Hey Guys- So I've been having a hell of a time. I have an aluminum part that I am machining with 8 holes/counterbores that are .170" Dia 1" deep with a flat bottom. tolerance is +/-.002. So I bought a .125" end mill with a 1" deep cutting depth. well I milled it and the hole came out tapered. Like the mill is defelecting a lot..... I've been thinking about this all day and am not sure what the best way to get this to work it. I thought about drilling and reamming it to .170" leaving .025" at the bottom and then clean that up with the .125" end mill. Or grinding the Reamer so it will cut to full depth? but with that i'm afraid it will chatter and be way oversized. Anyways I have 10 of these parts with 8 holes per piece and don't want to scrap anymore parts. If anyone has any ideas i'd love to hear them. I'm getting frustrated... :-)
Thanks guys!
-Nate