endmill specs for foam milling ?

[max_imum2000]

i need so answers on these questions please

1. what are the best endmill i can use for foam milling ? ball, ..etc
2. how deep should go in each path ?
3. what speed should i use ? lower or higher is better ?
4. what travel speed it better ?

thank you in advance

[afmcorp]

Hello

you forgot one more question and that is which type of milling. climb milling or conventional milling.

1. what are the best endmill i can use for foam milling ? ball, ..etc

well i would start with a 2 flute centercut for plunging. foam is plastic and is subject to heat. if you have any heat build up you will ruin the finish. the thing i would look at is using a HIGH VOLUME OF AIR to keep any chips from sticking to the endmill and clogging up the flutes. once the flutes are clogged you'll only be burning the foam. as for ball end or square end that will depend on what you're machining i.e. curved surface or flat or 3D. this will also dictate what size. you'll want the biggest endmill that you can use but your geometry will tell you the actual size. as for type of milling climb or conventional your material will tell you. make a few cuts to see how the foam comes off. does it leave a clean surface or is it raggity. so then you can program around that.

2. how deep should go in each path ?

don't be tempted to go too fast and too deep. use the same basic rules as you would for metal. go less than 1/2 the diameter for side milling and less than the diameter deep.

3. what speed should i use ? lower or higher is better ?
4. what travel speed it better ?

these 2 questions should be qrouped together. based on load per tooth and the rpm you will dictate what the feed rate is. rpm is judgement. take those test cuts and visually decide. too fast will burn too slow may rip so you need to do some test cuts. the foam material i'm assuming is not a tuff cut. so you can likely make a fairly heavy feed rate. i know that when i cut a solid plastic i run up to 3000 rpm with a 2 flute maybe somewhere between 10 to 20 ipm. just depends how much i have to do. these speeds are more for a smaller end mill say under 5/16" [8mm].

do your tests then decide. you might also check out the niagara endmill site. they may have a chart on your material.

good luck

[fractaledge3]

Hi,

What type of foam you use? white or blue, also what type of milling? 3D or just cutting.
Then I can give you some surprising answers.

[max_imum2000]

hello
and thanks for your reply.
by the way i have sent you an email before but i didnt get any answers from you, or maybe i did and i over looked it .
well
i use blue and white foam. (well anything i can find over here)
and i am using engraving , not cutting

actually i wanted to make a foam hot wire cutting and independent axis but i wanted to use a turn table to produce real 3D shapes, but i couldnt find any software to handle this.

so i went to making a foam milling instead

so what do u think ?

kol sana wenta tayeb, we 3eed sa3eed

[fractaledge3]

Hello,

Kol sana wenta tayb, I received your Email and replied to you but I didn't get answer from you.
I am not using end mill for foam cutting or engraving , I am using a plane rod instead (like nail or end mill shank) with 20,000 router RPM , but when I need 3D milling I use rounded tip rod or V shape tip rod, also you can use wood carving tools (rounded or v shape).

[swagman]

i use rotary burs . they give great finish and can be run quick.

[fractaledge3]

Originally Posted by swagman i use rotary burs . they give great finish and can be run quick.

Hi swagman,
What rotary burs looks like

[Sparktech]

Hi. I've found that standard metal cutting endmills don't have the correct flute geometry to do a real good job in foam (or wood). Foam and wood tools require a higher rake angle and smaller core. Look for some wood or plastic endmills, and they should work fine. I've never tried the routers, but I would think one of the single flute router type tools would also work. Hope this helps.

[swagman]

i will try to get pic up for you. they work really well, don't rip up the foam.

[fractaledge3]

Thanks Swagman.

[swagman]

2 pics of rotary burs used for foam cutting.

[fractaledge3]

Hi,
Many thanks. The photos show every thing I just can't get the meaning in English, Yes I used it before to engrave also in colored rubber foam.