miterfolding solid surface

[Stuart Douglas]

Has anyone been using the amana insert bits (specifically the 46 and 91 degree insert bits) to miterfold front edges and intergral cove splashes? I ran a test piece about 30" long and the chips rewelded and smoked the insert. Looking for anyone who has experience with these cutters in solid surface. I tested the 46 degree cutter and ran it at 220 IPM. the cut quality looked satisfactory, but the egde where the "fold" happens was packed and rewelded. Wondering if I need to rough out this cut with a different tool or what.

[Stuart Douglas]

Edit: I ran this bit @ 180 IPM, just tested a speed up to 200 and it snapped the insert and ruined the bit

[Stuart Douglas]

After digging around on the internet and talking to some product reps, it looks like miterfolding on the CNC is only a practical process on a 5 axis machine running a bit like a molding head. The issue is that on the z axis, tip velocity is practically 0. Lesson Learned.

[Zach Froble]

I have done miter folding on ours but only in plywood, never tried solid surface. I used a onsrud v-tipped bit designed for lettering and it worked great.

Zach

[Stuart Douglas]

Zach,

I'll bet the amana insert bit would work great on MDF or plywood, and I'll keep the bit (I chased the slot for the insert with a dremel cut off tool and an ignition file, should be usable again) for miter folding soft stuff like that, but SS is just too dense and brittle to make this an effective setup.

[Brad McIntosh]

Stuart,

You would not necessarily need a 5 axis machine. A "3 axis" machine with a saw/v-groove aggregate, a programmable C-axis (okay now "4 axis") and a CAD/CAM software that supports aggregates should be able to do the job.

In order to handle the aggregate, you would be probably looking at Model 45. (CS43s cannot be outfitted with aggregates.)

[Josh Rayburn]

Hi Stuart,
We use the 91 degree amana bit regularly with great results. Perhaps you need to set a max pen value for the tool if you have not done so already?
Hope this helps,
jnr

[Stuart Douglas]

Hi Stuart,
We use the 91 degree amana bit regularly with great results. Perhaps you need to set a max pen value for the tool if you have not done so already?
Hope this helps,
jnr

Ive been screwing around and it seems the 91 degree bit will work, but you need to run it ridiculously slow. I set the pen value to do the cut in 3 lifts and a finish pass. what kind of bit life do you get with the insert? I still doubt the feasibility of the 46 degree for the coped splash setup, there is just no room for the chips to escape and the tip of the insert gets smoked the second it hits the material. Do you rough out with some other bit? Do you mind sharing your feeds and speeds? Thanks.

[Josh Rayburn]

Stuart,
The 91 degree tool is the only one we have. We have to run it around 180-250 ipm to get a good result, along with multiple passes. Yes, we rough out first whenever possible, using a 3/8" super O. Personally I hate insert tooling no matter the application, but I can't find a carbide tipped 91 degree tool so this one gets it done.
Hope that helps!
jnr