CUTTING ACRYLIC SHEETS FASTER AND MORE EFFICIENTLY

There are many types of saws capable of cutting acrylic sheet. The CNC panel saw is the most efficient and is considered the center for operation control that most fabricators, distributors and manufacturers use for trimming and cutting to size. Today's CNC panel saws are powerful and flexible. They are powerful enough to meet the challenges of the highest production applications and flexible enough to handle small quantity cut-to-size orders with efficiency. This article will focus strictly on CNC panel saws.

Acrylic sheet is manufactured utilizing one of three different processes. They are, cell cast, continuous cast and extrusion. Each process is unique and creates different physical properties that must be addressed before the cutting operation begins. The selection of carriage speed and blade RPM will depend on the type of acrylic, the height of stacked sheets, sheet thickness and the saw tooth configuration. Carbide-tipped saw blades should always be used. However, the correct saw blade must be used in order to achieve maximum blade life, reduce friction and provide a sharp chip-free cutting edge. As a rule of thumb, the thinnest blade possible with the largest arbor (center hole) should be used. Thin blades "push" easier, save material and will cut cleaner. Blades should be sharpened at the first signs of dulling. Excessive dulling requires excessive regrinding to regain a sharp edge. It is strongly recommended that blades be sent to a factory authorized service center, or to a repair center with a proven record for quality sharpening.

Cast acrylic sheet requires blades with fewer teeth to increase chip load, reduce friction and reduce power requirements. Cast acrylic is easily cut using a high quality blade fitted with the hardest available carbide tips, ground to a triple chip configuration.

Extruded sheet however, requires blades with many teeth to reduce the chip load per tooth. In addition, extruded acrylic tends to melt from the friction of cutting, leading to smearing, chipping and generally poor quality of cut. A "low melt" geometry designed blade, that generates a minimum of cutting friction should be used.

It is especially important to correctly set the blade height above the sheet for sufficient cooling. The blade height should be set such that the teeth are fully above the sheet surface, with space between the bottom of the tooth pattern and the surface of the sheet. Generally, this space should be approximately 1/4". If the blade is raised above this point, chipping of the sheet edges becomes likely. For optimum edge quality, the material should be cut at lower feed rates. A cooling system should also be incorporated. Either a water mist a directed air stream will sufficiently cool the blade, prolong the life of the blade and optimizing the appearance of the cut.

Many of today's CNC panel saws provide more efficient value added opportunities than ever before. The latest models include technologically advanced saw carriages, updated computer controls, and are safer and run more than twice as fast as previous models. Programming is more user-friendly and systems are operating with fewer bugs, especially with non-proprietary controllers. Remote diagnostics brings a level of sophistication and a new meaning to service, troubleshooting and repair.

The plastics industry is taking it's cue from its woodworking friends. Huge efficiencies, up to 50%, are obtained when traditional front-loading CNC panel saws are upgraded to rear-loading or side-loading models with lifting platforms.

Overall efficiencies and cost-savings can be enormous, especially when combined with the proper blades, correct speeds, proper loading and handling along with today's technologically advanced panel saws. There's no argument that the competitive landscape of the plastics industry is rapidly changing. The playing field noticeably tilts in favor of the distributor, fabricator and manufacturer who operate their business more efficiently.

Written by Michael Batky, Vice President, Business Answers International, the exclusive U.S. dealer for SCM Group USA for the Plastics Industry.

For more information, contact Business Answers International, 4440 PGA Blvd. Suite 505, Palm Beach Gardens, FL 33410, 800-583-4726 X15, FAX 561-775-0520, E-mail: Plsticlink@aol.com.