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products/poly-mech/.gitattributes

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products/poly-mech/resources/material/hdpe/milling-hdpe.md

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+### Milling - Speeds & Feeds
+
+# Machining Guide
+
+## Basic Machining Tips for Engineering Plastics
+
+- **Keep heat to a minimum** and ensure heat build-up in the part is avoided.
+- **Keep tools sharp** at all times.
+- Ensure that only the **cutting edge contacts** the material.
+- Apply coolants (per guidelines) where heat is generated.
+- The lower rigidity of plastics may require **support or plugging** to avoid deflection in thin-walled sections.
+- Cutting tools should be **high-speed steel** or **carbide-tipped** for production runs, especially on graphite or glass-filled materials.
+
+## Matching Tolerance
+
+- It is much larger than for metal.
+- Watch for **stress relieving** where a large body of material is removed.
+- **Thermal conditioning** may be required after pre-machining on some parts.
+- Allow a tolerance of **0.1-0.2% of nominal size**.
+- Be aware of **thermal expansion** in larger parts or panels where fixings are required.
+- **Minimum tolerance** for small dimensions: **0.05mm**.
+
+| Endmill Diameter (Millimeters) | Surface Speed (SMM) | Feed Per Tooth (MMPT) |
+|--------------------------------|---------------------|-----------------------|
+| 3.175mm                         | 91-114 SMM          | 0.02286               |
+| 6.350mm                         | 91-114 SMM          | 0.04572               |
+| 12.700mm                        | 91-114 SMM          | 0.0889                |
+| 15.875mm                        | 91-114 SMM          | 0.1143                |
+| 19.05mm                         | 91-114 SMM          | 0.1397                |
+| 25.4mm                          | 91-114 SMM          | 0.1778                |
+
+| Endmill Diameter (inches) | Surface Speed (SFM) | Feed Per Tooth (IPT) |
+|---------------------------|---------------------|----------------------|
+| 1/8"                       | 300-375 SFM         | 0.0009               |
+| 1/4"                       | 300-375 SFM         | 0.0018               |
+| 1/2"                       | 300-375 SFM         | 0.0035               |
+| 5/8"                       | 300-375 SFM         | 0.0045               |
+| 3/4"                       | 300-375 SFM         | 0.0055               |
+| 1"                         | 300-375 SFM         | 0.007                |
+
+### References
+
+- [Source: Feed Calculator](https://www.easyspeedsandfeeds.com/plastic)

products/poly-mech/resources/material/hdpe/tests-milling.csv

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+Mill Diameter (mm),Material,Depth of Cut (mm),Width of Cut,Speed (RPM),Feed Rate (mm/min),Tool Material,Type,Type of Cutting,Tool,Error,Cooling Method,Surface Finish Quality,Observations
+17,HDPE,10,4mm,1500,300,Carbide,Climbing,Contour,2 Flute,0.3,Cooling Fluid,5,Toolmarks
+14,HDPE,10,5mm,2000,300,Carbide,Climbing,Contour,2 Flute,0.3,Cooling Fluid,5,Toolmarks | Bur
+14,HDPE,15,100%,2000,300,Carbide,Helix,Pocket-Round,2 Flute,0.1,Cooling Fluid,10,

products/poly-mech/resources/material/mdpe/tests-milling.csv

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+Mill Diameter (mm),Material,Depth of Cut (mm),Width of Cut,Speed (RPM),Feed Rate (mm/min),Tool Material,Type,Type of Cutting,Tool,Error,Cooling Method,Surface Finish Quality,Observations
+17,HDPE,10,4mm,1500,300,Carbide,Climbing,Contour,2 Flute,0.3,Cooling Fluid,5,Toolmarks
+14,HDPE,10,5mm,2000,300,Carbide,Climbing,Contour,2 Flute,0.3,Cooling Fluid,5,Toolmarks | Bur
+14,HDPE,15,100%,2000,300,Carbide,Helix,Pocket-Round,2 Flute,0.1,Cooling Fluid,10,

products/poly-mech/resources/material/mdpe/tests-pressing.csv

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+Thickness,Material,Mould Material,Mould Cover,Temperature,Tool,Flatness Error,Cooling Method,Surface Finish Quality,Observations
+20,MDPE,Cold Rolled Steel,Stainless,,,0.3,Natural,5,Toolmarks