Quadrant Machinists Handbook

The World’s Leading Manufacturer ofPlastic Stock Shapes.

Plastics increasingly replace traditional materials such as bronze, stainlesssteel, cast iron and ceramics. They are chosen for improved performance andcost reduction. Plastics can:

• Reduce Weight• Eliminate Corrosion• Improve Wear Performance in Unlubricated Conditions• Reduce Noise• Increase Part Life • Insulate & Isolate, Both Thermally and Electrically

Typical applications for engineering plastics range from semiconductor processing equipment components to heavy equipment wear parts, to food processing industry components. Machinable plastic stock shapes (sheet, rod, and tubular bar) are now available in more than 50 grades, spanning the performance/price range ofboth ferrous and non-ferrous metals to specialty ceramics. Plastics capable oflong term service up to 800°F (425°C), with short term exposures to 1,000°F(540°C) are now available. As the number of material options has increased, so has the difficulty of selecting the right material for a specific application.

Table of ContentsFabrication Guidelines . . . . . . . . . . . . . . . . 2-8

Machinability. . . . . . . . . . . . . . . . . . . . . . . 9-10

Drilling Guidelines. . . . . . . . . . . . . . . . . . 11-12

Troubleshooting - Drilling . . . . . . . . . . . 13-14

Sawing Guidelines . . . . . . . . . . . . . . . . . 15-16

End Milling / Slotting Guidelines. . . . . . 17-18

Face Milling . . . . . . . . . . . . . . . . . . . . . . . 19-20

Troubleshooting - Turning & Boring. . . . . . 21

Troubleshooting - Cutting Off . . . . . . . . . . . 22

Turning Guidelines . . . . . . . . . . . . . . . . . 23-24

Annealing. . . . . . . . . . . . . . . . . . . . . . . . . 25-26

Air Annealing Guidelines . . . . . . . . . . . . 27-30

Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

Conversions. . . . . . . . . . . . . . . . . . . . . . . 33-34

The following guidelines are presented for thosemachinists not familiar with the machining characteristics of plastics. They are intended as guidelines only, and may not represent the most optimum conditions for all parts. The troubleshootingquick reference guides in this booklet should be usedto correct undesirable surface finishes or materialresponses during machining operations.All Quadrant materials are stress relieved to ensure thehighest degree of machinability and dimensional stability. However, the relative softness of plastics(compared to metals) generally results in greater difficulty maintaining tight tolerances during and aftermachining. A good rule of thumb for tolerances of plastic parts is +/- .001" per inch of dimension although tighter tolerances are possible with very stable, reinforced materials.

FABRICATION GUIDELINESPlease return to:

Name:

Company:

Dept:

Address:

City: State: Zip:

Phone

E-mailwww.quadrantplastics.com 2

When machiningQuadrant stock shapes,remember...• Thermal expansion is up to 10 times greater

with plastics than metals

• Plastics lose heat more slowly than metals, soavoid localized overheating

• Softening (and melting) temperatures of plasticsare much lower than metals

• Plastics are much more elastic than metals

Because of these differences, you may wish toexperiment with fixtures, tool materials, angles,speeds and feed rates to obtain optimum results.

Getting Started• Positive tool geometries with ground peripheries

are recommended

• Carbide tooling with ground top surfaces is

suggested for optimum tool life and surface finish. Polycrystalline diamond tooling providesoptimum surface finish when machiningDuratron® PBI.

• Use adequate chip clearance to prevent

clogging

• Adequately support the material to restrict

deflection away from the cutting tool

3

Coolants

Coolants are generally not required for mostmachining operations (not including drilling andparting off). However, for optimum surface finishes and close tolerances, non-aromatic,water soluble coolants are suggested. Spray mistsand pressurized air are very effective means ofcooling the cutting interface. General purposepetroleum based cutting fluids, although suitablefor many metals and plastics, may contribute tostress cracking of amorphous plastics such asQuadrant PC 1000, Quadrant PSU, Duratron®

U1000 PEI, and Quadrant PPSU.

Machining Tips

• Coolants are strongly suggested during drilling

operations, especially with notch sensitivematerials such as Ertalyte® PET-P, Duratron® PAI,Duratron® PBI and glass or carbon reinforced products.

• In addition to minimizing localized part heat-up,

coolants prolong tool life. Two (flood) coolantssuitable for most plastics are Trim E190 andTrim Sol LC SF (Master Chemical Corporation –Perrysburg, OH).

www.quadrantplastics.com 4

ThreadingandTapping

Threading should bedone by single pointusing a carbide insertand taking four to five0.001" passes at theend. Coolant usage issuggested. For tapping,use the specified drillwith a two flute tap.Remember to keep thetap clean of chip build-up.Use of a coolant duringtapping is also suggested.

Milling

Sufficient fixturingallows fast table traveland high spindle speedswhen end milling plastics. When facemilling, use positivegeometry cutter bodies.

Sawing

Band sawing is versatilefor straight, continuouscurves or irregular cuts.Table saws are convenient for straightcuts and can be used tocut multiple thicknessesand thicker cross sections up to 4" withadequate horsepower.Saw blades should beselected based uponmaterial thickness andsurface finish desired.

5

Sawing Tips• Rip and combination blades with

a 0° tooth rake and 3° to 10°tooth set are best for generalsawing in order to reduce frictional heat.

• Hollow ground circular sawblades without set will yieldsmooth cuts up to 3/4" thickness.

• Tungsten carbide blades wearwell and provide optimum surface finishes.


DrillingThe insulating characteristics of plastics require consideration duringdrilling operations, especially whenhole depths are greater than twice thediameter.Small diameter holes (1/32" to 1" diameter)

High speed steel twist drills are generally sufficient for small holes. Toimprove swarf removal, frequent pull-out (peck drilling) is suggested. A slowspiral (low helix) drill will allow for better swarf removal.Large diameter holes (1" diameterand larger)

A slow spiral (low helix) drill or generalpurpose drill bit ground to a 118° pointangle with 9° to 15° lip clearance isrecommended. The lip rake should beground (dubbed off) and the web thinned.

It is generally best to drill a pilot hole(maximum 1/2" diameter) using 600 to1,000 rpm and a positive feed of0.005" to 0.015" per revolution. Avoidhand feeding because of the drill grabbing which can result in microcracks forming. Secondarydrilling at 400 to 500 rpm at 0.008 to0.020" per revolution is required toexpand the hole to larger diameters. A two step process using both drillingand boring can be used on notch sensitive materials such as Ertalyte®

PET–P and glass reinforced materials.This minimizes heat build-up andreduces the risk of cracking.

1. Drill a 1" diameter hole using aninsert drill at 500 to 800 rpm with afeed rate of 0.005" to 0.015" perrevolution.

2. Bore the hole to final dimensionsusing a boring bar with carbideinsert with 0.015" to 0.030" radii at500 to 1,000 rpm and a feed rate of0.005 to 0.010" per revolution.

www.quadrantplastics.com

7

Turning operations require insertswith positive geometries and groundperipheries. Ground peripheries and polished top surfaces generally reduce materialbuild-up on the insert, improving theattainable surface finish. A finegrained C-2 carbide is generallybest for turning operations.

Turning


Mac

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abili

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Mat

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l

Rel

ativ

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ach

inab

ility

(1 t

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eas

iest

)Acetron® GP POM-C

1Acetron® POM-H, Acetron® AF

1Acetron® AF Blend

1

Duratron® CU60 PBI

10Duratron® T4203 PAI






8Duratron® U1000 PEI & U2300 PEI

7

Ertalyte® PET-P

2Ertalyte® TX PET-P

2 Fluorosint® MT01

3Fluorosint® 500 PTFE


1Fluorosint® HPV

1

Ketron® 1000 PEEK

5Ketron® GF30 PEEK

7Ketron® CF30 PEEK

7Ketron® HPV PEEK

6

Nylatron® MC901 PA6 & MC907 PA6

1Nylatron® GS PA66 & GSM PA6

1Nylatron® GSM Blue PA6 & NSM PA6

2

Quadrant Nylon 101 PA66

1Quadrant PC 1000

2Quadrant PSU

3Quadrant PPSU

3

Techtron® CM PSBG PPS

5Techtron® PSBG PPS

5

Techtron® PPS

3Techtron® HPV PPS

6

Sem

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ater

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-

Follo

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ost

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POM-C

1410C

PEI

7420

PEI

7420V

PEI

7480

PEEK

6490 HR

PEEK

6500 HR

PTFE

1520 HR

PAI

6CMP LL5

PET

2CMP XL20

PAI

10

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Mac

hin

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Mat

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l

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1

Duratron® CU60 PBI







8Duratron® U1000 PEI & U2300 PEI

7

Ertalyte® PET-P

2Ertalyte® TX PET-P

2 Fluorosint® MT01



1Fluorosint® HPV

1

Ketron® 1000 PEEK

5Ketron® GF30 PEEK

7Ketron® CF30 PEEK

7Ketron® HPV PEEK

6

Nylatron® MC901 PA6 & MC907 PA6

1Nylatron® GS PA66 & GSM PA6

1Nylatron® GSM Blue PA6 & NSM PA6

2

Quadrant Nylon 101 PA66

1Quadrant PC 1000

2Quadrant PSU

3Quadrant PPSU

3

Techtron® CM PSBG PPS

5Techtron® PSBG PPS

5

Techtron® PPS

3Techtron® HPV PPS

6

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7480

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6500 HR

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1520 HR

PAI

6CMP LL5

PET

2CMP XL20

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10

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10


Drilling TipsSmaller diameter holes • High speed twist drills • Peck drill suggestedLarger diameter holes • Drill pilot hole • Use slow speed spiral drills or inserted drills

Drilling GuidelinesProteus PP, Quadrant PC 1000, Quadrant PSU, Quadrant PPSU

and Duratron® PEI based materialsFluorosint® PTFE (1)

based materials

NominalHoleDiameter

.007 - .015

.015 - .025

.020 - .050

.007 - .015

.015 - .025

.020 - .050

.002 - .005

.015 - .025

.020 - .050

.007 - .015

.015 - .025

.020 - .050

.007 - .015

.015 - .025

.020 - .050

1/2" or larger

.015 - .025

FeedIn./Rev.

Symalit®

PVDF and ECTFE based materials

Ertalyte® PET-Pbased materials

Duratron® PAI and Duratron® PI based materials

Duratron® PBIbased materials

Techtron® PPS based materials

TIVAR® UHMW-PE, Nylatron® PA6, Acetron® POM based materials

.002 - .005

.004 - .008

.008 - .012

Ketron® PEEK based materials

1/16" to 1/4"1/2" to 3/4"1" to >2"

.007 to .015

.015 to .025

.020 to .050

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

.002 - .005

.015 - .025

.020 - .050

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

(1) For Fluorosint® MT01 PTFE contact Quadrant’s Technical Service Team

The recommended speed for drilling operations is 150 to 200 ft./min.

11


Drilling TipsSmaller diameter holes • High speed twist drills • Peck drill suggestedLarger diameter holes • Drill pilot hole • Use slow speed spiral drills or inserted drills

Drilling GuidelinesProteus PP, Quadrant PC 1000, Quadrant PSU, Quadrant PPSU

and Duratron® PEI based materialsFluorosint® PTFE (1)

based materials

NominalHoleDiameter

.007 - .015

.015 - .025

.020 - .050

.007 - .015

.015 - .025

.020 - .050

.002 - .005

.015 - .025

.020 - .050

.007 - .015

.015 - .025

.020 - .050

.007 - .015

.015 - .025

.020 - .050

1/2" or larger

.015 - .025

FeedIn./Rev.

Symalit®






TIVAR® UHMW-PE, Nylatron® PA6, Acetron® POM based materials

.002 - .005

.004 - .008

.008 - .012


1/16" to 1/4"1/2" to 3/4"1" to >2"

.007 to .015

.015 to .025

.020 to .050

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

.002 - .005

.015 - .025

.020 - .050

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"

1/16" to 1/4"1/2" to 3/4"1" to >2"


12

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13

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14

www.quadrantplastics.comSawing Guidelines

Proteus® PP, Quadrant PC 1000, Quadrant PSU,

Quadrant PPSU and Duratron® PEI based materials

Fluorosint® PTFE (1) based materials

Symalit®PVDF and ECTFE based materials





TIVAR® UHMW-PE,Nylatron® PA6, Acetron® POM based materials



Tooth Form

MaterialThickness

PitchTeeth/In.

Band SpeedsFt./Min.

Precision Butress

10-14 6 3 3

2,500 2,000 1,5003,000

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

10-14 6 3 3

3,500 3,000 2,5004,000

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

4,300 3,500 3,0005,000

10-14 6 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

10-14 6 3 3

3,500 3,000 2,5004,000

<.5" >3.0".5"-1.0" 1.0"-3.0"

3,500 3,000 2,5004,000

Precision Butress

10-14 6-8 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

2,5003,000

Precision

10-14 6-8

<.5" .5"-1.0"

1,5002,000

3 3

1.0"-3.0" >3.0"

Butress

4,300 3,500 3,0005,000

Precision Butress

10-14 6-8 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

4,300 3,500 3,0005,000

10-14 6-8 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

3,000 1,500

10 10

.375"-1.0" 1.0"-2.0"

15

www.quadrantplastics.comSawing Guidelines

Proteus® PP, Quadrant PC 1000, Quadrant PSU,











Tooth Form

MaterialThickness

PitchTeeth/In.

Band SpeedsFt./Min.

Precision Butress

10-14 6 3 3

2,500 2,000 1,5003,000

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

10-14 6 3 3

3,500 3,000 2,5004,000

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

4,300 3,500 3,0005,000

10-14 6 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

10-14 6 3 3

3,500 3,000 2,5004,000

<.5" >3.0".5"-1.0" 1.0"-3.0"

3,500 3,000 2,5004,000

Precision Butress

10-14 6-8 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

2,5003,000

Precision

10-14 6-8

<.5" .5"-1.0"

1,5002,000

3 3

1.0"-3.0" >3.0"

Butress

4,300 3,500 3,0005,000

Precision Butress

10-14 6-8 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

4,300 3,500 3,0005,000

10-14 6-8 3 3

<.5" >3.0".5"-1.0" 1.0"-3.0"

Precision Butress

3,000 1,500

10 10

.375"-1.0" 1.0"-2.0"

16

Milling TipsClimb milling is recommended over conventional milling (See Diagram 1, Page 31)

End Milling / Slotting GuidelinesNylatron® and Acetron®

Polycarbonate (PC), Polysulfone (PSU)

Radel® (PPSU) & Ultem (PEI)

Depthof Cut

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

RecommendCarbide

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

0.015

270 - 450300 - 500

250 - 350

0.0020.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

Speed,Feet/Min.

Feed,In./Tooth

Ketron®PEEK based materials

Ertalyte®PET based materials

Torlon® (PAI) based materials Celazole® PBITechtron®

PPS based materials

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

Fluorosint® PTFEbased materials


.015 - 0.25

End Milling/ Slotting Guidelines


Depthof Cut

RecommendCarbide

Speed,Feet/Min.

Feed,In./Min.

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.1500.060

500 - 750

0.0200.005

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.1500.060

500 - 700550 - 750

0.0100.005

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.1500.060

1300 - 15001500 - 2000

0.0200.005

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.035

500 - 800

0.006 - 0.035

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.015

250 - 350

0.002 - 0.006

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

Proteus PP, Quadrant PC 1000, Quadrant PSU,








TIVAR® UHMW-PE,Nylatron® PA6, Acetron® POMbased materials


17

Milling TipsClimb milling is recommended over conventional milling (See Diagram 1, Page 31)

End Milling / Slotting GuidelinesNylatron® and Acetron®



Depthof Cut

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

RecommendCarbide

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

0.015

270 - 450300 - 500

250 - 350

0.0020.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

Speed,Feet/Min.

Feed,In./Tooth

Ketron®PEEK based materials


Torlon® (PAI) based materials Celazole® PBITechtron®

PPS based materials

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

Fluorosint® PTFEbased materials


.015 - 0.25

End Milling/ Slotting Guidelines


Depthof Cut

RecommendCarbide

Speed,Feet/Min.

Feed,In./Min.

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.1500.060

500 - 750

0.0200.005

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.2500.050

270 - 450300 - 500

0.002, 0.003, 0.005,0.008, 0.001, 0.002, 0.004

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.1500.060

500 - 700550 - 750

0.0100.005

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.1500.060

1300 - 15001500 - 2000

0.0200.005

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.035

500 - 800

0.006 - 0.035

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"

0.015

250 - 350

0.002 - 0.006

1/4", 1/2", 3/4", 1", 2",1/4", 1/2", 3/4"









TIVAR® UHMW-PE,Nylatron® PA6, Acetron® POMbased materials


18

www.quadrantplastics.comNOTES

Face Milling (C-2, Carbide Tool)

Depth of Cut 0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

0.0200.005

0.1500.060

0.015

1300 - 15001500 - 2000 250 - 350500 - 750

.002 - .006

0.035

500 - 800

.006 - .035 0.0200.005

0.1500.060

1300 - 15001500 - 2000

500 - 700550 - 750

0.0200.005

Speed,Feet/Min.

Feed,In./Tooth

Nylatron® and Acetron®

Ketron®

PEEK based materials

0.1500.060

0.0100.005

500 - 700550 - 750

0.1500.060

0.0100.005

Ertalyte®

PET based materials

Torlon® (PAI) based

materialsCelazole® PBI

Techtron®

PPS based materials



Fluorosint®

PTFE basedmaterials



Depthof Cut

Speed,Feet/Min.

Feed,In./Min.




Symalit®






TIVAR® UHMW-PE,Nylatron® PA6, Acetron® POM

based materialsKetron® PEEK

based materials

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

0.0200.005

500 - 750

0.1500.060

1300 - 15001500 - 2000

0.0200.005

500 - 700550 - 750

0.1500.060

0.0100.005

0.035

500 - 800

.006 - .035

0.015

250 - 350

.002 - .006

0.1500.060

1300 - 15001500 - 2000

0.0200.005

19



Depth of Cut 0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

0.0200.005

0.1500.060

0.015

1300 - 15001500 - 2000 250 - 350500 - 750

.002 - .006

0.035

500 - 800

.006 - .035 0.0200.005

0.1500.060

1300 - 15001500 - 2000

500 - 700550 - 750

0.0200.005

Speed,Feet/Min.

Feed,In./Tooth

Nylatron® and Acetron®

Ketron®

PEEK based materials

0.1500.060

0.0100.005

500 - 700550 - 750

0.1500.060

0.0100.005

Ertalyte®

PET based materials

Torlon® (PAI) based

materialsCelazole® PBI

Techtron®

PPS based materials



Fluorosint®

PTFE basedmaterials



Depthof Cut

Speed,Feet/Min.

Feed,In./Min.




Symalit®






TIVAR® UHMW-PE,Nylatron® PA6, Acetron® POM

based materialsKetron® PEEK

based materials

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

1300 - 15001500 - 2000

0.0200.005

0.1500.060

0.0200.005

500 - 750

0.1500.060

1300 - 15001500 - 2000

0.0200.005

500 - 700550 - 750

0.1500.060

0.0100.005

0.035

500 - 800

.006 - .035

0.015

250 - 350

.002 - .006

0.1500.060

1300 - 15001500 - 2000

0.0200.005

20

Cu

ttin

g O

ffD

iffic

ult

y

Mel

ted

Surfa

ce1.

Du

ll to

ol2.

In

suffi

cien

t sid

e cl

eara

nce

3.

Insu

ffici

ant c

oola

nt s

uppl

y

1.

Feed

too

heav

y2.

To

ol im

prop

erly

sha

rpen

ed3.

Cu

tting

edg

e no

t hon

ed

1.

Tool

rubs

dur

ing

its re

treat

2.

Burr

on

poin

t of t

ool

1.

Poin

t ang

le to

o gr

eat

2.

Tool

not

per

pend

icul

ar to

spi

ndle

3.

Tool

def

lect

ing

4.

Feed

too

heav

y5.

To

olm

ount

ed a

bove

or

be

low

cen

ter

1.

Poin

t ang

le n

ot g

reat

eno

ugh

2.

Tool

dul

l3.

Fe

ed to

o he

avy

1.

No c

ham

ber b

efor

e cu

t-of

f

diam

eter

2.

Dull

tool

Roug

h Fi

nish

Spira

l Mar

ks

Conc

ave

or

Conv

ex S

urfa

ces

Nibs

or B

urrs

at C

ut-o

ff Po

int

Burr

s on

Out

side

Diam

eter

Com

mon

Cau

se

NOTE

S

Turn

ing

& B

orin

gD

iffic

ult

y

Mel

ted

Surfa

ce

Roug

h Fi

nish

Burr

s at

Edg

eof

Cut

Crac

king

or

Chip

ping

of

Corn

ers

Chat

ter

Com

mon

Cau

se

NOTE

S

1.

Tool

dul

l or h

eel r

ubbi

ng2.

In

suffi

cien

t sid

e cl

eara

nce

3.

Feed

rate

too

slow

4.

Spin

dle

spee

d to

o fa

st

1.

Feed

too

heav

y2.

In

corr

ect c

lear

ance

ang

les

3.

Shar

p po

int o

n to

ol

(slig

ht n

ose

radi

us re

quire

d)4.

To

ol n

ot m

ount

ed o

n ce

nter

1.

No c

ham

fer p

rovi

ded

at

sh

arp

corn

ers

2.

Dull

tool

3.

Insu

ffici

ent s

ide

clea

ranc

e4.

Le

ad a

ngle

not

pro

vide

d on

to

ol (t

ool s

houl

d ea

se o

ut o

f

cut g

radu

ally,

not

sud

denl

y)

1.

Too

muc

h po

sitiv

e ra

ke o

n to

ol2.

To

ol n

ot e

ased

into

cut

(to

ol s

udde

nly

hits

wor

k)3.

Du

ll to

ol4.

To

ol m

ount

ed b

elow

cen

ter

5.

Shar

p po

int o

n to

ol

(slig

ht n

ose

radi

us re

quire

d)

1.

Too

muc

h no

se ra

dius

on

tool

2.

Tool

not

mou

nted

sol

idly

3.

Mat

eria

l not

sup

porte

d pr

oper

ly4.

W

idth

of c

ut to

o w

ide

(use

2 c

uts)

Trou

bles

hoot

ing

• Qu

ick

Refe

renc

e Gu

ide

ww

w.q

uadr

antp

last

ics.

com

21

Cu

ttin

g O

ffD

iffic

ult

y

Mel

ted

Surfa

ce1.

Du

ll to

ol2.

In

suffi

cien

t sid

e cl

eara

nce

3.

Insu

ffici

ant c

oola

nt s

uppl

y

1.

Feed

too

heav

y2.

To

ol im

prop

erly

sha

rpen

ed3.

Cu

tting

edg

e no

t hon

ed

1.

Tool

rubs

dur

ing

its re

treat

2.

Burr

on

poin

t of t

ool

1.

Poin

t ang

le to

o gr

eat

2.

Tool

not

per

pend

icul

ar to

spi

ndle

3.

Tool

def

lect

ing

4.

Feed

too

heav

y5.

To

olm

ount

ed a

bove

or

be

low

cen

ter

1.

Poin

t ang

le n

ot g

reat

eno

ugh

2.

Tool

dul

l3.

Fe

ed to

o he

avy

1.

No c

ham

ber b

efor

e cu

t-of

f

diam

eter

2.

Dull

tool

Roug

h Fi

nish

Spira

l Mar

ks

Conc

ave

or

Conv

ex S

urfa

ces

Nibs

or B

urrs

at C

ut-o

ff Po

int

Burr

s on

Out

side

Diam

eter

Com

mon

Cau

se

NOTE

S

Turn

ing

& B

orin

gD

iffic

ult

y

Mel

ted

Surfa

ce

Roug

h Fi

nish

Burr

s at

Edg

eof

Cut

Crac

king

or

Chip

ping

of

Corn

ers

Chat

ter

Com

mon

Cau

se

NOTE

S

1.

Tool

dul

l or h

eel r

ubbi

ng2.

In

suffi

cien

t sid

e cl

eara

nce

3.

Feed

rate

too

slow

4.

Spin

dle

spee

d to

o fa

st

1.

Feed

too

heav

y2.

In

corr

ect c

lear

ance

ang

les

3.

Shar

p po

int o

n to

ol

(slig

ht n

ose

radi

us re

quire

d)4.

To

ol n

ot m

ount

ed o

n ce

nter

1.

No c

ham

fer p

rovi

ded

at

sh

arp

corn

ers

2.

Dull

tool

3.

Insu

ffici

ent s

ide

clea

ranc

e4.

Le

ad a

ngle

not

pro

vide

d on

to

ol (t

ool s

houl

d ea

se o

ut o

f

cut g

radu

ally,

not

sud

denl

y)

1.

Too

muc

h po

sitiv

e ra

ke o

n to

ol2.

To

ol n

ot e

ased

into

cut

(to

ol s

udde

nly

hits

wor

k)3.

Du

ll to

ol4.

To

ol m

ount

ed b

elow

cen

ter

5.

Shar

p po

int o

n to

ol

(slig

ht n

ose

radi

us re

quire

d)

1.

Too

muc

h no

se ra

dius

on

tool

2.

Tool

not

mou

nted

sol

idly

3.

Mat

eria

l not

sup

porte

d pr

oper

ly4.

W

idth

of c

ut to

o w

ide

(use

2 c

uts)

Trou

bles

hoot

ing

• Qu

ick

Refe

renc

e Gu

ide

ww

w.q

uadr

antp

last

ics.

com

22

Turning Guidelines (C-2, Carbide Tool)

www.quadrantplastics.comNOTESTurning Tips

Inserts with positive geometries and ground peripheries • Use Recommended Turning Tooling Geometry (See Diagram 2, page 32).

Nylatron®, Nylon (PA), Acetron®,Polycarbonate (PC), Polysulfone (PSU) and Ultem® PEI based materials

Fluorosint® PTFE basedmaterials

Depthof Cut

.150" deep cut

.025" deep cut.150" deep cut.025" deep cut

.150" deep cut

.025" deep cut

500 - 600600 - 700

350 - 500500 - 600

600 - 1000600 - 700

.010 - .015

.004 - .007.010 - .015.003 - .008

.150" deep cut

.025" deep cut

350 - 500500 - 600

.010 - .015

.003 - .008

.010 - .016

.004 - .007

.025" deep cut

150 - 225

.002 - .006

SpeedFeet/Min.

Feed,In./Min.



Torlon® (PAI) based materials

Celazole® PBITechtron®PPS based materials

TurningTipsInserts with positive geometries and ground peripheries • Use Recommended Turning Tooling Geometry (See Diagram 2, page 32).


.015 - 0.25

Turning Guidelines (C-2, Carbide Tool)


Depthof Cut

Speed,Feet/Min.

Feed,In./Min.







Duratron® PBI

based materialsTechtron® PPS based materials



.150" deep cut

.025" deep cut

500 - 600600 - 700

.010 - .015

.004 - .007

.150" deep cut

.025" deep cut

600 - 1000600 - 700

.010 - .016

.004 - .007

.150" deep cut

.025" deep cut

350 - 500500 - 600

.010 - .015

.003 - .008

.150" deep cut

.025" deep cut

500 - 600600 - 700

.010 - .015

.004 - .007

.150" deep cut

.025" deep cut

100 - 300250 - 500

.010 - .020

.005 - .010

.025" deep cut

300 - 800

.004 - .025

.025" deep cut

150 - 225

.002 - .006

.150" deep cut

.025" deep cut

500 - 600600 - 700

.010 - .015

.004 - .007

.150" deep cut

.025" deep cut

500 - 600600 - 700

.010 - .015

.004 - .007

24

ANNEALING :: POST MACHININGWhen should parts be annealed after machining to ensure optimum part performance?

Experience has shown us that very few machined plastic partsrequire annealing after machining to meet dimensional or performance requirements.All Quadrant stock shapes are annealed using a proprietary stressrelieving cycle to minimize any internal stresses that may resultfrom the manufacturing process. This assures you that the materialwill remain dimensionally stable during and after machining.Machined-in stress can reduce part performance and lead to premature part failure. To prevent machined-in stress, it is important to identify the causes.

Machined-in stress is created by:

• Using dull or improperly designed tooling

• Excessive heat – generated from

inappropriate speeds and feed rates

• Machining away large volumes of material –

usually from one side of the stock shape

To reduce the potential for machined-in stress,review the fabrication guidelines for the specificmaterial. Recognize that guidelines change asthe material type changes.

25

Benefits of Post-Machining Annealing


Improved Chemical Resistance

Polycarbonate, polysulfone, andDuratron® PEI, like many amorphous(transparent) plastics may be annealedto minimize stress crazing. Duratron® PAIalso benefits from post machiningannealing. Annealing finished partsbecomes more important as machiningvolume increases. Annealing aftermachining reduces “machined-in”stresses that can contribute to prema-ture failure.

Better Flatness and Tighter Tolerance Capability

Extremely close–tolerance parts requiring precision flatness and non-symmetrical contour sometimes requireintermediate annealing between machining operations. Improved flatness can be attained by roughmachining, annealing and finish machining with a very light cut.Balanced machining on both sides ofthe shape centerline can also help prevent warpage.

Improved Wear Resistance

Extruded or injection molded Duratron® PAI parts that require highPV’s or the lowest possible wear factor benefit from an additional cureafter machining. This curing process optimizes the wear properties. Only Duratron® PAI benefits from such a cycle.

G :: POST MACHINING


Tips to Succeed • Ensure parts are fixtured to desired shape or flatness. • Do not unfixture until parts have completed entire cycle and are cool to the touch. • Do not take short-cuts.

Post Machining Air Annealing GuidelinesMaterial

Type 6 Nylons

Type 6/6 Nylons

Ertalyte® PET-P

Acetron® GP POM-C

Acetron® POM-H

Quadrant PC 1000

Quadrant PSU

4 hours to 300˚ F

4 hours to 350˚ F

4 hours to 350˚ F

4 hours to 310˚ F

4 hours to 320˚ F

4 hours to 275˚ F

4 hours to 330˚ F

30 minutes per 1/4” thickness







50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

Oil or Nitrogen

Oil or Nitrogen

Oil or Nitrogen

Nitrogen or Air

Nitrogen or Air

Air

Air

Heat Up Hold Cool Down Environment

27


Tips to Succeed • Ensure parts are fixtured to desired shape or flatness. • Do not unfixture until parts have completed entire cycle and are cool to the touch. • Do not take short-cuts.

Post Machining Air Annealing GuidelinesMaterial

Type 6 Nylons

Type 6/6 Nylons

Ertalyte® PET-P

Acetron® GP POM-C

Acetron® POM-H

Quadrant PC 1000

Quadrant PSU

4 hours to 300˚ F

4 hours to 350˚ F

4 hours to 350˚ F

4 hours to 310˚ F

4 hours to 320˚ F

4 hours to 275˚ F

4 hours to 330˚ F








50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

Oil or Nitrogen

Oil or Nitrogen

Oil or Nitrogen

Nitrogen or Air

Nitrogen or Air

Air

Air


28

Finish machining of critical dimensions should be performed after annealing.

Important: Annealing cycles have been generalized toapply to a majority of machined parts. Changes in heatup and hold time may be possible if cross sections arethin. Parts should be fixtured during annealing to prevent distortion.

www.quadrantplastics.comNOTESTips to Succeed

• Ensure parts are fixtured to desired shape or flatness. • Do not unfixture until parts have completed entire cycle and are cool to the touch. • Do not take short-cuts.

Post Machining Air Annealing Guidelines cont’d.Material

Quadrant PPSUDuratron® PEI

Duratron® PAI

Duratron® PI

Techtron® PPS

Ketron® PEEK

4 hours to 390˚ F

4 hours to 350˚ F

4 hours to 300˚ F4 hours to 375˚ F4 hours to 300˚ F4 hours to 420˚ F4 hours to 470˚ F4 hours to 500˚ F4 hours to 300˚ F4 hours to 450˚ F4 hours to 600˚ F


30 minutes per 1/4” thickness60 minutes per 1/4” thickness60 minutes per 1/4” thickness

60 minutes per 1/4” thickness60 minutes per 1/4” thickness

1 day1 day1 day

3 to 10 days

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

Nitrogen or Air

Air

Air

Air

Air


29

www.quadrantplastics.comNOTESTips to Succeed

• Ensure parts are fixtured to desired shape or flatness. • Do not unfixture until parts have completed entire cycle and are cool to the touch. • Do not take short-cuts.

Post Machining Air Annealing Guidelines cont’d.Material

Quadrant PPSUDuratron® PEI

Duratron® PAI

Duratron® PI

Techtron® PPS

Ketron® PEEK

4 hours to 390˚ F

4 hours to 350˚ F

4 hours to 300˚ F4 hours to 375˚ F4 hours to 300˚ F4 hours to 420˚ F4 hours to 470˚ F4 hours to 500˚ F4 hours to 300˚ F4 hours to 450˚ F4 hours to 600˚ F


30 minutes per 1/4” thickness60 minutes per 1/4” thickness60 minutes per 1/4” thickness

60 minutes per 1/4” thickness60 minutes per 1/4” thickness

1 day1 day1 day

3 to 10 days

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

50˚ F per hour

Nitrogen or Air

Air

Air

Air

Air


30

Finish machining of critical dimensions should be performed after annealing.

Important: Annealing cycles have been generalized toapply to a majority of machined parts. Changes in heatup and hold time may be possible if cross sections arethin. Parts should be fixtured during annealing to prevent distortion.

CUTTERROTATION

TABLE FEED

CUTTERROTATION

TABLE FEED

CLIMB MILLING CONVENTIONAL MILLING

DIA

GR

AM

1

31Climb Milling vs. Conventional MillingClimb Milling vs. Conventional Milling

5˚

5˚

3˚30'

3˚30' 11̊

CPG D

IAG

RA

M 2

32

Recommended Turning Tooling GeometryRecommended Turning Tooling Geometry

Con

vers

ion

s

Frac

tion

sD

ecim

al

MM

.015

6.0

312

.046

8.0

625

.078

1.0

937

.109

3.1

25.1

406

.156

2.1

718

.187

5.2

031

.218

7.2

343

.250

.265

6.2

812

.296

8.3

125

.328

1.3

437

.359

3.3

75.3

906

.406

2.4

218

.437

5.4

531

.468

7.4

843

.500

.515

6.5

312

.546

8.5

625

.578

1 5

937

.609

3.6

25.6

406

.656

2.6

781

.687

5.7

031

.718

7.7

343

.750

.765

6.7

812

.796

8.8

125

.828

1.8

437

.859

3.8

75.8

906

.906

2.9

218

.937

5.9

531

.968

7.9

843

1.00

0

1/64

1/32

3/64

1/16

5/64

3/32

7/64 1/8

9/64

5/32

11/6

43/

1613

/64

7/32

15/6

41/

417

/64

9/32

19/6

45/

1621

/64

11/3

223

/64

3/8

25/6

413

/32

27/6

47/

1629

/64

15/3

231

/64

1/2

33/6

417

/32

35/6

49/

16

37/6

419

/32

39/6

45/

841

/64

21/3

243

/64

11/1

645

/64

23/3

247

/64

3/4

49/6

425

/32

51/6

413

/16

53/6

427

/32

55/6

47/

857

/64

29/3

259

/64

15/1

661

/64

31/3

263

/64

1

0.

396

0.

793

1.

190

1.

587

1.

984

2.

381

2.

778

3.

175

3.

571

3.

968

4.

365

4.

762

5.

159

5.

556

5.

953

6.

350

6.

746

7.

143

7.

540

7.

937

8.

334

8.

731

9.

128

9.

525

9.

921

10.

318

10.

715

11.

112

11.

509

11.

906

12.

303

12.

700

13.

096

13.

493

13.

890

14.

287

14.6

84 1

5.08

1 1

5.47

8 1

5.87

5 1

6.27

1 1

6.66

8 1

7.06

5 1

7.46

2 1

7.85

9 1

8.25

6 1

8.65

3 1

9.05

0 1

9.44

6 1

9.84

3 2

0.24

0 2

0.63

7 2

1.03

4 2

1.43

1 2

1.82

8 2

2.22

5 2

2.62

1 2

3.01

8 2

3.41

5 2

3.81

2 2

4.20

9 2

4.60

6 2

5.00

3 2

5.40

0

NOTE

S

ww

w.q

uadr

antp

last

ics.

com

33

Con

vers

ion

s

Frac

tion

sD

ecim

al

MM

.015

6.0

312

.046

8.0

625

.078

1.0

937

.109

3.1

25.1

406

.156

2.1

718

.187

5.2

031

.218

7.2

343

.250

.265

6.2

812

.296

8.3

125

.328

1.3

437

.359

3.3

75.3

906

.406

2.4

218

.437

5.4

531

.468

7.4

843

.500

.515

6.5

312

.546

8.5

625

.578

1 5

937

.609

3.6

25.6

406

.656

2.6

781

.687

5.7

031

.718

7.7

343

.750

.765

6.7

812

.796

8.8

125

.828

1.8

437

.859

3.8

75.8

906

.906

2.9

218

.937

5.9

531

.968

7.9

843

1.00

0

1/64

1/32

3/64

1/16

5/64

3/32

7/64 1/8

9/64

5/32

11/6

43/

1613

/64

7/32

15/6

41/

417

/64

9/32

19/6

45/

1621

/64

11/3

223

/64

3/8

25/6

413

/32

27/6

47/

1629

/64

15/3

231

/64

1/2

33/6

417

/32

35/6

49/

16

37/6

419

/32

39/6

45/

841

/64

21/3

243

/64

11/1

645

/64

23/3

247

/64

3/4

49/6

425

/32

51/6

413

/16

53/6

427

/32

55/6

47/

857

/64

29/3

259

/64

15/1

661

/64

31/3

263

/64

1

0.

396

0.

793

1.

190

1.

587

1.

984

2.

381

2.

778

3.

175

3.

571

3.

968

4.

365

4.

762

5.

159

5.

556

5.

953

6.

350

6.

746

7.

143

7.

540

7.

937

8.

334

8.

731

9.

128

9.

525

9.

921

10.

318

10.

715

11.

112

11.

509

11.

906

12.

303

12.

700

13.

096

13.

493

13.

890

14.

287

14.6

84 1

5.08

1 1

5.47

8 1

5.87

5 1

6.27

1 1

6.66

8 1

7.06

5 1

7.46

2 1

7.85

9 1

8.25

6 1

8.65

3 1

9.05

0 1

9.44

6 1

9.84

3 2

0.24

0 2

0.63

7 2

1.03

4 2

1.43

1 2

1.82

8 2

2.22

5 2

2.62

1 2

3.01

8 2

3.41

5 2

3.81

2 2

4.20

9 2

4.60

6 2

5.00

3 2

5.40

0

NOTE

S

ww

w.q

uadr

antp

last

ics.

com

34

35 Notes

36

Notes

EUROPEHardstrasse 5CH-5600 LenzburgTel +41 (0) 62 8858150Fax +41 (0) 62 8858181e-mail: [email protected]

2120 Fairmont AvenuePO Box 14235 - Reading, PA 19612-4235Tel (800) 366 0300 / +1 610 320 6600Fax (800) 366 0301 / +1 610 320 6868e-mail: [email protected]

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NORTH AMERICARegional Headquarters

ASIA-PACIFIC

Quadrant Engineering Plastic Products

Visit our website for additional information: www.quadrantplastics.com

All statements, technical information and recommendations contained in this publication are presented in good faith, based upon tests believed to be reliable and practical field experience. The reader is cautioned, however, that Quadrant Engineering Plastic Products does not guarantee the accuracy or completeness of this information and it is the customer’s responsibility to determine the suitability of Quadrant’s products in any given application.

Acetron, Duraspin, Duratron, Erta, Ertacetal, Ertalene, Ertalon, Ertalyte, Extreme Materials, Fluorosint, Ketron, MC, Monocast, Novatron, Nylatrack, Nylatron,Polypenco, Proteus, Sanalite, Semitron, Symalit, Techtron, TIVAR, Ultrawear and Vibratuf are registered trademarks of the Quadrant group of companies.

*Classix is a registered trademark of Invibio Ltd. Corp.*Rulon is a registered trademark of Saint Gobain Performance Plastics*Torlon is a registered trademark of Solvay Advanced Polymers*Vespel is a registered trademark of E.I. DuPont

This guide was created by Quadrant Engineering Plastic Products. Design and content are protected by copyright law. © 2010 Quadrant Engineering Plastic Products.

37

Thermoplastics& ThermosetsPlastics are commonly described asbeing either a thermoplastic(meltable) or a thermoset (nonmeltable). Thermoset materials suchas phenolic and epoxy were developed as early as 1900 andwere some of the earliest “high volume” plastics. Both thermoplasticand thermoset stock shapes areavailable for machined parts,although thermoplastic stock shapesare much more commonly usedtoday. Their ease of fabrication, self-lubricating characteristics, andbroad size and shape availabilitymake thermoplastics ideal for bearing and wear parts as well asstructural components.

Documents

Quadrant Machinists Handbook