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Marv,

I had a similar problem over the weekend. The remedy was to significantly
decrease feed and increase RPM when plunging. This gave more time and force
to throw the chips away from the cut. This was with a 4 flute center
cutting end mill. Obviously a 2 flute would have worked better for plunging
offering more room for chip evacuation, but I didn't.t have one at hand.
Also, a bit of cutting fluid at the plunge location helps to keep the chips
from sticking and can delay the packing problem.

Regards,

Howard Bailey

----- Original Message -----
From: "Marv Frankel" <dcdziner@p...>
To: <CAD_CAM_EDM_DRO@y...>
Sent: Tuesday, October 22, 2002 11:15 PM
Subject: Re: [CAD_CAM_EDM_DRO] Dumb question on the drilling of holes

Jon,
Thanks for your input. My spindle is tight, so are the bearings, and
the 1/4" end mill is held in a pretty new collet. When I tried plunging

the

end mill through an 1/8" wall aluminum extrusion, I could feel resistance

on

the quill. Then I realized that, as the cut started, the chips built up
between the end flutes, and caused some galling and hole distortion, since
the chips, unlike a fluted drill which gets rid of it's own chips, had no
place to go. I'll try to do some testing, and document my findings, to
arrive at the best solution.

Marv Frankel
Los Angeles

----- Original Message -----
From: "Jon Elson" <elson@p...>
To: <CAD_CAM_EDM_DRO@y...>
Sent: Tuesday, October 22, 2002 10:25 PM
Subject: Re: [CAD_CAM_EDM_DRO] Dumb question on the drilling of holes

Marv Frankel wrote:

Tim,
I'm pretty familiar with reaming holes for proper fit, but the

holes

I'm talking about, are sometimes so misshapen, they almost look

triangular.

They're 1/4" holes, and I've even tried cutting them through with an

end

mill, and that wasn't great either.

A properly sharpened drill bit will not do this except on very thin
sheet. A dull drill bit can
sure do things like this. End mills generally make VERY round and
smooth holes, even when
plunged. If you are trying to plunge an HSS end mill into tool steel,
however, that could cause
deflection. Are you sure your spindle is solid? A bad spindle bearing
or loose quill could
do this. I hope you aren't holding a 1/4" end mill in a Jacob's chuck.
That really won't work,
and isn't safe, either!

Jon


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