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Cutting
Marlon FS is easy to saw and cut on standard workshop equipment. It can be machined on conventional milling machines with standard high speed tools. Notches adversely affect the mechanical properties of polycarbonate and should be avoided.
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Circular Saw |
Band Saw |
Milling Machine |
| Clearance Angle |
20-30° |
20-30° |
20-25° |
| Rake Angle |
15° |
0.5° |
0-5° |
| Cutting Speed |
1800-2400 m/min |
600-1000 m/min |
100-500 m/min |
| Feed Speed |
19-25 m/min |
20-25 m/min |
0.1-0.5 mm/Rev |
| Tooth Spacing |
2-5 mm |
1.5-2.5 mm |
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Drilling
Any commercially available metal drill without a specially ground bit is suitable for use with Marlon FS. The following points should be observed when drilling Marlon FS:
. Do not use cutting oils with Marlon FS. The sheet may break as a result of notching.
. Fixing threads should only be used if there is no other alternative (through-hole, bonding, clamping).
. The sheet may break as a result of notching.
Drill Data
| Parameter |
Value |
| Clearance angle |
5-8° |
| Tip angle |
90-130° |
| Helix angle |
30° |
| Rake angle |
3-5° |
| Cutting speed |
0.1-0.5mm/rpm |
| Drill tip speed |
10-60m/min |
NB - The hole should be at least 1.5 x hole diameter from the sheet edge.
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Thermoforming & Hot Bending
Before thermoforming, remove masking films and pre-dry at 120°C to remove absorbed moisture. Air circulation ovens with accurate temperature control are most efficient - air must circulate between sheets. Sheet age and storage conditions determine drying time.Dry storage can reduce pre-drying time in oven by up to one third - some experimentation is usually necessary. As moisture re-absorption starts when the dried sheet temperature falls below 100°C, thermoforming should be performed immediately after drying.Pre-drying is not normally required when hot line bending. |
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Guidelines for Drying
Marlon FS can be moulded on any standard vacuum or pressure forming equipment. Forming can be made at temperatures between 175°C and 200°C. When the mould temperature falls below 125°C formed parts can be removed. Mould shrinkage will be between 0.5% and 1.0%. The recommended temperature for hot
bending is between 155°C and 165°C.
Sheet Drying
Thickness(mm) |
Time at 120°C(hr) |
| 2 |
4 |
| 3 |
8 |
| 4 |
13 |
| 5 |
18 |
| 6 |
22 |
| 8 |
26 |
| 10 |
30 |
| 12 |
33 |
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Cold Curving
Marlon FS can easily be cold curved. At low radii high stresses are
built up in the material which will lower chemical resistance. Radii
should be as large as possible to minimise stresses. The minimum allowable
radius for cold curved applications is SHEET THICKNESS x 175. This
incorporates a factor of safety to cope with the stress effects produced
by curving and environmental stress factors.
Bonding
The material can be bonded using one of the following adhesives; Epoxy, Polyurethane, Hot Melt or Silicone. Ask your adhesive supplier for the most appropriate type of adhesive for your particular application. Solvents such as Methylene Chloride give a good bond but can lead to stress cracking and are therefore not recommended.
Cleaning
A mild detergent with lukewarm water and a soft cloth or sponge should be used to clean Marlon FS. Always rinse thoroughly with clean water. Ethyl Alcohol can be used to remove paint and other such substances. This should always be washed and rinsed thoroughly afterwards. |
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