I need to cut melamine chip free for a customer. We are making a desk system for her to sell to the public. She sees the melamine stuff in stores and wants that chip free manufacturing. We are using a CNC. I have tried compression bits, but they leave a line that is noticeable after edgebanding. Currently, we are cutting with a downshear leaving .05 and through cutting with an upshear to get as good a finish as we can. However, we still get chips. Sometimes they are minimal, but sometimes quite noticeable. Today I'm increasing the final pass to .1 inch. I have a new spoilboard, new cutters and I’m resurfacing the spoilboard after each cut. I need help. I'm about to halt production. What is acceptable chip rate in other shops? How do you repair your little chips?
From contributor A:
I'm going to say it’s all in the feed and rotation speeds. Generally, you should increase your feed speed or slow the rpms down, or a combination of both – just the opposite of what you'd think. Without knowing any more I'd tell you to increase feed to about 7-8k mm and back the rpms off to about 12-13k and use a compression bit.
1. the collet is old – replace it
Also, you should not have any chipping with an up/down spiral. The downshear you are using will give you a great edge finish at the top, but when you use the upshear fore (I'm thinking golf) the final cut you will get chipping on the top side. I'll put my money were my mouth is - we will send you a tool, and if it works, buy it - if not send it back, no questions asked.