Plastics

A closer look at various types of plastics shows an almost unbelievable abundance of material, processing and application possibilities. However, a key distinction is made between the material groups of thermoplastics, duroplastics and elastomers. Each of these material groups has its own special properties and each material has different features which have to be taken into account during machining.

Leitz knows that only tool solutions adapted to the material and the respective process guarantee optimum success in terms of quality, efficiency and safety. Leitz proves this with the solutions from its standard tool range but also within individual tool system solutions that make for very satisfied Leitz customers.

In the machining of thermoplastics, the choice of process parameters is of great importance, besides the special tooth geometries and gullet areas. Transparent plastics, such as acrylic glass, also play a special role. It is here above all that all the cutting edges and cutting surfaces that must be smooth and free of marks so that the overall appearance of the workpiece is not damaged. This is made possible by special machining tools that are equipped with corresponding geometries and cutting materials.

Leitz offers a variety of tried and tested tool solutions in the field of panel cutting, shape and contour milling. In addition, Leitz has solutions for boring blind and through-holes for materials such as acrylic glass (PMMA), polycarbonate (PC), polyvinyl chloride (PVC) or polystyrene (PS).

Cutting of PMMA and PC panels with circular sawblades

When sawing transparent plastics, it is essential that the cutting edges and cutting areas require special attention. The highlight in the Leitz range of saws for plastics is the BrillianceCut circular sawblade. This circular sawblade guarantees absolute finish cut quality. Users save a complete working cycle due to the absolutely mark-free cutting surfaces and the break-out-free cutting edges. The subsequent cutting and grinding of the workpiece edge is completely eliminated with the use of the BrillianceCut circular sawblade.

Shape and contour cutting of PMMA and PC

High cutting qualities are only possible with tool solutions that are perfectly matched to the material and process. Pre-cutting in particular is an important machining point here. Marathon-roughing and finishing cutters from Leitz offer perfect performance and machining quality every time.

Leitz spiral roughing/finishing cutter Marathon

Shape and contour cutting of PVC, PP and PS

The quality of the surface after machining is also important when cutting plastics such as PVC, PP or PS. The pre-cutting can be easily mastered with the special Marathon roughing and finishing cutters. The use of diamond shank tools, which can be individually adapted to customer requirements, is recommended for optimal finish processing.

Leitz spiral roughing/finishing router cutter Marathon

Boring of blind and through-holes in PMMA and PC

The material-specific properties of acrylic glass must be taken into account in all machining operations – the choice of the right tool composition is also very important when boring. It is important to avoid cracks in the material, tears at the inlet and outlet of the hole and melting due to overheating.

Duroplastics are usually brittle and hard. The temperature is not the most important factor during machining sothe cutting speeds are higher than for thermoplastics. Because of the brittle-hard material properties and the abrasive effect of the embedded fibres, the tools differ in geometry and cutting material from those used for machining thermoplastics. Diamond is the preferred cutting material.

Typical examples of duroplastic materials include compact laminates, high-pressure laminates (HPL laminates) made of melamine or phenolic resin-impregnated paper or printed circuit boards (PCBs) made of hard paper.

Cutting with circular sawblades

Layer press materials, such as HPL, set high demands on the tooling. The Leitz RazorCut circular sawblade guarantees the best cutting quality with edges free of breakouts. Its special trapezoidal/trapezoidal tooth geometry delivers optimum cutting surfaces.

Jointing and rebating

The Leitz Diamaster WhisperCut is the optimum tool solution for HPL jointing and rebating. It is characterized by its exchangeable cutting edges, which can even be reground. This makes the process efficient and economical.

Leitz jointing cutterhead WhisperCut® PRO EdgeExpert

The best-known mineral material is Corian^® and consists of one third acrylic glass (PMMA) and two thirds natural minerals with the main component of aluminium hydroxide. The fields of application are vast and range from decorative materials in thin sheet thickness, to medium-thick worktops, through to thicker sheets for covers, claddings and tables.

Mineral working materials can be processed with conventional wood processing tools, and with its comprehensive standard range, Leitz offers ideal tool solutions for the most varied types of machining.

Sizing of panel material

When cutting Corian^® or other mineral materials, the quality of the cutting edges and cutting surfaces is of the utmost importance. The highlight in the Leitz range of sawblades for plastics is the BrillianceCut circular sawblade. This circular sawblade ensures absolute finish cut quality. The resulting mark-free cutting surfaces and breakout-free cutting edges allow the direct bonding of individual parts after sawing. The subsequent cutting and grinding of the workpiece edges is completely eliminated with the use of the BrillianceCut circular sawblade.

Sizing on CNC processing machines

The extensive Leitz standard range of carbide shank cutters is recommended for CNC machining of single pieces or small series. Where long tool life is of particular importance in series production, the Leitz diamond programme should be the first choice.