For ABS-Polycarbonate, need chipless or near chipless hole

Can you put it on a water-jet table?

No the expense of the water jet would exceed our allowable cost.

Thanks

Try grinding your drill point to a steeper angle possibly 60deg included. This will allow the chips to exit before the full dia. of the hole is reached. You can also increase the rpm (probably 2800 max or you will melt the plastic) and reduce the feed rate to about .001 to .002 chip load. Try about 8 inches per minute. This will give you a finer chip. Of course continue pressurizing the spoiler.

He's got my money.

And since he said what I was going to say, I can spend this time rambling about something completely unrelated. It is like having bonus time.

Or: If I am going to buy a new car for 30,000 USD and get it for 20K. I have 10K to spend on a boat. If I get the boat for 7K I now have 3K to buy gear. If I get outfitted for 1500 I now have 1.5K to buy fishing vacation. If I get this trip for 700 I have 700 left. Now, 200 on licensing. 200 on fuel.

Now I go down to the jeweler and buy a pretty little pendant and I jerking redfish for a season.

See, bonus time.

cr3

Thanks for the tip. We are going to try this this week.

Good luck. If you are grinding the drill by hand, remember to leave a small chisel edge at the tip, just like on a normal 118deg drill tip. Do not grind to a sharp point or it will not cut.

Gary

How did it go?

Try using a diamond abrasive bit. This will be slower so that you don't melt the ABS, but the result will be dust instead of chips.

There are plunge router bits that have more and smaller teeth, these would produce smaller chips that wouldn't rattle as much?

The other thing is that you have to have the bit moving very slowly as you break through the ABS to finish the hole.

The other thought would be to use a water soluble lubricant that could be flushed out.

Any of this is going to add time and cost though.

Good Luck!

I don't know if this will help, but when we drill through concrete walls we hold a vaccuum beside the hole we are drilling to remove all the dust. Along with the above suggestions this might help solve your problem.

This sounds like a good application for a CO2 laser. Depending on the application they can be very cost effective.

What about using a heated metal pin to melt the hole,probably with a vacume to remove the fumes.