TECH

Fabrication BRIEF
#5 Routing
There are three basic machine designs:
Gantry type machines have an overhead beam that
This brief gives advice for: supports one or more routing heads or motorized
spindles on a column. The column can be programmed
l Equipment to travel along the gantry beam both horizontally and
vertically. The beam itself rides on two vertical supports
l Procedures
that travel along parallel tracks set on both sides of a
l Trouble Shooting stationary worktable. This facilitates a third axis of
movement.
l Equipment Suppliers
l Additional Technical Information Stationary bridge machines are similar to gantry type
machines except that the bridge is stationary. The third
and Assistance
axis of movement is facilitated by a worktable that can
move in a horizontal plane perpendicular to the station-
ary bridge.

Machining centers originate in the tool industry. They

Equipment offer higher precision and are commonly used for the
production of small component parts. These machines
Manual Feed Routers
typically have smaller worktables than the stationary
Many commercially available types of routers are bridge or gantry machines and carry a higher price,
acceptable. These include hand held routers, table corresponding to their accuracy and versatility.
routers, pin routers and fixed position routers. The router
should have a minimum of one horsepower and a no All of these CNC machine types are available for
load speed of 20,000 RPM. purchase with hardware and software to facilitate
machining on 2 ½, 3, 4 and 5 axis. There are machines
CNC (Computer Numerical Controlled) suitable for any requirement from fabrication of small
Routers prototypes to large part production runs. CNC machines
Computerized Numerical Control (CNC) machines are can handle repetitive production cycles, using one or
available from several manufacturers for high volume two tables. They are also available with multiple routing
production. Today there are many companies manufac- heads or spindles, so several parts can be produced at
turing CNC routers servicing industries that fabricate the same time. Options such as turret heads and tool
wood, metal and plastic products. As a result, a variety changing spindles to facilitate tool changes without
of machine designs are available to fit the job demand. stopping the machine are available. CNC machines can
be set up for semi-automatic or fully automatic opera-
Light duty routers made for engraving or routing thin tions that incorporate material pallet changers and
(.118") single sheet, are commonly fitted with one to automated loading and unloading equipment.
three horsepower spindle motors. Medium duty routers
as seen in the sign industry use four to seven horse- If business demands justify a step up in production,
power motors. Large volume and multiple head routers CNC routing is one of the best ways to increase produc-
have motors ranging from seven to twenty horsepower. tivity, as well as assure reproducible results and quality.

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 Router Bits
Router bits may be made of high-speed steel (HSS), carbide-tipped, solid carbide or diamond-tipped. They
can be one piece, multiple part, bearing guided, straight cutting, forming or specialty bits.

Router bits for machining acrylic may consist of one to three flutes. Single and double fluted bits are commonly
used. When using HSS or brazed carbide bits, the length of the cutting edge should not exceed three times the
diameter of the tool or a ratio of 3 to 1. With the proper use of solid carbide bit technology, this ratio can be
increased to 4.5 to 1. Bit shank diameter should always be equal to or larger than the cutting tool diameter. The
length of the shank should be long enough so that the entire cutting edge is usable. Bits should be mounted in a
clean collet chuck and set to allow maximum tool bit support and flute clearance to facilitate chip ejection.

For hand held routing, two-flute straight bits are usually recommended.

For table routers, pin routers and fixed position routers, single-flute or two-flute bits can be used. Single flute
straight bits will give good results when contour routing. Single or double flute up-spiral bits will produce better
results when cutting grooves or channels since the up-spiral configuration will assist in removing chips. Both “O”
flute and “V” flute geometries work well.

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When processing acrylic using a CNC router, solid hold the template to the material and moved when
carbide, up-spiral “O” flute router bits will produce the necessary. Templates can be made from plywood,
best results. They are available with one, two or three fiberboard or rigid plastic. A hand-held router can be
flutes. Common bit sizes are 1/8" to 1/2" diameter. piloted around the pattern in several ways. Offsets can
These bits are less susceptible to friction and heat build be calculated making allowances for the router sub-
up because the O-flute design allows chips to curl base, template guide, or a piloted bearing follower bit.
naturally as they are formed and facilitates better
evacuation of the chips from the cutting area. In less
demanding applications, standard twist bits (V-flute
geometry) can also be used with success.

In general, up-spiral bits are recommended because

they pull chips up and out of the way, reducing frictional
heat build-up. However, when material hold down is an
issue, straight flute or down-spiral geometries may be
beneficial. Increasing the number of flutes on the bit will
usually result in a better quality finish on the edges of
the routed surface. However, tooling cost also increases
with the number of flutes on the bit. Therefore, it is best
to start with a one or two flute bit and only step up to a
higher number of flutes if necessary.

Tools with a single flat-faced cutter are commonly

employed for engraving applications. These include
profile cutters, parallel cutters and braille cutters.
Rigidity is important so solid carbide tools should be
used. When engraving letter widths greater than 0.060",
other router bit types may be necessary to provide the
desired finish on the inside of the letter. These include V-
grooving, veining, up-spiral ball nose and double-edge
bottom surfacing bits.

Tool Maintenance
The cutters should be kept sharp. Chipping or overheat-
ing will occur with a dull cutter. Both will impart stress
into the sheet.

Procedures
Be sure to follow the manufacturers’ safety recommen-
dations for equipment and materials used with
ACRYLITE® FF acrylic sheet.

Safety
When using routing equipment always wear protective
face shields or safety goggles. Hearing protection is
recommended for extended periods of routing. If a
vacuum system is not used, a respirator or dust mask
will offer protection from dust particles.

Hand Routing
Prototype and replacement parts can be produced using
a hand router. The router is guided around a precut
template pattern that is fastened to the acrylic sheet.
The template is typically held to the sheet using vacuum
or two-sided adhesive tape. Clamps may also be used to

3
 Circle Routing 10,000 RPM and feed rates at 55 to 65 IPM. In general,
Circles of varying diameter can be fabricated with a chip loads (IPT) of 0.003" to 0.006"/tooth should be
cutting fixture consisting of a fixed position router and a used for engraving applications (refer to the Operation
sliding adjustable rotary table. The adjustable table is Terminology and Formulas section for more details).
mounted on a sliding shaft and column. This can be Machines will vary in performance so this information
adjusted for variable center distances. The sheet is held should only be used as a starting reference.
on the rotating table with vacuum. Once set up, the
sheet is moved into the cutter and rotated 360° to Computerized Numerical Control (CNC) Routing
machine the circle. This method allows for easy machin- – Machine Characteristics and Fixturing
ing and size adjustment. It can also be adapted to In order to optimize machining on a CNC router, there
machine other shapes by following a pattern. Circles can are several key points to consider. The first is the
also be cut using a hand router and precut circle tem- machine type and condition. This includes the integrity
plates. of the spindle, the selection and condition of the collets,
the machine table and the fixturing. The quality of the
Pin Routing / Overhead Routers equipment and fixtures being used will have a significant
Pin routing machines are very versatile. Pin routers impact on the rate at which parts can be processed and
utilize a horizontal column to support a pneumatically the quality of the finished parts.
activated guide pin. This pin is set directly over a spindle
which holds the router bit below the worktable. Both the Fixturing or part hold down will change with the part
pin and router bit are fed to a preset stop and are design and size. The most common way of holding
activated by a foot pedal. Plunge routing can be accom- material on a CNC routing table is by using vacuum to
plished using this feature. The template has the material hold parts onto a spoilboard base. Spoilboard is a
to be machined fastened below it. An operator feeds the medium density fiberboard (MDF) that can be machined
template along the table to the pin and then guides the or milled to facilitate part hold down. The two types
top edge of the template along the pin. As the template commonly used are: Conventional Vacuum Spoilboard
is rotated 360° around the pin, the rotating router bit cuts and Universal Vacuum Spoilboard.
the material fastened below the template. The material is Conventional Vacuum Spoilboard is used in conjunc-
commonly fastened to the template using double-stick tion with a high vacuum, low volume pump. Generally
tape or vacuum. Overhead routers work in the same fixtures are specially designed for the parts being
manner with the router and pin locations inverted. processed and therefore different fixtures are required
Contour Routing for each part design. Fixtures are made by machining
grooves into the spoilboard to supply vacuum to the
Pin routing machines may also be used for multiple part,
part. A gasket is usually attached to the spoilboard just
stepped or contoured part manufacture. To accomplish
inside the outer contour of the part to help maintain a
this a contour jig must be employed. The desired pattern
good vacuum seal between the part and the spoilboard.
is cut on the base of the contour jig to match a depth
This type of fixture provides the greatest holding force
stop preset below the worktable. Several pieces of
for the part.
material are secured to each other to form a stepped
template. The cutting tool is then guided by a series of Universal Vacuum Spoilboard is used in conjunction
step pin stops set below the worktable. These pins with a low vacuum, high volume pump to provide
control the cutting depth of the router bit. The process vacuum through the pour structure of the entire
does not cut all the way through the sheet. The material spoilboard. Material laid on the spoilboard will be held in
is only separated following the final cut. This multi-cut place once the vacuum is turned on. The advantage of
process enables the cutting of contoured patterns. this board is that it does not require grooves to direct the
vacuum or gasket to ensure a good seal. As a result, a
Engraving
single spoilboard base can be used for many different
Machining ACRYLITE FF sheet using engraving bits part designs. Universal vacuum spoilboards are not
requires the correct spindle speed (RPM), feed rate recommended for working with small parts or parts with
(IPM) and depth of cut. The ability to remove chips and rough surfaces.
keep the sheet cool while cutting is a key consideration
when engraving. Speeds should be set at 9,000 to

4
Other methods of part hold down include: bolting down Operating Conditions
the material, using cam lock clamps, and holding the Once the optimum processing parameters have been
work in a vice that is bolted to the router table. determined, consideration must be given to the operat-
ing conditions for the CNC router. This includes settings
Processing Parameters for the spindle speed and cutter feed rate through the
The part requirements and how they impact processing material. Rotational speeds of 16,000 to 18,000 revolu-
must be considered. Knowing the depth of cuts to be tions per minute (RPM) and feed rates of 100 to 300 per
made, the minimum inside radius required on the minute (IPM), normally produce the best results with
finished part and the edge finish quality requirements 1/4", 3/8" and 1/2" diameter bits.
will guide the selection of tooling and processing param-
eters. Typical processing parameters will include the For smaller bits (1/8" and 3/16") rotational speeds of
number of tool bit passes chosen to complete the part 18,000 to 20,000 RPM, with feed rates of 100 to 200
and whether or not the part needs to be roughed to IPM range will produce the best edge and tool life.
shape before finishing passes are made to achieve the
desired finish. It is important to note that dust/chip collection systems
as well as coolants such as compressed air, mist
Machine horsepower and work hold-down (or fixturing) coolants and cold air/vortex tube technology, will greatly
are the two factors affecting the amount of material that reduce the heat build up and improve the quality of the
can be removed during each cutter pass. When multiple edge as well as extend the life of the tool.
passes are required, start with a large diameter roughing
cutter to remove the bulk of the material. Keep the part Direction of Travel
minimum inside radius in consideration for secondary Proper feed direction is essential for a smooth cut.
and/or finishing passes. In most cases, two cutters are Routers rotate clockwise when viewed from the spindle
used to machine parts to shape, one for roughing and or colleted side of the router. This is also referred to as
one for finishing. In some cases, three cutters may be Right Hand Cutting. If a hand held router is fed into the
required to complete the part and achieve the desired sheet in a clockwise direction, the cutting edges of the
edge finish and inside radius. bit will pull the bit into the work rendering control nearly
impossible. This routing method is referred to as Climb
For determining the depth of cut (DOC) to make on each Cutting. Climb Cutting should only be used on machinery
pass, the following guidelines can be used: that has rigid spindles and worktables that are free of
leadscrew backlash. Climb Cutting will improve product
Face Milling surface finish and increase tool life.
Use a material removal ratio of 3:2. For example if the
cutter diameter is 3", then a 2" cut is the maximum Note: This type of machining can only be done on CNC
depth of material that can be removed per pass. machinery. Climb Cutting is not recommended for most
routing applications.
Routing/Periphery Milling
Start with a 0.100" depth of cut per pass and increase The feed direction for external cuts should be counter-
the DOC to 1/2 - 2/3 the cutter diameter. Note: The cutter clockwise. When routing inside edges, the router should
edge length (CEL) listed by the cutter manufacturer may be fed clockwise. This practice will allow an operator to
be fully engaged as required. Many single flute up-spiral maintain proper control of the router and attain a smooth
and center cutting bits can be plunged or programmed to edge. This method is referred to as Conventional Cut-
ramp in and take the full cutter diameter for slotting and ting.
part cut out. The DOC for a finishing pass should be no
Note: Conventional Cutting is the recommended method
less than .010" and provide a chip load of at least 0.004"
for most routing operations. Refer to the routing direction
/tooth (refer to the section Operation Terminology and
diagram on page 6.
Formulas for more details).

5
 edge. Cutter diameter is normally dictated by the design
of the part. The key consideration is material removal.
Initial machining steps should employ the largest cutter
diameter to rough out the part. Secondary cutting
operations should utilize bits that match the proper
radius or leave the required edge and surface finish on
the sheet.

Speed – Surface Feet Per Minute (SFM) is the actual

speed at which the cutting edge of the tool is striking the
material. It is used to determine spindle revolutions per
minute (RPM). There are two formulas that relate these
two values and take into consideration the tool bit
diameter.

SFM = .262 x Diameter (inches) x RPM

Slotting, routing shapes out of a sheet, periphery RPM = 3.82 x SFM / Diameter (inches)
routing, and cutting a part by machining around the
For most operations the RPM commonly runs between
outside edge of the part, employ both conventional and
10,000 to 20,000. Depending on bit diameter, the speed
climb routing. Care should be taken in the machining
can be as low as 300 SFM and may run as high as 2400
techniques and programs to allow for the desired finish.
SFM although it more commonly runs from 500 to 1500
Vibration SFM. This will change based on the demand for material
It is of the utmost importance that balance of the tool, removal and edge finish requirement. This is the first of
collet and spindle is maintained so that vibration is kept three factors that will affect material finish.
to a minimum. Even small vibrations can introduce Chip load - Inches Per Tooth (IPT) corresponds to the
stress that will eventually result in crazing and fractures amount of material removed by each tooth of the cutter
in acrylic sheet during fabrication or use. The mainte- every time it contacts and passes the material. Suffi-
nance of spindles and collets is a key factor in control- cient chip load will create stability between the cutter
ling vibration. The spindle and collet must be thoroughly and the work piece. The optimum chip load for acrylic
cleaned every time there is a bit change. sheet is .004" to .015"/tooth.
Operation Terminology and Formulas Feed Rate – Inches per Minute (IPM) is the distance
Cutting Edge - The leading edge of the cutter tooth. that the cutting tool travels along the edge or surface of
the material being processed in one minute. The proper
Flute - The space between the back of one tooth and range for feed rate can be determined by considering the
the face of the following tooth. chip load. Operating in the lower part of the recom-
Axis - The imaginary straight line that forms the longitu- mended range for chip load will tend to provide a better
dinal center line of the cutter. finish but at the expense of throughput. Operating at the
high end of the recommended range for chip load will
Helix Angle - The angle that is formed as the cutting result in a rough finish on the part but higher part
edge spirals around the outside of the tool. It is mea- throughputs. Typical feed rate parameters for ACRYLITE
sured relative to the axis of the tool. FF sheet range from 100 to 300 IPM. To establish the
feed rate knowing the desired chip load, the number of
Shank - The portion of the cutter that is held in the cutting edges on the bit and the RPM use the following
spindle in order to drive the tool. formula:
Diameter – Equals the largest outside cylindrical IPM = IPT x No. Teeth x RPM
dimension of the cutting tool, measured at the cutting

6
Trouble Shooting
Problem Cause Solution
Chipped Edges Dull tool Replace or sharpen tool
Spindle speed too slow Increase speed (RPM)
Feed rate too fast Reduce feed rate (IPM)
Vibration Clamp securely
Rigidity Check fixture clamping
Improper mounting
Cutter Damage Improve storage and handling. Cutters should
not be thrown unprotected in drawers.
Total Indicator Run-Out (TIR) Check tool and tool holder for run-out
Defective or worn collets Replace
Bearing wear Replace when tool run out exceeds .001-.002 inches
Chatter Rigidity Check holder
Check machine for wear
Use shortest possible cutting tool
Spindle speed too high Decrease spindle speed (RPM)
Chip load too high Decrease feed (IPT)
Fixturing Check for part movement
Melted Edges Dull tool Replace or sharpen tool
Feed rate too low Increase feed rate (IPM)
Spindle speed too high Decrease speed (RPM)
Chip load too low Increase feed (IPT)
No cooling Add air or water mist cooling
Plastic melt or plastic Tool finish Rough bit finishes allow material to adhere to cutting
chips sticking to bit edge. Use bit with polished flute.
Chip Packing Too many flutes on bit Make sure flute space is adequate
Use only one or two flutes for roughing
Plunge cutting Use two flute up-spiral bit
Incorrect helix angle
Depth of cut too large Make multiple passes
Tool Breakage Exceed tool strength Reduce feed rate
Reduce cutting edge length
Increase diameter of cutter
Reduce depth of cut
Rigidity Check machine and part deflection
Ensure tool is fully engaged in chuck
Use the largest diameter bit
Use shorter bits
Cutter misaligned in collet Correct cutter alignment
Defective or worn collets Replace
Bearing wear Replace when tool run out exceeds .001-.002 inches
Tool Burning Dull tool Sharpen or replace tool
Carbide Chipping Loose collet Tighten shank in collet
Deflection Ensure shank is fully engaged in chuck
Use shorter cutting edge
Use larger diameter tool
Incorrect chip load Increase number of flutes
Reduce feed rate
Causes of Premature Excess heat Increase chip load (reduce spindle speed or increase
Wear feed rate)
Tool alloy Use more wear resistant alloy (carbide)
Coolant If coolant is used, it should be clean and high quality.
Use cold air gun or compressed air.

7
Equipment and Materials Suppliers
The suppliers listed below offer materials and equipment tested and approved by CYRO Industries.
Authorized ACRYLITE Sheet Distributors may also offer materials and equipment. Visit www.cyro.com
for a list of authorized CYRO sheet distributors.

Router Bits Toolmasters LLC

1400 Railroad Avenue
Ekstrom, Carlson & Co. PO Box 1611
5196 27th Avenue Rockford, IL 61110
P.O. Box 1611 815-968-0961
Rockford, IL 61109 Fax: 815-968-5559
815-394-1744 www.toolmastersllc.com
Fax: 815-398-9439
www.ekstromcarlson.com Trend Lines, Inc.
100 Justin Drive
Great Lakes Carbide Tool Mfg., Inc. Chelsea, MA 02150
101 N. Old Peshtigo Road 800-767-9999
Peshtigo, WI 54157 Fax: 800-735-3825
715-582-3884 www.trend-lines.com
Fax: 715-582-4373
www.glct.com Union Butterfield
P.O. Box 50000
Kennametal, Inc. Asheville, North Carolina 28813
1600 Technology Way 800-222-8665
Latrobe, PA 15650-0231 Fax: 800-432-9482
724-539-5000 www.unionbutterfield.com
800-446-7738
www.kennametal.com Wisconsin Knife Works
2505 Kennedy Drive
Onsrud Cutter, Inc. Beloit, WI 53511
800 Liberty Drive 800-225-5959
Liberty, IL 60048 Fax: 800-336-1254
800-234-1560 www.wkwinc.com
Fax: 800-557-6720
www.onsrud.com Woodworkers Supply
125 Jay Lane
Paso Robles Carbide, Inc. Graham, NC 27253
731-C Paso Robles Street 800-645-9292
Paso Robles, CA 93446 Fax: 800-853-WOOD
805-238-6144 or 336-578-1401
Fax: 805-238-4263 www.woodworker.com

Continued on next page

8
Equipment and Materials Suppliers Continued from previous page

Collets and Tool Holders KOMO Machine, Inc.

11 Industrial Blvd.
Centaur Precision Tools Inc. Sauk Rapids, MN 56379
13098 SW 133 Court 800-255-5670
Miami, FL 33186 Fax: 320-656-2470
888-COLLETS www.komo.com
Fax: 305-251-0756
www.centaurtools.com MultiCam, Inc.
8920 North Royal Lane
REGO-FIX Tools Irving, TX 75063
7752 Moller Rd. 972-929-4070
Indianapolis, IN 46268 Fax: 972-929-4071
800-734-6349 www.multicam.com
Fax: 317-870-5955
www.rego-fix.com SB Power Tool Corp.
4300 W. Peterson
Chicago, IL 60646
Routers
888-394-4646
Black & Decker Mfg. Co. 800-301-TALK
Fax: 800-547-1998
701 E. Joppa Road
Towson, MD 21287 Shoda CNC Routers
410-716-3900
www.shodausa.com
www.blackanddecker.com
www.boschtools.com
C.R. Onsrud, Inc.
Skil Tools
867 S. Main Street
877-754-5999
Troutman, NC 28166
www.skiltools.com
704-528-4528
Fax: 704-528-6170 Thermwood Corp.
www.cronsrud.com P.O. Box 436
Dale, IN 47523
Delta International
800-533-6901
4290 E Raines Road
Fax: 812-937-2956
Memphis, TN 38118
www.thermwood.com
800-223-7278
Fax: 800-535-6488
www.delta-portercable.com

Gerber Scientific Products, Inc.

151 Batson Drive
Manchester, CT 06040
800-222-7446
Fax: 860-645-5645
www.gspinc.com

9
 Additional Technical Information
and Assistance
We invite you to visit our TechKnowlogy Center
on www.cyro.com.
Visitors have immediate access to frequently asked
questions, technical concerns, physical properties,
processing conditions, fabrication tips,
regulatory compliance information,
engineering guidelines, tips for
troubleshooting, and hundreds
of other facts about acrylics
from one of North America’s
leading manufacturers of
acrylic-based polymer and For additional information contact:
sheet products. Degussa, CYRO Industries
379 Interpace Parkway,
PO Box 677, Parsippany, NJ 07054-0677

800-631-5384
www.cyro.com
www.degussa.com

CYRO Industries is a wholly-owned subsidiary of Degussa.

Fire Precautions
ACRYLITE FF sheet is a combustible thermoplastic. Precautions should be taken to protect this material from flames and high heat sources. ACRYLITE FF sheet
usually burns rapidly to completion if not extinguished. The products of combustion, if sufficient air is present, are carbon dioxide and water. However, in many fires
sufficient air will not be available and toxic carbon monoxide will be formed, as it will when other common combustible materials are burned. We urge good judgement
in the use of this versatile material and recommend that building codes be followed carefully to assure it is used properly.
Compatibility
Like other plastic materials, ACRYLITE FF sheet is subject to crazing, cracking or discoloration if brought into contact with incompatible materials. These materials
may include cleaners, polishes, adhesives, sealants, gasketing or packaging materials, cutting emulsions, etc. See the Tech Briefs in this series for more informa-
tion, or contact your ACRYLITE Sheet Distributor or the CYRO Technical Center for information on a specific product.
Important Notice
The information and statements herein are believed to be reliable but are not to be construed as a warranty or representation for which we assume legal responsibility.
Users should undertake sufficient verification and testing to determine the suitability for their own particular purpose of any information or products referred to herein.
NO WARRANTY OF FITNESS FOR PARTICULAR PURPOSE IS MADE. Nothing herein is to be taken as permission, inducement or recommendation to practice any
patented invention without a license.

CYRO Industries, Parsippany, New Jersey 07054

10 1319(5F)-0302-5RA © 2002 CYRO Industries. All rights reserved. Printed in USA.