grunzster:
Are there any special considerations that need to be taken as far as which tools to use?
For example, I've heard that with Acrylic you shouldn't use a high speed saw, because it will actually melt the plastic. Would this also be true for polycarbonate?
Are there specific types of drill bits and taps that should be used when working with Delrin and Polycarbonate?
Also can you use a wood lathe to work with Delrin rods?
I second what the Kracken said.
Sharp tools don't just mean new or recently sharpened, what is more important is rake angle. Go with lots of positive rake.
Drill specifically used for thermoplastics will be ground with a small included angle at the point, i.e more like a pencil point than most common drills.
It's not uncommon for tapped holes in plastic to be tight, or undersized. Depending on what you are try achieve this may be a benefit, if not and you need a free running thread, you can order taps that are oversized (greater H-Limit). A "poormans" solution is to first tap the hole, then wedge a piece of toothpick etc into one of the flutes of the tap and take a second pass. This will make the tap cut oversize. (practice on scrap first.)
If your needs are infrequent I would stick to tools designed for either wood or aluminum, as these will typically have sufficent rake.
Almost all thermoplastics are good insulators. This presents a problem when machining as the heat from cutting will rise locally.
Go slower than you would with wood, and let the material cool between cuts. For example when drilling, "peck" and wait, peck and wait.
Can't say I'd use a wood lathe, delrin can be grabby.
Good Luck,
Tobin George
