Cutting XPS Foam

[harryball]

I have my foam and I've done a few test cuts. I'd hoped for cleaner edge cuts than I'm getting. I stole an idea from the "Men Only" thread and used the 1/8" tapered bit to do all the cutting. The face carving works very well, but when cutting the profile the edges are not smooth.

What feeds and speeds are you guys that cut the blue board using?

I've tried a range but I saw the best quality so far at 4 ips and 8000 RPM with the 2 flute 1/8" bit. I'm cutting conventional, the climb sides of the cuts are the poorest quality.

/RB

[Gary Campbell]

Robert..
Did you try jacking the rpm up as high as it will go? That might help with tearing. Nice to see you back here.
Gary

[harryball]

I tried up to 10k RPM... I was concerned about going too fast that it might melt the material. But I think I'll keep jacking up the RPMS instead of lowering them to see what happens.

I've been hanging around, just been ultra busy lately. Our first "Bat Safari" is coming up April 26th at Panola Mountain State Park. No idea what to expect yet, but I've got to prepare all the same. I updated our website and all our prices to cover shipping and fuel increases and designed a new workshop program for schools.

I'm planning for a good year this year, think positive, plan to succeed and see your goals so you can realize them.

/RB

[Brady Watson]

Robert,
You will not melt the material. The idea is to keep chipload as low as possbile. This will minimize tear-out. As Gary suggests, jeck the RPM all the way up & then try a 4-flute end mill. That should do it. Use your MS as a throttle for the right chipload/speed to prevent tearing and fuzzies.

-B