What is the value of a possibly damaged 20mm carbide endmill versus the value 
of a 2.5 inch diameter 1.75 inch long plug of aluminum?

-----Original Message-----
From: Robin Szemeti via Emc-users <emc-users@lists.sourceforge.net> 
Sent: February 28, 2023 8:51 PM
To: Enhanced Machine Controller (EMC) <emc-users@lists.sourceforge.net>
Cc: Robin Szemeti <ro...@redpoint.org.uk>
Subject: Re: [Emc-users] Milling Strategies?

A 20mm cutter will be fine, with a 16mm to remove the final bit of skin and be 
safely away from the plug, leaving some tabs.

On Wed, 1 Mar 2023 at 01:36, <ken.stra...@gmail.com> wrote:

> A few comments/questions:
> Is this a one-off job? If so your time is more valuable than the 
> possible recovery of a usable scrap of aluminum. Besides, do you have 
> a use for a
> 1.75x3 chunk of aluminum?
>
> The stock is 1.75 thick. That means an endmill with a stickout of 2 
> inches or more. A small endmill cannot be used. Chip evacuation will 
> be an issue if slotting. Having a jam damages a large endmill is 
> expensive! I definitely would not trust masking tape + super glue to 
> secure against the cutting forces.
>
> Everything considered, turning the plug into chips seems the best 
> approach from here.
>
>
> -----Original Message-----
> From: Greg Bernard <marzetti...@gmail.com>
> Sent: February 28, 2023 6:57 PM
> To: Enhanced Machine Controller (EMC) 
> <emc-users@lists.sourceforge.net>
> Subject: Re: [Emc-users] Milling Strategies?
>
> It seems like a slotting tool path would be the way to go. Tabs to 
> hold the center in place has been suggested but it could be 
> accomplished also with the masking tape and super glue method:
> https://www.youtube.com/watch?v=e-coDYZCmEw
>
>
> On Tue, Feb 28, 2023 at 4:26 PM Robin Szemeti via Emc-users < 
> emc-users@lists.sourceforge.net> wrote:
>
> > I'd mill it down do within 1 or 2 mm of the bottom of the material 
> > and then swap to a smaller cutter to remove just the outer of the 
> > thinner material and leave 3 supporting tabs.  Remove the centre 
> > piece by hand and then do a single full depth cleanup pass.
> >
> > I do this a lot when routing sheet MDF
> >
> > On Tue, 28 Feb 2023 at 21:46, Matthew Herd <herd.m...@gmail.com> wrote:
> >
> > > You could use a slotting strategy and tabs (at the bottom) to 
> > > retain the piece if you wanted to save the material.  Then cut the 
> > > tabs out
> by hand.
> > > Optionally do another finish pass after manual removal if the wall
> > surface
> > > matters.  But I’d probably just use an adaptive strategy to turn 
> > > it into chips.  Easier and probably faster.  As long as you can 
> > > clear the chips without standing there with an air gun or vacuum.
> > >
> > >
> > > > On Feb 28, 2023, at 3:53 PM, Todd Zuercher 
> > > > <to...@pgrahamdunn.com>
> > > wrote:
> > > >
> > > > I need to mill about a 3.75" hole through a piece of aluminum 
> > > > about
> > > 1.75" thick.  What is the best strategy to accomplish this on a 
> > > cnc
> mill.
> > > Is it best to us a pocketing strategy and mill out the entire hole 
> > > from
> > the
> > > center out, or would it be better to use some kind of cutting 
> > > strategy
> > and
> > > mill some size slug out of the middle?  I can see the first option 
> > > being simpler, but the 2nd option saves a potentially useful piece 
> > > of material, but with the added complication of how to hold and 
> > > prevent the chunk of scrap from wreaking havoc when cut free.
> > > >
> > > > Todd Zuercher
> > > > P. Graham Dunn Inc.<http://www.pgrahamdunn.com/index.php>
> > > > 630 Henry Street
> > > > Dalton, Ohio 44618
> > > > Phone:  (330)828-2105ext. 2031
> > > >
> > > >
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>
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