Plunge milling might be an option?

https://www.sandvik.coromant.com/en-us/knowledge/milling/milling-holes-cavities-pockets/plunge-milling
Plunge milling
sandvik.coromant.com


This has the same chip issues as other pocket milling strategies but the 
federates can be much higher, particularly with small tool diameters and deep 
holes.
A horizontal mill uses gravity to help with the chip issue.


> On Feb 28, 2023, at 2:53 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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