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Machining Guidelines - Turning

Turning Guidelines for Plastics

Essential information for successful turning operations on plastic materials

Turning plastic materials requires different approaches than those used for metals. Due to the low thermal conductivity and elastic properties of plastics, heat buildup and deflection are major concerns. This guide provides key parameters for successful turning operations across various plastic materials.

Key Considerations for Turning Plastics:

  • Tool Geometry: Sharp cutting edges with positive rake angles (typically 5-15°) reduce cutting forces and heat generation.
  • Cutting Speed: Generally lower than metals to prevent melting and burning. Refer to the guidelines table for specific recommendations.
  • Feed Rate: Use moderate to high feed rates to ensure chip formation rather than pushing or rubbing.
  • Cooling: Compressed air cooling is often sufficient, but water-soluble coolants may be used for higher-temperature operations.
  • Tool Material: Carbide and PCD (Polycrystalline Diamond) tools are recommended for most applications.

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

Note: Always perform test cuts on scrap material before machining production parts, as specific plastic grades may require parameter adjustments.

Troubleshooting Guide

Solutions for common issues with plastic machining operations

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TURNING
Turning Parameters Diagram
Plastic Material Trade Names Relavtive Machinability
(Unfilled)
1 = Easiest
10 = Hardest		 Relative Machinability
(CA, GF Filled)
1 = Easiest
10 = Hardest		 Clearance
Angle		 Rake
Angle		 Side
Angle		 Depth of Cut
(inches)		 Speed
(ft/min)		 Feed
(inches/rev)
Acrylonitrile Butadiene Styrene (ABS) Tecaran®
GEHR ABS®
ABSylux®		 2   5-15 25-30 15 0.15 500-600 .010-.015
Acrylonitrile Butadiene Styrene (ABS) Tecaran®
GEHR ABS®
ABSylux®		 2   5-15 25-30 15 0.025 600-700 .004-.007
Polyvinyl Chloride
PVC Type 1 & 2
Chlorinated Polyvinyl Chloride (CPVC)		 PVC-CAW
Vintec® I & II
Corzan® - resin		 2   8-10 0-5 50-60 0.15 500-600 .010-.015
Polyvinyl Chloride
PVC Type 1 & 2
Chlorinated Polyvinyl Chloride (CPVC)		 PVC-CAW
Vintec® I & II
Corzan® - resin		 2   8-10 0-5 50-60 0.025 600-700 .004-.007
Polyphenylene Oxide (PPO) Tecanyl®
GEHR PPO®
SustaPPO®		 2   5-12 6-8 45-60 0.15 500-600 .010-.015
Polyphenylene Oxide (PPO) Tecanyl®
GEHR PPO®
SustaPPO®		 2   5-12 6-8 45-60 0.025 600-700 .004-.007
Polymethyl-Methacrylate (PMMA) Acrylics Plexiglas®
Acrylite®
Lucite®		 2   5-10 0-4 15 0.15 500-600 .010-.015
Polymethyl-Methacrylate (PMMA) Acrylics Plexiglas®
Acrylite®
Lucite®		 2   5-10 0-4 15 0.025 600-700 .004-.007
Polyehtylene (PE)
LDPE, HDPE, UHMW-PE		 Tecafine®
UHMWPE / Hy-pact®
TIVAR®
Polystone®		 1   6-10 0-5 45-60 0.15 500-600 .010-.015
Polyehtylene (PE)
LDPE, HDPE, UHMW-PE		 Tecafine®
UHMWPE / Hy-pact®
TIVAR®
Polystone®		 1   6-10 0-5 45-60 0.025 600-700 .004-.007
Polypropylene (PP) Tecapro®
Proteus®
Polystone®		 2   6-10 0-5 45-60 0.15 500-600 .010-.015
Polypropylene (PP) Tecapro®
Proteus®
Polystone®		 2   6-10 0-5 45-60 0.025 600-700 .004-.007
Nylon Polyamide (PA)
Type 6, Type 66, Type 46
Type 11, Type 12		 Nycast®
Tecamid® / Nylatron®
Sustamid® / ZL®1100, 250
Hydlar®		 1   6-10 0-5 45-60 0.15 500-600 .010-.015
Nylon Polyamide (PA)
Type 6, Type 66, Type 46
Type 11, Type 12		 Nycast®
Tecamid® / Nylatron®
Sustamid® / ZL®1100, 250
Hydlar®		 1   6-10 0-5 45-60 0.025 600-700 .004-.007
Acetal Polyoxymethylene (POM)
Copolymer (POM-C)
Homopolymer (POM-H)		 Delrin® / Tecaform®
GEHR Acetal® / Acetron®
Sustarin®
ZL® 900		 1   6-8 0-5 45-60 0.15 500-600 .010-.015
Acetal Polyoxymethylene (POM)
Copolymer (POM-C)
Homopolymer (POM-H)		 Delrin® / Tecaform®
GEHR Acetal® / Acetron®
Sustarin®
ZL® 900		 1   6-8 0-5 45-60 0.025 600-700 .004-.007
Polycarbonate (PC) Tacanat®
Tuffak® / Sustanat®
Zelux® / ZL® 1600
Lexan® - Resin		 2   5-12 6-8 45-60 0.15 500-600 .010-.015
Polycarbonate (PC) Tacanat®
Tuffak® / Sustanat®
Zelux® / ZL® 1600
Lexan® - Resin		 2   5-12 6-8 45-60 0.025 600-700 .004-.007
Sulfones
Polysulfone (PSU)
Polyphenylsulfone (PPSU)		 Tecason®
Sultron®
Sustason®
Udel®, Radel® - resins		 3   5-10 0-5 45-60 0.15 500-600 .010-.015
Sulfones
Polysulfone (PSU)
Polyphenylsulfone (PPSU)		 Tecason®
Sultron®
Sustason®
Udel®, Radel® - resins		 3   5-10 0-5 45-60 0.025 600-700 .004-.007
Polyeitherimide (PEI) TecaPEI®,
Duratron®
SustaPEI® ZL® 1000
Ultem® 1000 - resin		 3   5-10 0-10 45-60 0.15 500-600 .010-.015
Polyeitherimide (PEI) TecaPEI®,
Duratron®
SustaPEI® ZL® 1000
Ultem® 1000 - resin		 3   5-10 0-10 45-60 0.025 600-700 .004-.007
Polyethylene-terephthalate (PET-P)
Polyester - precrystallized
Polybutylene-terephthalate (PBT)		 GEHR PET®
TecaPET® / Ertalyte®
Sustadur® / ZL® 1400
Hydex®		 3   5-15 0-15 45-60 0.15 500-600 .010-.015
Polyethylene-terephthalate (PET-P)
Polyester - precrystallized
Polybutylene-terephthalate (PBT)		 GEHR PET®
TecaPET® / Ertalyte®
Sustadur® / ZL® 1400
Hydex®		 3   5-15 0-15 45-60 0.025 600-700 .004-.007
Polyetheretherketone (PEEK)
PAEK, PEEK, PEK, PEKK, PEKEKK
CA30%, GF30%		 TecaPEEK® / GEHR PEEK®
Ketron®
SustaPEEK®
ZL® 1500		 5 7 5-10 3-8 45-60 0.15 350-500 .010-.015
Polyetheretherketone (PEEK)
PAEK, PEEK, PEK, PEKK, PEKEKK
CA30%, GF30%		 TecaPEEK® / GEHR PEEK®
Ketron®
SustaPEEK®
ZL® 1500		 5 7 5-10 3-8 45-60 0.025 500-600 .003-.008
Polytetrafluoroethylene (PTFE)
Unfilled, Glass, or Mica Filled
Ethylene TetrafluoroEthylene (ETFE)		 Teflon® - Resin
Fluorosint® / Rulon®
Tefzel® - Resin		 1 3 5-10 5-8 10 0.15 600-1000 .010-.016
Polytetrafluoroethylene (PTFE)
Unfilled, Glass, or Mica Filled
Ethylene TetrafluoroEthylene (ETFE)		 Teflon® - Resin
Fluorosint® / Rulon®
Tefzel® - Resin		 1 3 5-10 5-8 10 0.025 600-700 .004-.007
Polyvinylidene fluoride (PVDF)
Fluorinated Ethylene Propylene (FEP)
Polychlorotrifluoroethylene (PCTFE)
Perfluroalkoxy (PFA)		 Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   5-12 5-15 10 0.15 500-600 .010-.015
Polyvinylidene fluoride (PVDF)
Fluorinated Ethylene Propylene (FEP)
Polychlorotrifluoroethylene (PCTFE)
Perfluroalkoxy (PFA)		 Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   5-12 5-15 10 0.025 600-700 .004-.007
Ethylene chlorotrifluoroethylene (ECTFE)* Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   6-10 0-5 45-60 0.15 500-600 .010-.015
Ethylene chlorotrifluoroethylene (ECTFE)* Kynar® - Resin
Kel-F®, Neoflon® - Resins
Hyflon® - Resin
Halar® - Resin		 2   6-10 0-5 45-60 0.025 600-700 .004-.007
Polyphenylene sulfide (PPS) Tecatron®
GEHR PPS®
Sustatron®		 5   5-10 0-5 45-60 0.15 600-1000 .010-.016
Polyphenylene sulfide (PPS) Tecatron®
GEHR PPS®
Sustatron®		 5   5-10 0-5 45-60 0.025 600-700 .004-.007
Polyamideimide (PAI) Tecator®
Duratron®
Torlon® - resin		 5 8 5-10 3-8 45-60 0.025 300-800 .004-.007
Polyimide (PI) Plavis®
Vespel®
XP-131 PI
Duratron®		 5   5-10 3-8 45-60 0.025 300-800 .004-.007
Polybenzimidazole (PBI) / Polyetheretherketone (PEEK) Blend Celazole® TU-60 8   5-10 3-8 45-60 0.15 350-500 .010-.015
Polybenzimidazole (PBI) / Polyetheretherketone (PEEK) Blend Celazole® TU-60 8   5-10 3-8 45-60 0.025 500-600 .003-.008
Polybenzimidazole (PBI) / Polyethketoneketone (PEKK) Blend Celazole® TK-60 8   5-10 3-8 45-60 0.15 350-500 .010-.015
Polybenzimidazole (PBI) / Polyethketoneketone (PEKK) Blend Celazole® TK-60 8   5-10 3-8 45-60 0.025 500-600 .003-.008
Polybenzimidazole (PBI) Celazole® U-60
Duratron® CU 60		 10   5-10 3-8 45-60 0.15 100-150 .005-.010
Polybenzimidazole (PBI) Celazole® U-60
Duratron® CU 60		 10   5-10 3-8 45-60 0.025 150-225 .002-.006
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