Acrotech, Inc.

Custom Urethane Manufacturing

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    • k-prene-urethaneK•Prene®Polyurethane
      • Round Rods
      • Precision Cast Sheets
      • Square & Rectangle Bars
      • Versa Rolls™For wheels, casters, rollers, sheaves
      • Metric Sized Products
      • Solid Urethane Balls
      • Tubes & Springs
      • Additional Tubes/Spring Sizes
    • acrotech-metalworkingMetalworkingApplications
      • Large Radius Forming
      • K•Prene Press Brake Dies
      • Acroform™ InsertsSimple & economical
      • Acro-hyde™ Urethane FilmFor Press Brake Forming
      • SurStrip™ Punch Strippers
      • Wiedeman® Punch Strippers
      • Piranha® Punch Strippers
      • Di-Acro Punch Strippers
    • acrotech-industrialIndustrial ProductsAPPLICATIONS
      • Washers, Seals & Gaskets
      • Slick Strip™ Tape
      • Bumpers
      • Metal Backed Sheets
      • K-20 Adhesive
      • Tool Holsters
      • FDA Approved Polyurethane
      • Custom Bumpers
      • Urethane Tool Holster and Hammer
    • drive-wheelsWoodworkingAPPLICATIONS
      • Urethane for the Wood Industry
      • Powerfeed Replacement Tires
      • Power Feed Tires and Reuseable Hubs
      • OEM Replacement/Recovering
      • OEM Replacement Parts
    • acrotech-automotiveAutomotiveAPPLICATIONS
      • High Performance ApplicationsSpring Rubbers
      • Automotive High PerformanceIncluding Motorcycle and snowmobiles
  • Roll Bending Machines
    • small-model-roll-bending3Benefits & Custom RollingVarious Models Available
    • LD and HD Models
    • Models 1212, 1618, 1824
    • Model V-1006
    • Roll Bending Machine Restoration
    • Art of Bending
  • Custom Urethane
    • custom-molding1Custom MoldingAPPLICATIONS
      • Industries Served
      • Roller Manufacturing
      • Roller Recovery Service
      • Custom Machining
      • Custom Urethane Colors
  • Custom Metal Rolling
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  • Application Chart of K•Prene
  • Machining of K•Prene
  • Physical Properties of K•Prene®
  • Metal Forming Applications Using Urethane
  • Urethane Compared with Natural & Synthetic Rubbers

Machining of K•Prene

machined urethane partsMachining of K•Prene® urethane proves useful when the required tolerances cannot be obtained by conventional molding methods, or when low production runs do not justify the cost of molds. We maintain a complete inventory of sheets, round rods, and bars in six different hardnesses which can often be used to make prototypes or limited production quantities.

The table below details the general machining characteristics of K•Prene® urethane K-900A durometer and harder. For K•Prene® urethane below K-800A durometer, cutting tools are often not satisfactory and grinding may be required. In some cases, machinability can be improved by freezing K•Prene® urethane below K-800A durometer with dry ice or liquid nitrogen.

Machining of K•Prene® urethane is similar to that of metals, and in most cases the same tools can be used.

The principle differences between metal and urethane machining are:

Modulus of Elasticity
Urethanes are resilient and can be easily distorted, so care must be taken to avoid distortion due to holding or cutting forces.

Softening Point
Gumming, poor finishes and poor dimensional control will readily occur if excess heat is generated and allowed to accumulate. Proper tool geometry, feed rates and cutting speed in conjunction with coolants can usually overcome these problems. Water-soluble cutting oils and/or light machine oils are good coolants for urethanes.

Lower Thermal Conductivity
Heat generated by the cutting tools stays close to the tool and raises the urethane temperature rapidly. This heat must be controlled. Melting can occur above 350° F.

Elastic Memory
Elastic recovery occurs in urethanes both during and after machining, so the cutting tool must provide clearance to compensate accordingly. Without compensation, expansion of the urethane after cutting will result in increased friction between the cut surface and the cutting tool. Excess heat build-up will result. Elastic recovery after machining can result in smaller internal diameters or larger external diameters than were measured during cutting.

Machining ApplicationsRecommended ToolsSize LimitationsMaximum SpeedsWorkholding RecommendationsSuggestions
BandsawingSharp 2-4 hook carbide blade with raker setMax. 8″ thick, Min. 1/8″ thick sheets 1800 ft./min. (reduce to 1200 ft./min. below K-900A)Vises or clamps (not required with flats or sheets)
  • Rotate rounds when sawing.
  • Maintain high blade tension.
Cutting, Shearing, SlittingShears or belt-cutting machines with up to 1/8″ knife blade Thin sheets (up to 1/2″)Friction clamps
  • Use bevel edge blades (square degree, compress urethane, resulting in uneven cuts). 
DrillingHigh speed 90º + twist  drills with blunt pointMin. of 3/8″ (no minimum if clamped between steel)600-800 RPMVises or clamps
  • Good tolerances possible with K-750D, for other grades use over-size drills.
TappingRegular high speed tapsNoneVises or clamps
  • Except for K-750D, use over-size tap to allow for shrinkage or urethane.
Turning, BoringH.S.S. toll bits with positive rake of 5º-10ºNo limits on dia. length restricted (long soft bars may flex)800 surface ft./min.Angle of cut to work: 90º-120º
  • Form tools may be used (especially when machining K-750D). 
GrindingTool post grinder, 20-80 grit wheelLathe: 150 RPM or lower, Grinder: 2000-3500 RPMFixtures or friction mandrels
  • Air blast to eliminate build up.
KnifingCarbide or H.H.S. razor sharp and as thin as possible 600-1000 RPMFixtures or friction mandrels
  • Use lubricant to help prevent dishing.
MillingSharp single-blade flycutters with 10º back rake and good clearanceMin. 3/8″ thick Approx. 2000 surface ft./min. Vise or double-face clamping tape
  • Flycutting at approx. 3″ dia. give best results. 

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News + Videos

  • Roller Data Form January 14, 2019
  • The Fabricator: The science of bending perforated sheet and tread plate December 17, 2018
  • Urethane Metal Backed Sheets December 3, 2018

(800) 345-0583

K•Prene® Urethane products & services for…
Custom Molding
Standard Products
Metal Forming
The Applications Are Unlimited!

Acrotech, Inc.

980 West Lakewood Avenue
P.O. Box 466
Lake City, MN 55041
Toll Free: (800) 345-0583
Fax: (651) 345-3759

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