuracy required. This blog discusses the importance of choosing the right speeds and feeds for your application, the do’s and don’ts and how to calculate the right parameters.

What do you mean by ‘Feeds and Speeds’

‘Feeds and speeds’ is generally used to refer to ‘feed rate’, ‘slew rate’, ‘plunge rate’ and ‘spindle rpm’.

The feed rate represents how fast the machine will move the router bit though the material when cutting and is critical to get right for leaving a good quality cut edge.

Slew rate is the speed that the machine moves when above the material and is travelling between cuts. This is normally set to as high a level as possible in order to reduce cycle times.

Plunge rate is the speed at which the router bit is driven down into the material when starting a cut and will vary depending on the bit used and the material being processed. It is important not to plunge too fast as it is easy to damage the tip of the cutter during this operation.

The Spindle speed in rpm should be set to a value that is appropriate for the tool being used and the material being processed. Feed rate and spindle speed are inter-related. Sometimes it is possible to cut at a faster feed rate by increasing the spindle rpm. Similarly, if you cut at too low a feed rate or with too high a spindle rpm there is a risk of overheating the router bit and potentially burning or melting the workpiece.

How to calculate the right parameters

Feeds and speeds are usually all set in the programming software that is used to create the machine program. There are many resources available to help determine suitable settings for particular material / router bit combinations.

These often provide a good starting point but can usually be further improved through a small amount of trial and error. Most machine controllers allow you to adjust the feed rate while a program is running and by listening to the sound the cutter makes this can be a good way of optimizing the parameters.

You can find our very own CNC cutter chart at www.cncroutershop.com. This CNC cutting chart shows starting points for depth per pass, feed rate, spindle speed and whether to use lubricant or not for your chosen tool and material.

The Do’s and Don’ts

Do …

  • Make sure you have the right router bit for the material to be processed
  • Look up recommended settings when programming for a new type of material of router bit
  • Check with your machine supplier if you aren’t achieving the expected quality or productivity
  • Make sure your collet is not worn and the tool is fitted correctly
  • Start with lower feed and plunge rates if not sure to avoid potential tool breakage or machine damage

Don’t …

  • Forget that doing some test cuts on a spare piece of material is a good way of checking settings before running your main program
  • Use worn or damage router bits which can cause overheating and poor cut quality
  • Continue cutting if you hear an unusual cutting noise. Pause the machine and check the router bit and settings
  • Cut too deep in a single pass. Sometimes it can be more efficient to use a higher feed rate and two or more passes rather than a single cut at a low feed rate

Author: Kevin Recinos is an Application Specialist for AXYZ, a global manufacturer of CNC router and knife systems. Kevin has covered many areas during his spell at AXYZ to ensure he has gained holistic exposure to both the needs of customers and the functionality of our CNC machines.

(article originally appeared on the AXYZ website HERE)

You can find more information about speeds and feeds by checking out the links below:

AXYZ is a leading global manufacturer of CNC router machines and knife systems. Designed and built at our state-of-the-art factory in Burlington, Ontario, Canada, AXYZ CNC routers are supplied and supported through a global network of sales and support offices and authorized dealers. With more than 366,918 standard machine configurations and over 25 years experience, AXYZ specializes in matching machinery to customer’s unique needs and budgets.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane material used in both the signage and tooling industries.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

Cal Poly Human Powered Vehicle Team to Race at Battle Mountain

The Human Powered Vehicle (HPV) Team at Cal Poly San Luis Obispo is doing something a little different this year.  Rather than race at the student competition put on by the American Society of Mechanical Engineers (ASME), they decided to compete at the World Human Powered Speed Challenge (WHPSC) in Battle Mountain, Nevada this September.

Five members attended last year as guests of George Leone and his wife Carole (former president of the International Human-Powered Vehicle Association).  George has a long history with Cal Poly and is a font of knowledge when it comes to both composites and Human Powered Vehicle Racing.  He volunteered sporadically helping Cal Poly’s HPV teams from 1980 to 1989, and then continuously from 1989 to the present.  George also ran the Cal Poly Projects Shop from 2001 to 2017.  This shop includes facilities for machining, student welding, woodworking, sheet metal work, advanced composites and design space for senior projects, as well as nine engineering clubs that compete at a national level.  He has also built and raced his own HPVs since 1988.

“After retiring in July 2017, I signed up as a volunteer again. I’m working with student Teams and Senior Projects at least 1 day a week,” he says.  “It’s never felt like ‘work’, it’s a joy to watch young people develop into confident, skilled hands-on engineers! And they teach me a lot, too!” he adds.

Leone says being at the 2018 WHPSC event inspired the HPV Team to build and race.  They are documenting their entire process for future teams and are one of the best organized teams George has seen in the last 38 years of his involvement with Cal Poly. Along with extensive engineering, they are fundraising and getting close to their goal!  You can sponsor them by donating HERE.

The team is bonding sheets of PBLT-15 Precision Board HDU with PB Bond 240 adhesive, following the instructions in our training video (you can check that out here).

George says, “Precision Board HDU is easy for both beginners and experienced people to work with, has a high recyclables content and is amazingly consistent. It’s a great experience for Engineering majors to work with such a well thought-out product line!”

The fairing will be machined by Safran Aerosystems, formerly Zodiac Aerospace. The Team will build the carbon/Kevlar fairing using room-temperature vacuum bagging techniques they are experienced with. Their twin goals are to break the Cal Poly record of 59.89 mph and the undergraduate collegiate record (designed, built and ridden by undergraduate students) held by UC Berkeley at 61.2 mph.

You can follow the HPV Team’s progress at their website, on  their Instagram and Facebook accounts and donate towards their project here or at their Crowdfund site here.

ABOUT THE CPHPV

Starting in 1978, Cal Poly students began to lead inquiries into the limits of bicycle performance. They were the first Mechanical Engineering design/build club at Cal Poly, producing many faired bicycles. These bikes were excellent for their time, but were only just scratching the surface of Cal Poly’s human powered potential.

In 1983, the American Society of Mechanical Engineers (ASME) began formally hosting competitions for HPVs. Before this, the HPV club raced in general recumbent bicycle competitions, but with a clearly defined and regular competition, the team was able to tailor their bike more effectively. They quickly found success in these competitions, consistently placing well, including numerous 1st place finishes.

However, over time the ASME competition became overly defined, forcing teams to design concurrently for speed, safety, stability, baggage capacity and steering. This made it difficult to create a bike that excelled in any one category. For this reason, the Team withdrew from the ASME competition this year and transitioned to a competition focused on one thing – pure speed.

This year, the Team is embarking on a new journey: traveling to Battle Mountain, Nevada in September 2019 to best the U.S. collegiate team speed record of 61.3 miles per hour. Follow the Team on our journey, and if you’d like to support us, links and information can be found here.

ABOUT COASTAL ENTERPRISES

At Coastal Enterprises, we like to look at the composites industry as a fully collaborative effort. Every fresh new development by an individual is really a contribution to a collective knowledge base. Like any scientific pursuit, the most potent advancements are made when information is shared freely between likeminded groups of people. For this reason, we feel obliged to do everything we can to enlighten and empower the future community of composites professionals.  That’s why we support school programs with donations of Precision Board HDU.  Click HERE to find out more about the program or give us a call with your questions at 800-845-0745.

 

Sign Invitational 2019 Update from Dan Sawatzky

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to host guest blogs written by some of the signage industry’s biggest movers and shakers, posted to the Precision Board Blog.  This guest blog is written by Dan Sawatzky with Imagination Corporation in Chilliwack, British Columbia, Canada.  This month, Dan gives us an update on his 2019 ISA Sign Invitational entries (made with a variety of materials, including PBLT-30) and some insight into his creative process, especially when it comes to the little details that pull the entire story into focus.

sign invitational

In Dan Sawatzky’s own words…

The fourth annual Sign Invitational at the International Sign Association EXPO is to be held on April 24-26 in Las Vegas. That means the pressure is on to finish up my pieces and I have no doubt the others in the competition are busy as well. I am doing two entries this year. Because I am twice defending champion I suspect everyone will be putting their best foot forward and I’ll be ready with my attempts in answer.

The contest is being hosted by Signs of the Times Magazine, booth number 2135 at the show. There will be four large entries on display and five small ones in the smaller table top/wall mount category.

My first piece is in the large category with the build envelope measuring 2’ x 2’ x 6’ tall. That leaves a lot of room for creativity and a ton of detail. Over the last year (since the last Sign Invitational) I have been putting in a few hours each week building the clockmaker’s factory. Although I had a fairly firm plan in mind when I started, I knew I would be adding a bunch of little things as I went, all in the service of telling the fun story. I finished the bulk of the sculpting some time ago and then began painting and glazing which brought the building to life. As I worked I would think up some little idea and then I would sculpt a little more, then go back to painting. That process is almost complete and I am very happy with the efforts so far. This piece has an incredible amount of detail packed into every square inch.

sign invitational

We love detail in our shop. And it is sometimes surprising how much the seemingly mundane items make the story believable. Our journey begins on the ground floor of the building. Beside the well worn front stone steps is a scooter, leaned up against a no parking sign. A somewhat beat up garbage can is tucked in the corner. A rusty down pipe drains the roof. Around back the delivery truck is parked against the wood decked loading bay. I still have to add a dolly load of boxes to that area. On the other side of the building is the ancient and well used steam boiler. We can almost feel the heat wave and hear the steam hiss from the rusty rivets. (A hidden miniature smoke machine will provide that effect when it is at the show.) Loose rocks and bricks litter the area and even more details are yet to be added. It is amazing just how much you can squeeze into a space two feet square.

The second, smaller category has a build envelope of 3’ x 3’ x ?.  The ‘official’ rules leave this dimension as a question mark and open to interpretation. On my piece it is 17” deep.  It can be either table or wall mounted. I am building an entry for that category as well although it will not be officially entered in the competition. Instead the time piece will be on display in the Coastal Enterprises booth (#860) as a way to help promote the competition at the show. Precision Board has been a proud and enthusiastic sponsor from the very first year.

This piece is well on the way to being finished. I routed the last component today using a small piece of PBLT-30 Precision Board HDU of course. This piece is called ‘Slowing down time’ and is the back side of a large steam driven clock. There is still some sculpting to complete for this piece and I will also be building a small table/stand for the display.

Both pieces have been a great deal of fun with no clients holding me back or trying to art direct my efforts. I am enjoying the leisurely process of both of these builds and this approach has allowed me to go completely wild in the process. I look forward to seeing all the other entries at the Sign Invitational and welcome everyone to come and cast a vote for their favourite.

Sawatzky’s Imagination Corporation is a small family company that specializes in the design and creation of dimensional signs and environments. They tackle projects of any size from small signs to entire theme parks. Their work has garnered numerous national and international awards.

Dan Sawatzky is best described as a creative force and visual storyteller extraordinaire. His art career spans almost fifty years of magic. Dan’s passion is to design and create imaginative places that take people from the normal world to a setting of delight and wonder.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

CR Onsrud Routed a Porsche 917k from a Precision Board Bonded Block

CR Onsrud wanted to show off their 5-axis Qube CNC machine at trade shows, so they got in touch with Coastal Enterprises to throw some ideas around.  Onsrud regularly uses Precision Board as demo material on their routers, but they wanted to really highlight the capabilities of the Qube for high-speed machining and trimming of advanced materials used for aerospace, automotive, marine, defense and pattern shops.  They decided they would fabricate a prototype of the Porsche 917k out of a custom-bonded Precision Board block live at IMTS 2018.  This is how they did it.

porsche 917k

While CR Onsrud sent a detailed drawing to Coastal Enterprises that laid out what the dimensions of the custom-bonded block would need to be, customers can submit anything from a rough sketch with dimensions all the way up to a detailed drawing.  We’ll design a custom bonded step-tool from that sketch or drawing, saving you material costs and routing time.

In order for Onsrud to machine the Porsche 917k shape out of the Precision Board, it would need to be 74″ x 34″ x 18″ and fabricated from PBLT-15 Precision Board Tooling Board.  Coastal would create three bonded blocks; one for testing at Onsrud’s facility in North Carolina, one for the International Woodworking Fair in Atlanta and one for the International Manufacturing Technology Show in Chicago.

According to Jeff Onsrud, Director of Sales and Business Development at CR Onsrud, “we typically will do a setup where we prove out the program and then do a final test cut at our facility.”  He added, “this ensures that there are no machining defects due to bond lines, which is important to achieving a usable mold straight off the machine.”

Onsrud did the Porsche project in collaboration with Autodesk, using their Powermill software.

The PBLT-15 Precision Board pieces were bonded together using EP-76, a two-part epoxy manufactured by Coastal Enterprises.

“We add PB Granules to the EP-76 epoxy to match the density of the material when bonding pieces together” said Chuck Miller, President of Coastal Enterprises. “This allows for smooth routing straight through the material without having to take bond-lines into account.  This also helps create an almost imperceptible bond-line in the finished piece and reduces issues associated with bond-line shrinkage and print,” he added.

When bonding custom step tools in-house, Coastal Enterprises has three adhesive options to choose from depending on the application and project requirements.  In most tooling applications we use our EP-76 Epoxy adhesive, but we also offer PB Bond 240 and PB Fastset.

The three bonded blocks were shipped to CR Onsrud who took them on the road to the IWF show last August and the IMTS show last September.  They sent us the video above from the live demonstration at IMTS of machining a Porsche 917k from a Precision Board bonded block.

Jeff added, “the Precision Board block was bonded together so tightly and the densities matched so perfectly that we didn’t even notice the bond lines when machining the material.”

CR Onsrud used their Qube CNC to rout the Precision Board with the following speeds and feeds settings:

  • Total cycle time was around 16 hours
  • Roughing feed rates were 500 inches per minute (IPM)
  • Finishing feed rates were 400 inches per minute (IPM)

And here’s another look at that Porsche 917k prototype being routed by CR Onsrud.

Of course, the fine folks at CR Onsrud had a little fun with this project, posting updates to their Instagram account throughout the process.  Our favorite is the “pretending to drive the car” photo.

The QUBE from C.R. Onsrud was developed for companies seeking 5-axis high-speed trimming and machining of advanced materials used in the aerospace, automotive, defense, marine, and pattern shop industries. This enclosed solution gives users a large work volume for machining molds, prototypes, and complex composite or thermoformed plastic parts while containing debris and isolating the operator from the machining zone and airborne particles. The machine design allows for various methods of work holding such as mechanical hold down and vacuum. Accommodation for oversized parts is achieved via removable side panels.

C.R. Onsrud, Inc. is located in Troutman, NC and specializes in 3-Axis and 5-Axis CNC Machining Centers, CNC Routers, CNC Mills, and Inverted Routers, primarily for the Composite Machining, Aerospace Industries, Plastics Routing, Hard Wood Routing, Panel Processing, Solidwood Routing, Aluminum Milling, Steel Milling, FRP machining, Composite Mold Making, Alloy Milling, Superalloy Machining, Carbon Fiber Machining, Carbon Graphite Machining, Door, Stair, Window, and Custom Millwork.

With its roots in Aerospace, Precision Board High-Density Urethane Tooling Board is specifically engineered to meet the demands of a broad range of tooling and tool making applications. Both PBLT Tooling Board (<200º F) and PBHT Tooling Board (<300º F), possess excellent machining characteristics and dimensional stability for tool making. Precision Board HDU Tooling Board is ideal for soft tooling and rapid prototyping because it can be more rapidly machined and it is more economical than alloy or epoxy-based alternatives.

Ask about our custom-bonded blocks, fast turnaround time, and sign up for our weekly e-blasts, including the monthly Tooling Tidbit (bite-size bits of info on using Precision Board).

Making the Aquaman Trident from PBLT-20 Precision Board

Zach Manring with Southern Ginger Workshop wanted to make a full-size movie prop replica of the Aquaman trident, but he didn’t want to make it from wood because it would be too heavy.  That’s when he decided to use foam board and reached out to Coastal Enterprises.  He ultimately went with PBLT-20 Precision Board HDU.  Zach shared his learning process with us as he fabricated the trident on his Axiom AR8 CNC with V-Carve Pro software, and then primed and painted it for action!  You can read an excerpt from the article he wrote on the Aquaman trident project as well as look at photos and view a super helpful how-to video below.

In Zach’s own words…

So a while back I made a small 18in tall Aquaman Trident out of some cherry wood. But then it made me wonder.. what would it take to go full size?

So this project breaks down to 4 pieces. The Trident top / fork, which I made in 2 halves. The bottom / handle and the pole. The pole is just a 1in wooden dowel so the fun part is the rest.

I knew if I made this out of wood that it would be too heavy so I wanted to use some kind of foam board. This is when I reached out the Precision Board for some samples.

To be fair, this is not a cheaper alternative but a better solution if you are concerned about the weight.

It cuts, sands and mills beautifully and was perfect for this project.

This process is the same for all 3 CNC’ed sections. Yes I had to use a CNC. Starting with a 1/4in endmill I created some 3/8in alignment holes for dowels. This is what I will use to register the two halves. The main thing here is that the pins are centered around your design. (I made that mistake before)

After I ran the rough and finishing passes on side one, I flipped the piece, clamped it and crossed my fingers! Oh, I think I forgot to mention, this was my first attempt at doing something like this.. lol.

Looks like it went well, took about an hour to cut both sides and I am totally happy with it!

After it’s cut out using anything you got, this stuff cuts nice! I sanding it down to 220 grit and test fit it on a 3/8in down that I centered on both the center pole (1in dowel) and the handle.

You can read the rest of the article HERE on making the Aquaman trident and also check out a more detailed step-by-step on Instructables.

We love how cool Zach’s project turned out and think he nailed the Aquaman trident using Precision Board HDU!  Our material is often used in theming and modeling projects, including movie props.  There is no limit to your creativity with high-density urethane.

Southern Ginger Workshop is run by Zach Manring.  You can check out his website HERE.

From Zach:

Growing up, I watched my father & grandfather weld & woodwork in their shops. I bit off my first major project by converting the attic in my mom’s garage to a loft apartment when I was 18. I pursued a career in web development & worked my way up to a senior level developer.

The thirst for building & making things never left me. In my Atlanta based basement workshop, I’ve built light up wooden signs, custom benches, aluminum badges & teardrop trailers. I also create weekly YouTube videos to show my design & build processes. Nothing is as rewarding as creating a custom solution to solve a customer’s problem. If you have a project in mind or are trying to figure out a solution, feel free to contact me. I pride myself in high quality craftsmanship, unique designs & fair, honest pricing.

Hi, I’m Zach Manring & I’d love to discuss your ideas.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for weekly newsletters packed with helpful information, including the monthly Blog Roundup.