I am cutting 23/32" hardwood plywood with a router. Some of the cuts for example are 33", 22", 15", 10" and 5" diameter circles, and curves with similar radii. I estimate that I cut about 500 lineal inches out of a 4'x8' sheet, and up to two sheets per week. I use a Porter Cable 7539 with a radius jig and with templates I have made.
For cutting, I've been using a Whiteside spiral compression bit, a 1/4" with two flutes: part UD2102. I bought it because it was less expensive and could do what I needed. After cutting a few thousand inches with it, it has worked acceptably but I wonder if I could do better with a larger bit.
I cut the 23/32" in one pass. With the 1/4" bit, I'm getting about 36 inches per minute.
I'm wondering if I go to a larger 3/8" or 1/2" bit whether I will be able to get a higher feed rate and whether this will still work well for hand-held use following a template. The wider bit will chew more wood and will require more torque from the router, but I think the 7539 will provide that. But will it feed faster?
With two flutes, the finish is acceptable. Will 3 flutes feed faster or just provide a better finish?
I think the up/down compression bit slows feed because chips get crammed between the up and down sections. A up cut or down cut bit might have better chip ejection and feed better but I'm concerned it will tear-out the veneer. I haven't tried it so I don't know.
I see the "ultimate compression" bits with extended up-cut flutes to improve chip ejection, but they are chamfered from a 1/2" shank to a 3/8" cutting width. That would make the depth setting very particular and it could complicate my use of templates. I would have to use a 1/2" guide but get a 3/8" cut, so my templates would have to be sized to compensate. I've got enough to think about that I don't think I want to rework the templates. I think the "ultimates" would work great with CNC, but my production volume would have to increase ten-fold before I go CNC.
So I'm thinking either a 3/8" or 1/2" compression. The claims regarding the ultimate compression bits suggest 3/8" is optimal for sheet goods because it takes less power than 1/2", but they don't compare it to 1/4" which should take even less power. So I'm wondering if there is any improvement to be had at all.
Is the UD2102 the best bit for my purpose or will a 3/8" or 1/2" bit work better?
For cutting, I've been using a Whiteside spiral compression bit, a 1/4" with two flutes: part UD2102. I bought it because it was less expensive and could do what I needed. After cutting a few thousand inches with it, it has worked acceptably but I wonder if I could do better with a larger bit.
I cut the 23/32" in one pass. With the 1/4" bit, I'm getting about 36 inches per minute.
I'm wondering if I go to a larger 3/8" or 1/2" bit whether I will be able to get a higher feed rate and whether this will still work well for hand-held use following a template. The wider bit will chew more wood and will require more torque from the router, but I think the 7539 will provide that. But will it feed faster?
With two flutes, the finish is acceptable. Will 3 flutes feed faster or just provide a better finish?
I think the up/down compression bit slows feed because chips get crammed between the up and down sections. A up cut or down cut bit might have better chip ejection and feed better but I'm concerned it will tear-out the veneer. I haven't tried it so I don't know.
I see the "ultimate compression" bits with extended up-cut flutes to improve chip ejection, but they are chamfered from a 1/2" shank to a 3/8" cutting width. That would make the depth setting very particular and it could complicate my use of templates. I would have to use a 1/2" guide but get a 3/8" cut, so my templates would have to be sized to compensate. I've got enough to think about that I don't think I want to rework the templates. I think the "ultimates" would work great with CNC, but my production volume would have to increase ten-fold before I go CNC.
So I'm thinking either a 3/8" or 1/2" compression. The claims regarding the ultimate compression bits suggest 3/8" is optimal for sheet goods because it takes less power than 1/2", but they don't compare it to 1/4" which should take even less power. So I'm wondering if there is any improvement to be had at all.
Is the UD2102 the best bit for my purpose or will a 3/8" or 1/2" bit work better?