Finocyl Mandrel Cutting

November 28, 2018

Test	Kerf Input	Voltage	Speed	Lead-in	Notes	Pictures
0	?	? changed in middle of cut to 20 V	.03 in/s	.25	glue fell apart kerf was too big dimensions were off	N/A
1	.06 in	? either 20 V or ~18 V	.04 in/s	.25	glue fell apart wire was not cleaned in between cuts	N/A
2	.06 in	~18 V	.04 in/s	.25	glue fell apart (it appeared that the surfaces that were glued together were not flat, but had dents) wire cut right down seam it looked odd (it's the one on the right in the picture)
3	.06 in	~18 V	.06 in/s	.15	glue fell apart (it appeared that the surfaces that were glued together were not flat, but had dents) new offset avoided seam cut was clean

Changes to investigate:

use styrofoam?
- Dow Blue at Lowes is out
- https://www.insulation4us.com/xps-4-x-8-x-2-blue-board.html
cutting many cross-sections and stacking them
- more gluing involved
cutting quarters instead of halves to avoid glue issue
measure correct kerf

A different type of foam is being used:

Test	Kerf Input	Voltage	Speed	Lead-in	Notes
1	0.06	26 V	0.06 in/s	0.5 in	The right shape wasn't cut Values need to be adjusted for new foam type Speed was too fast, causing blob shape Voltage had to be increased
2	0.06	26 V	0.04 in/s	0.5 in	Shape was improved, but speed is still too fast Cut was aborted partway though, causing vertical edge
3	0.06	26 V	0.025 in/s	0.5 in	Fins are too skinny Kerf input should be increased Finish is rough
4	0.075	24 V	0.025 in/s	0.5 in	Shape is good Voltage was reduced to reduce kerf Slightly smoother finish