Need advise. I wanna cut some MDF (who doesn’t). I have a couple of solid carbide end mills, 6mm, TiAln, 30deg helix. One of them is 2 flute the other is 4 flute.
Recommendations on RPM, feederate and plungerate?
YMMV: But, I cut MDF with a straight flute bit (1/4") around 18k RPM at 1/8" depth pass, moving around 60IPM.
The important thing to remember when cutting MDF is dust - It is terrible for your health, so a nice mask is a good thing. PLUS the dust gets EVERYWHERE, leaving a thin later on everything within 20ft of the machine. Plan accordingly.
There are several sites that can calculate speeds and feeds. Google it. 
I read it was a function of (bit diameter * Pi * RPM) / (1000 * 60). But usually I just guess
@MoserLabs I do that too =) I find it easier.
In my experience, I wouldn’t use that tools, for me, the best option to cut MDF is the vertical flute tool, like this:
In my blog, I already talked about the problems using tools for metal, and the results was not good, take a look on the post:
http://o3ozono.com/en/mecanizado-en-mdf-flores/
In fact, at the end of the post you will see the look of the tool after the work
So, I’ve tried the correct tool, (the one of the first link) and it work perfect. Here you have some samples of how it works.
http://o3ozono.com/paso-23-el-cuarto-eje-estructura-mdf/
For a Ø6mm, with a 5mm depth, I used 24.000rpm, and a feed of 500mm/min.
(it depends on the power of you stepper motors)
About the dust I agree with Edward Ford, I have a vacuum system, and it’s very necessary.
Hope it helps!
Good luck!
@Oscar_Terrer Yep, that’s the same type of bit I was talking about, and thanks for backing me up on the dust. Really… it’s nasty!
500mm/min seems a little slow to me at 24k RPM, I’ve had the misfortune of scorching some bits by running them with too slow a feedrate at too high an RPM. So I tend to start faster (feedrate) and then back off until I find the sweet spot (somewhere between 1000mm/min - 1500mm/min). But, a lot of this depends on both your machine’s rigidity and the power of your router.
Either way @MoserLabs uses the same method as me: trial and error
@Edward_Ford from what I recall from the few courses I took on CNC programming/milling/lathe, use the formulas to get you close and then listen to the machine. You will hear it improve as you adjust the speed and feed manually.
I won’t cut mdf if I can avoid it. It comes out as ultra fine dust as they say. The dust is poisonous and the vacuum needs a very fine filter to capture it all. Besides that the mdf wears the tools down in no time. Use plywood of you can make it work for your needs.
I used 600 mm/m and around 15000 rpm for a 6mm carbid 2 flute end mill, to level my surface, as initial settings. I then adjusted the 15000 rpm, while cutting, to lowest posible rpm, go down to the cutter has a hard time getting thru and then up a bit. Do some test cuts if needed.
To fast and you will burn your cutter.
And yes the dust is a problem to consider.
At close thourght i think i changed the speed to 600 mm/m in the final cut.
I use a faster cut than that for 18mm mdf I use a 3mm up cut ball come and run at around 1700mm/min or so mach tells me not had a problem yet
At what RPM?
Not quite sure it’s a cheap Chinese thing maybe 12000