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Machining Guidelines - Milling

Milling Guidelines for Plastics

Essential information for successful milling operations on plastic materials

Milling plastic materials requires specific tool geometries and machining parameters to achieve quality finished parts. Due to plastics' tendency to generate heat and deflect under cutting forces, proper tool selection and cutting techniques are essential to prevent melting, burrs, and dimensional inaccuracies.

Key Considerations for Milling Plastics:

  • Tool Geometry: Use end mills with 2-4 flutes for most plastics. Fewer flutes provide better chip evacuation while maintaining adequate surface finish.
  • Helix Angle: A 30-45° helix angle helps create shearing action rather than scraping, reducing heat generation.
  • Rake Angle: Positive rake angles (0-10°) reduce cutting forces and heat generation during milling operations.
  • Relief Angle: A 10-15° relief angle prevents tool rubbing and subsequent heat buildup.
  • Cooling: Compressed air cooling is recommended for most applications to prevent heat-related deformation.

The table below provides specific milling parameters for different plastic materials based on their machinability ratings and physical properties.

Note: Always ensure adequate workpiece fixturing to prevent movement during machining. If possible, use vacuum fixtures for sheet materials to provide uniform clamping without distortion.

Troubleshooting Guide

Solutions for common issues with plastic machining operations

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MILLING
Milling Parameters Diagram
Plastic Material Trade Names Relavtive Machinability
(Unfilled)
1 = Easiest
10 = Hardest		 Relative Machinability
(CA, GF Filled)
1 = Easiest
10 = Hardest		 Clearance
Angle
α		 Rake
Angle
ϒ		 End Milling / Slotting

High Speed
Steel (M2, M7)		 End Milling / Slotting

Depth of Cut
(Inches)		 End Milling / Slotting

Speed
(RPM)		 End Milling / Slotting

Feed
(Inches/Min)		 C-2 Carbide Tool

Depth
of Cut		 C-2 Carbide Tool

Speed
(RPM)		 C-2 Carbide Tool

Feed
(Inches/Min)
Acrylonitrile Butadiene Styrene (ABS) Tecaran®
GEHR ABS®
ABSylux®		 2   5-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Acrylonitrile Butadiene Styrene (ABS) Tecaran®
GEHR ABS®
ABSylux®		 2   5-20 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Polyvinyl Chloride
PVC Type 1 & 2
Chlorinated Polyvinyl Chloride (CPVC)		 PVC-CAW
Vintec® I & II
Corzan® - resin		 2   5-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Polyvinyl Chloride
PVC Type 1 & 2
Chlorinated Polyvinyl Chloride (CPVC)		 PVC-CAW
Vintec® I & II
Corzan® - resin		 2   5-20 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Polyphenylene Oxide (PPO) Tecanyl®
GEHR PPO®
SustaPPO®		 2   5-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Polyphenylene Oxide (PPO) Tecanyl®
GEHR PPO®
SustaPPO®		 2   5-20 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Polymethyl-Methacrylate (PMMA) Acrylics Plexiglas®
Acrylite®
Lucite®		 2   5-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Polymethyl-Methacrylate (PMMA) Acrylics Plexiglas®
Acrylite®
Lucite®		 2   5-20 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Polyehtylene (PE)
LDPE, HDPE, UHMW-PE		 Tecafine®
UHMWPE / Hy-pact®
TIVAR®
Polystone®		 1   10-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 6500-8000 35-45 0.15 2500-4500 40-60
Polyehtylene (PE)
LDPE, HDPE, UHMW-PE		 Tecafine®
UHMWPE / Hy-pact®
TIVAR®
Polystone®		 1   10-20 5-15 1/4", 1/2",
3/4"		 0.05 7000-8500 25-30 0.06 2500-4500 40-60
Polypropylene (PP) Tecapro®
Proteus®
Polystone®		 2   10-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 40-60
Polypropylene (PP) Tecapro®
Proteus®
Polystone®		 2   10-20 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 20-25 0.06 2500-4500 40-60
Nylon Polyamide (PA)
Type 6, Type 66, Type 46
Type 11, Type 12
Type 66 - Kevlar® Filled		 Nycast®
Tecamid® / Nylatron®
Sustamid® / ZL®1100, 250
Hydlar®		 1   10-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 6500-8000 35-45 0.15 2500-4500 30-45
Nylon Polyamide (PA)
Type 6, Type 66, Type 46
Type 11, Type 12
Type 66 - Kevlar® Filled		 Nycast®
Tecamid® / Nylatron®
Sustamid® / ZL®1100, 250
Hydlar®		 1   10-20 5-15 1/4", 1/2",
3/4"		 0.05 7000-8500 25-30 0.06 2500-4500 15-20
Acetal Polyoxymethylene (POM)
Copolymer (POM-C)
Homopolymer (POM-H)		 Delrin® / Tecaform®
GEHR Acetal® / Acetron®
Sustarin®
ZL® 900		 1   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 6500-8000 35-45 0.15 2500-4500 30-45
Acetal Polyoxymethylene (POM)
Copolymer (POM-C)
Homopolymer (POM-H)		 Delrin® / Tecaform®
GEHR Acetal® / Acetron®
Sustarin®
ZL® 900		 1   5-15 5-15 1/4", 1/2",
3/4"		 0.05 7000-8500 25-30 0.06 2500-4500 15-20
Polycarbonate (PC) Tacanat®
Tuffak® / Sustanat®
Zelux® / ZL® 1600
Lexan® - Resin		 2   5-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Polycarbonate (PC) Tacanat®
Tuffak® / Sustanat®
Zelux® / ZL® 1600
Lexan® - Resin		 2   5-20 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Sulfones
Polysulfone (PSU)
Polyphenylsulfone (PPSU)		 Tecason®
Sultron®
Sustason®
Udel®, Radel® - resins		 3   5-15 0-10 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Sulfones
Polysulfone (PSU)
Polyphenylsulfone (PPSU)		 Tecason®
Sultron®
Sustason®
Udel®, Radel® - resins		 3   5-15 0-10 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Polyeitherimide (PEI) TecaPEI®,
Duratron®
SustaPEI® ZL® 1000
Ultem® 1000 - resin		 3   5-15 0-10 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 15-25 0.15 2500-4500 10-15
Polyeitherimide (PEI) TecaPEI®,
Duratron®
SustaPEI® ZL® 1000
Ultem® 1000 - resin		 3   5-15 0-10 1/4", 1/2",
3/4"		 0.05 3000-4500 10-15 0.06 2500-4500 10-15
Polyethylene-terephthalate (PET-P)
Polyester - precrystallized
Polybutylene-terephthalate (PBT)		 GEHR PET®
TecaPET® / Ertalyte®
Sustadur® / ZL® 1400
Hydex®		 3   5-15 0-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 12-15 0.15 2500-4000 10-12
Polyethylene-terephthalate (PET-P)
Polyester - precrystallized
Polybutylene-terephthalate (PBT)		 GEHR PET®
TecaPET® / Ertalyte®
Sustadur® / ZL® 1400
Hydex®		 3   5-15 0-15 1/4", 1/2",
3/4"		 0.05 3000-4500 12-15 0.06 2500-4000 10-12
Polyetheretherketone (PEEK)
PAEK, PEEK, PEK, PEKK, PEKEKK
CA30%, GF30%		 TecaPEEK® / GEHR PEEK®
Ketron®
SustaPEEK®
ZL® 1500		 5 7 5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.15 2500-4000 12-15 0.15 2500-4000 10-12
Polyetheretherketone (PEEK)
PAEK, PEEK, PEK, PEKK, PEKEKK
CA30%, GF30%		 TecaPEEK® / GEHR PEEK®
Ketron®
SustaPEEK®
ZL® 1500		 5 7 5-15 5-15 1/4", 1/2",
3/4"		 0.06 2500-4000 10-12 0.06 2500-4000 10-12
Polytetrafluoroethylene (PTFE)
Unfilled, Glass, or Mica Filled
Ethylene TetrafluoroEthylene (ETFE)		 Teflon® - Resin
Fluorosint® / Rulon®
Tefzel® - Resin		 1 3 10-20 5-15 1/4", 1/2",
3/4", 1", 2"		 0.15 6500-8000 35-45 0.15 2500-4000 10-15
Polytetrafluoroethylene (PTFE)
Unfilled, Glass, or Mica Filled
Ethylene TetrafluoroEthylene (ETFE)		 Teflon® - Resin
Fluorosint® / Rulon®
Tefzel® - Resin		 1 3 10-20 5-15 1/4", 1/2",
3/4"		 0.06 7000-8500 25-30 0.06 2500-4000 10-15
Polyvinylidene fluoride (PVDF)
Fluorinated Ethylene Propylene (FEP)
Polychlorotrifluoroethylene (PCTFE)
Perfluroalkoxy (PFA)		 Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 12-15 0.15 2500-4000 10-12
Polyvinylidene fluoride (PVDF)
Fluorinated Ethylene Propylene (FEP)
Polychlorotrifluoroethylene (PCTFE)
Perfluroalkoxy (PFA)		 Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   5-15 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 12-15 0.06 2500-4000 10-12
Ethylene chlorotrifluoroethylene (ECTFE)* Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.25 2500-4000 12-15 0.15 2500-4000 10-12
Ethylene chlorotrifluoroethylene (ECTFE)* Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   5-15 5-15 1/4", 1/2",
3/4"		 0.05 3000-4500 12-15 0.06 2500-4000 10-12
Polyphenylene sulfide (PPS) Tecatron®
GEHR PPS®
Sustatron®		 5   5-15 5-10 1/4", 1/2",
3/4", 1", 2"		 0.15 2500-4000 12-15 0.15 2500-4000 10-12
Polyphenylene sulfide (PPS) Tecatron®
GEHR PPS®
Sustatron®		 5   5-15 5-10 1/4", 1/2",
3/4"		 0.06 2500-4000 10-12 0.06 2500-4000 10-12
Polyamideimide (PAI) Tecator®
Duratron®
Torlon® - resin		 5 8 5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.035 2500-4000 10-15 0.035 2500-4000 10-12
Polyimide (PI) Plavis®
Vespel®
XP-131 PI
Duratron®		 5   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.035 2500-4000 10-15 0.035 2500-4000 10-12
Polybenzimidazole (PBI) / Polyetheretherketone (PEEK) Blend Celazole® TU-60 8   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.15 2500-4000 12-15 0.15 2500-4000 10-12
Polybenzimidazole (PBI) / Polyetheretherketone (PEEK) Blend Celazole® TU-60 8   5-15 5-15 1/4", 1/2",
3/4"		 0.06 2500-4000 10-12 0.06 2500-4000 10-12
Polybenzimidazole (PBI) / Polyethketoneketone (PEKK) Blend Celazole® TK-60 8   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.15 2500-4000 12-15 0.15 2500-4000 10-12
Polybenzimidazole (PBI) / Polyethketoneketone (PEKK) Blend Celazole® TK-60 8   5-15 5-15 1/4", 1/2",
3/4"		 0.06 2500-4000 10-12 0.06 2500-4000 10-12
Polybenzimidazole (PBI) Celazole® U-60
Duratron® CU 60		 10   5-15 5-15 1/4", 1/2",
3/4", 1", 2"		 0.015 2500-3500 6-10 0.015 2000-3000 8-10
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