Beesleys Tool Shop Materials Overview

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Materials Overview

Knowing the materials you work with ensures you are using the right tool, attachment or bit for the job. Dremel tools have literally thousands of uses.

Wood

Wood can be categorised into two main groups; hardwood and softwood. The characteristics of these woods will affect various results of your project.

The difference between hardwood and softwood is understood best by the difference in the cell structure, the grain and the chemical attributes, which help define the mechanical and physical properties of the wood. Softwoods have a much simpler cell structure than hardwoods. The grain is not as dense in softwoods and because there are fewer cell types in softwood, there is less variety in the grain of softwood. Chemical makeup will have some affect on the color of the wood, however extractives will also affect density and strength.

Some extractives are actually minerals. They contribute to the rapid wear and tear on cutters. Some extractives are a more waxy substance, adding to the buildup on cutting accessories. When using a higher speed, they can also contribute to the accessory smoking or burning. (They can also be difficult to finish and glue, as the finish and glue may not absorb or stick as easily to the surface.)

Wood is generally rated for a few different factors. Specific gravity indicates the strength of wood and how easy the wood is to work with. Higher gravities are generally stronger, but also harder to work with. Hardness ratings indicate how the wood will be in regard to resisting damage. Strength ratings show how a wood is rated for compressive strength and bending strength. Woods are also rated for movement and stability. That is determined by knowing how the wood shrinks from the time it is fresh cut and green to the time it is completely dry. The less the wood shrinks the more stable it is.

Another type of wood common to projects is plywood. Plywood is a laminated panel. Generally there are several layers (between 3 and 7 plies). The layers are held together with an adhesive. The core, or material that makes up the inside layers, can be made from wood veneer or from particleboard or fiberboard. The layers alternate in grain direction to help increase the stability of the panel. This crossbanding will hold nails and screws better than regular wood. Similarly, when cutting with any depth into the ply panel, the adhesive will generate additional heat and the cutter will work twice as hard to get through the multi-directional plies.

Wood is used for all kinds of projects, for a variety of reasons. It's important to choose a wood that will be strong enough for the specific project you are working on. Keep in mind that each wood will cause a little different wear and tear on your accessories.

Plastic

There are several kinds of plastics. The most common plastics are acrylics, polycarbonates, Ultrahigh-Molecular Weight Plastics (UHMW), phenolics and plastic laminates. Acrylics are strong and somewhat brittle. Polycarbonates are less brittle and more rigid than acrylics. Ultrahigh-Molecular Weight Plastics (UHMW) are more flexible and slide more easily. Phenolics are more rigid and somewhat heat resistant. Plastic laminates are generally used as a covering over wood.

When working with plastics of any kind, slower speeds have to be used. With plastics, we would recommend going as slow as possible and working with the most coarse accessory or blade possible. Friction and either a "short cutting stroke" or an accessory constantly in the material will create excess heat, causing plastics to soften and fuse together. One way to have a cooling effect is to place a layer of masking tape over the plastic material. Also work with a slower feed or cutting rate.

This information will work in many situations, but keep in mind that it may not work in every situation. Always experiment with a material first to get some idea of what will be the most successful.

Metal

Metals come in a variety of hardness and makeup. There can easily be as many speed recommendations and accessory recommendations as there are metals. Whatever cutter or blade you are choosing needs to be at least as hard or harder than the metal you are working with. For example, brass is a soft metal. It will cut easily on a scroll saw with a metal-piercing blade at speeds of 1000 strokes per minute. The cut will be very smooth. On the other hand, aluminium is considered a soft metal. While considered a soft metal, aluminium can be a combination of various metals, so the complexity of the cutting can range from easy to very difficult.

When working with harder metals, like steel, it can be helpful to put paraffin wax on the surface prior to beginning your application. It can help keep the surface and the accessory a little cooler. Slower speeds will also be necessary when working with a harder metal.

Ceramic

Ceramic material is generally a very hard, brittle, heat-resistant and corrosion-resistant material made by firing clay (or other minerals consisting of one or more metals) in combination with a non-metal, most usually oxygen. Because it is so hard and brittle, working on ceramic will generally require at least a silicon carbide stone, a tungsten carbide cutter or a diamond wheel point. Silicon carbide stones can be used for putting a custom shape into a ceramic wall tile. If you're cutting wall tile, we would recommend using our tile cutting bit and the Cutting Guide Attachment on the rotary tool. A diamond point can be used for other small details.

Working with this material will get very hot. Some applications may not be possible because of the excessive heat. We do not have any tools or accessories that can cut ceramic floor tile.

Porcelain

Porcelain is finished differently than ceramic. Porcelain is a very hard, white, translucent ceramic made by firing a pure clay and glazing it with variously colored fusible materials. Fine china is porcelain. Because of the multiple layers of glazing, porcelain is generally harder than ceramic. This hardness will make applications more difficult and place different kinds of stress on the accessories capable of grinding or shaping the porcelain. The accessories will wear out more quickly and slow speeds can be helpful in reducing the heat from the material and application.

Glass

There are few materials as tough to conquer as glass. Glass is one of the hardest, most brittle materials. This hardness makes it difficult to recommend attempting some applications with our tools. For example, because some applications require a "bath" or constant coolant on the accessory, we do not recommend trying them with our tools. We do not have a way to drill a precision hole in glass or cut glass.

It is possible to etch glass, smooth glass or grind glass. When doing these types of applications, remember that your accessory will wear out more rapidly. The combination of excessive heat and hard material will dull tungsten carbide cutters and diamond wheel points and it will wear away silicon carbide stones more quickly. Using additional pressure on the accessory will not complete your application more expeditiously, it will only reduce the life of the accessory.

Terra Cotta

Terra cotta is not just for plants any more. It is decorative and can hold a variety of materials. You can grind shapes into the terra cotta, adding your own decorative touch to this clay material. Terra cotta is brittle and breakable, yet it is very tough material. The result of speed against a tough material like terra cotta is heat. With that in mind, as you begin working on terra cotta, conservative frequent passes with the high-speed rotary tool will always produce the best results. Part of the terra cotta can be removed, or a gradual, complete removal of the material is possible.

There are four basic Dremel accessories that will add to the potential for success: diamond wheel points, tungsten carbide cutters, silicon carbide grinding stones and a tile cutting accessory bit. Terra cotta is very dusty; therefore, if you soak it in water first it will help reduce the dust. Let the terra cotta dry before using the tool on it. Don't go too fast to start. The aggressive nature of these accessories can cause them to grab the terra cotta and it will chip. Finding a comfortable speed and simply guiding the tool will bring the best results. If you find the tool is chattering, you should turn the tool speed up a little bit.

Stone and Brick

Stone can come in many shapes and sizes and degrees of hardness. Soap stone is soft enough that it can be carved, shaped or engraved with an engraving cutter. Heavier, more dense stone will require a more durable cutting or grinding accessory. The cutter or grinding point will need to be at least as hard or harder than the stone piece you are working on. To keep the cutter or grinding point from wearing away too quickly, do not force it into the stone. Keep the speed moderate and pressure light. It is better to make a more frequent but conservative pass.

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Index Dremel Spares & Advice Materials Overview