1. #1
    marbles's Avatar
    Lives in glasgow, United Kingdom. Last Activity: 19 Hours Ago Has been a member for 5-6 years. Has a total post count of 96. Received thanks 8 times, giving thanks to others 34 times. Referred 1 members to the community.
    Howdy,

    I'm just running some test milling forms in blue styrofoam board. I am making lost foam masters for aluminium casting.
    I'm running cut tests on a low relief model (150mmx150mmx40mm). I'm using a 8mm OD rasp bit to rough out and using a 2mm OD end mill to finish. I run both at a feed rate of about 2 cm/sec but the spindle on its slowest RPM (approx 11000rpm). This combination seems to give me the best results.

    However I see that the final finish is still quite hairy and the rasp sometimes still gets too hot/ and or melts the styrene. Are there some know techniques or bits for working with styrene I should try? I think i'm pretty close but just wondering if there is anything I can tweak.

    Thanks
    Last edited by marbles; 05-05-2017 at 06:05 PM.

  2. #2
    I use downcutters with some success on blue Styrofoam. Both in 8mm and 2mm. But lately broke the 2mm on another job and looking for a re-source should you find one?
    The finish was marginally better and surface stringing much better. Not to the same degree as wood downcutting, as you might expect. But for me better!

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  4. #3
    marbles's Avatar
    Lives in glasgow, United Kingdom. Last Activity: 19 Hours Ago Has been a member for 5-6 years. Has a total post count of 96. Received thanks 8 times, giving thanks to others 34 times. Referred 1 members to the community.
    Thanks. I bought a couple of 4 flute upcutters recently but your right I should try a new sharp downcutter to compare. Looking at the endmills specifically sold for polystyrene and foams lots of them are upcutters but what i am adviced is to run these bits below 6000rpm so just about to see how my spindle, which currently has a minimum of 12,000rpm likes running at half that.

  5. #4
    Try doubling your feedrate.
    Gerry
    ______________________________________________
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  6. #5
    Quote Originally Posted by Leadhead View Post
    I use downcutters with some success on blue Styrofoam. Both in 8mm and 2mm. But lately broke the 2mm on another job and looking for a re-source should you find one?
    The finish was marginally better and surface stringing much better. Not to the same degree as wood downcutting, as you might expect. But for me better!
    https://www.sorotec.de/shop/Cutting-...l/2-Flute-366/

    Rob
    Albert Einstein may have been a genius, but his brother Frank, was a monster

    Having just moved to Windows 10 (which is crap) My stress levels are through the roof !!!

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