Machining depth question (Ø2.0mm cutter)

[GarethW]

I'm designing an aluminium part which has a slot measuring 8.6mm x 4.3mm. Corner rads required are 1mm. Therefore a Ø2.0mm cutter would need to be used.

What’s the max depth that could be achieved? Could I get away with 10mm?

Note that good dimensional accuracy is required for this feature (+/-0.05mm)

 

[Ramana Rao]

You will be able to achieve more than that on a CNC machine, with a high enough spindle rpm. To reduce the lateral load on the cutter, it's dia has to be relieved by about 0.2mm, after 2mm from the cutting edge.The depth of cut may be increased from an initial 0.05mm by looking out for cutter vibrations. You have to be careful while programming for the cutter path at the corner radii, as usually it is here that it fails.

Ramana Rao

 

[Dave B]

Perhpas the corner accuracy can be obtained by first drilling the 4 corners carefully with pecking then mill the slot. Plunge cuts are more accurate then with side cutting do to load deflections on small radius end mills. Then of course the issue is milling out to the tangent of each corner with a smaller and smaller end milll until you reach 2mm. Short of edm it is difficult to get a slot depth of 10 mm 5:1 aspect ratio. If it is possible to avoid the issue by designing the slot as a dog bone to get full corner relief with a larger radius cutter. That assumes your other design constraints would permit this.

 

[baron.g]

I'm designing an aluminium part which has a slot measuring 8.6mm x 4.3mm. Corner rads required are 1mm. Therefore a Ø2.0mm cutter would need to be used.

What’s the max depth that could be achieved? Could I get away with 10mm?

Note that good dimensional accuracy is required for this feature (+/-0.05mm)

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