A versatile technique, enabling diversity of edge fabrications and trimming of PALSUN sheets, notably for parts too large or of irregular shape for a band saw. With sharp two-flute straight cutters it can generate very smooth edges.
● The feed rate should be slow, to avoid excessive heat buildup and shattering.
● When routing, the moving object, whether the sheet or router, should be guided by a suitable jig.
● A jet of compressed air can be used to cool the bit and the sheet at the spot of cutting and assist in chip removal.

Static bench routers:
Fast, strong and stable, for complex and accurate straight-line fabrications.

Portable routers:
Less powerful, for smaller or on site jobs. Also used for trimming and edge fabrications of irregular shapes. Can perform certain small milling jobs like butt shaping on rectangular or round apertures or tongue and groove butt finish on thicker sheets.

Applications

Primary edge finishing:
● Quick and accurate trimming or finishing of straight-edged or curved cut PALSUN sheets.
● Easily produced straightedge corners or curved butts.
● Preparation of varied lap and butt joint fabrications.

Tooling:
● Routers: Universal, commercially available equipment.
● Routing cutters: new metalworking cutters, kept at utmost sharpness.

Table 14: Routers' Configuration

Clearance Angle	5 – 10°
Rake Angle	0 – 10°
Router speed (w/o load)	15,000 – 22,000 rpm
Cutting Speed	100 – 500 m/min (330 -1640 ft./min)
Feed Rate	0.1 – 0.5 mm/rev (0.004 - 0.07 in.rev)

Routing and milling tips For clean, smooth routing work ensure cutter’s sharpness and faultless alignment before starting work.
Compressed air jet cooling following the cutting head improves the culter’s speed, cut quality and blows the swarf away.
Let the tool reach its maximum (unloaded) operating speed before commencing work.

Milling & Joining
A portable router, with suitable cutters, can be used for small milling jobs.
A standard woodworking jointer-planer, preferably with carbide or high-speed blades/cutters, can be used for trimming, acquiring good quality edge finish.
Avoid excessive stock removal, which may result in shattering or rough edges. A cut of 0.4 mm (0.016 in.) or less per pass is recommended.