Machining ABS plastic

[cropwell]

Hi,

I have a plastic project box, which is probably ABS. I have tried to cut out for the various panel items (32 switches, for a start), but the cutter (1mm single flute spiral) just keeps gathering melted chips. So I rejigged the Gcode to cut 1 switch at a time, to let me clean the cutter - PITA and my Acrylic coolant (de-ionised water 75% isopropanol 24.5% and a dash of rinse aid) seemed to have no effect.

Now I have changed the design and intend to replace the rather messy front panel with an engraving laminate, so I need to hog out the plastic. That can be a larger cutter. Any suggestions on feeds, speeds, cutter geometry and coolant that might avoid the claggy mess?

Ta folks !