What is the best router to cut this foam/rubber?

[Darc]

Hi guys,
I tried to cut this foam/rubber with a 30° endmill, then I tried a 45° endmill but as you can see it just tore the hell out of it.
I also noticed the plastic ontop just melted around the edges.
I've got a proper router on the way, so I tried to machine it in our VMC, I ran it at 8000 RPM.
Could someone please advise what is the best style of router to machine this material?
Thanks

[DieGuy]

Originally Posted by Darc Hi guys, I tried to cut this foam/rubber with a 30° endmill, then I tried a 45° endmill but as you can see it just tore the hell out of it. I also noticed the plastic ontop just melted around the edges. I've got a proper router on the way, so I tried to machine it in our VMC, I ran it at 8000 RPM. Could someone please advise what is the best style of router to machine this material? Thanks

Try putting it in a freezer and then cutting it.

[Darc]

Hey that mightn't be as crazy as it sounds.........thanks

[Splint]

Take some reference cuts in an offcut area on your first attempt to make sure you can calculate the effects of thermal contraction. Let it thaw out and then measure it and see how much the dimensions change, scale the toolpath/cad drawing accordingly and you should be able to accurately cut it.
Splint

[Mcgyver]

Originally Posted by Darc Hey that mightn't be as crazy as it sounds.........thanks

I know freezing is a standard way to cut rubber, is this common with foam rubber? did it work for you?