Tufnol / Phenolic

[simonh]

Has anyone cut 20mm Tufnol or Solid Phenolic with a Festool track saw?  I'm wondering how well it will tool using this method for cutting down a larger sheet?

-Simon

 

[Rob-GB]

I have cut Tufnol with a router, accidentally  [big grin] but it does cut well with normal tools, high speed low feed rate seems to be the norm'.
Found this link , that may be of more help though.
Rob.

 

[rst]

If you are cutting phenolics, be sure to have good dust control and wear a good mask as well.  Phenolics are mostly paper based products bonded with epoxies.  The dust and fumes are nasty, health wise.

 

[Tracky]

What kind of phenolic are you cutting? Paper based, or cloth based?

Paper based phenolic material is quite abrasive and I found it is best cut with a metal blade (negative rake, TCG tips) to ensure long blade life. This was cutting tubing material on a miter saw.

Cloth based material seems easier on the carbide tips.

 

[demographic]

Not tried them personally on Phenolic but have heard that those PCD diamond tipped blades are good on Phenolic.
I have used and do know they are excellent on fibre cement boards and last waaaaay better than TCT blades cutting them.

I'm currently trying out a De-Walt PCD blade in my HKC saw for cutting decking boards that have two chanels of resin and grippy sand type stuff.
Those boards have been killing my standard TCT Festool blades at a rate of one a day from new to useless so I'm hoping the Poly Crystalline Diamond blade is as good as the one I had in my Hitachi when I cut all the cement boards.

 

[MueMi]

You can cut Phenolic/Novotex/hard stuff plates/Pertinax with standard tools for wood or metal working at low to medium speeds. You can turn, file, saw, mill, turn or drill it. It is a nice material....but during machining it has a smell as a puplic toilet [wink]. I would deeply recommend to machine that stuff outside in order to avoid any trouble with other people living in your house. (you will have the smell for days in your shop/house). After machining clean all tools carefully (epecially the vac) in order to keep the bad smell outside.

 

[fritter63]

ON that topic, anybody have a good source for phenolic sheets? I've searched and always find a confusing assortment of them in weird colors and can't tell if it's what I need.

I'm really just wanting the black phenolic that they use to make table saw and router table inserts. I need something that will stay flat for making CNC vacuum holding jigs.

Thanks.

 

[tallgrass]

have you thought about making your own. that is what I do. The control you get is fantastic. Unless you are talking about large sheets. I make 2x2 sheets.

 

[Michael Kellough]

have you thought about making your own. that is what I do. The control you get is fantastic. Unless you are talking about large sheets. I make 2x2 sheets.

Gotta know more about this  [popcorn]

 

[fritter63]

have you thought about making your own. that is what I do. The control you get is fantastic. Unless you are talking about large sheets. I make 2x2 sheets.

I figure that fails my “build vs buy” test....don’t need another project!

 

[tallgrass]

If it was difficult. it is not. just 2 pieces of 1 inch float glass and the material of your choice. Paper, canvas , what ever. I use west system epoxy. Do the layup the day before and off to the racers. If it was a pain in the ass I would agree. The real pain in the ass is getting what you want on the open market. You can look at knife suppliers and industrial suppliers.

 

[Michael Kellough]

@ Tallgrass Doesn't this need to be done in a vacuum to get all the air out of (and out from between) the paper and fabric materials?

 

[tallgrass]

As with many things it is about how far down the rabbit hole you wish to go. Yes, vacuum degassing and a vacuum press are how i do it. However I have had very good results buy simple saturation of material, then making layup , placing between 2 pieces of thick float glass and putting a couple of weights on top. It is very much like making your own carbon fiber or fiberglass plate. I started making this because it was such a hard thing to find. Especially if you are looking for something particular, in none industrial quantities.

 

[Michael Kellough]

@ Tallgrass  have you checked Garolite sheets at McMaster?

 

[Cheese]

However I have had very good results buy simple saturation of material, then making layup , placing between 2 pieces of thick float glass and putting a couple of weights on top.

That's very interesting  [cool], any issues with releasing from the glass plates or do you spray on a release agent?

 

[tallgrass]

I have looked into it but that is like 50-100 bucks a foot. It has its place, but what if I want it a little different? I have made sheets with Kevlar, carbon fiber or fiber glass mixed in with the paper or canvas or what ever. Old blue jeans and Silk even. I am not against buying it. It is just one of those things that is not hard to make. As far as sticking to glass. no I have not had problems with it. I get quite a nice surface finish to boot.  I don't make it often, but when i do I make a couple of sheets at the same time. The last batch I made was using black denim and carbon fiber. 

 

[Cheese]

The last batch I made was using black denim and carbon fiber.

[cool] very [cool] Do you have a photo to share?

 

[tallgrass]

I'll look. I think I am an odd duck. I don't take lots of pictures of stuff. However I will look.