I would use an endmill something like this one.
http://www.harveytool.com/ToolTechInfo.aspx?ToolNumber=35512
Ooohhh, that's a nice bit of kit.
I would use an endmill something like this one.
http://www.harveytool.com/ToolTechInfo.aspx?ToolNumber=35512
IMO, you are correct. An on size end mill will cut an oversized slot due to tool deflection. I have had good results cutting with a slightly undersized end mill and making a finishing pass along each side. However, the +/- .01" tolerance is fairly loose and depending upon the finish you require , you may be overthinking the problem. I would still use the undersized EM for roughing out the hole. If you used a 5/32" EM, you would have some material for a cleanup pass.Am I correct in my thinking that its an absolutely terrible idea to run a 3/16" end mill (effectively standard milling AND climb milling at the same time) through the slot?
And do you guys think that 1/16" is enough clearance for chip evac (i.e.: a 1/8" end mill in a 3/16" slot)?
I'd open up the center before doing the edges.
- Drill the two end holes undersize
- Ream holes to 3/16"
- run a 1/8" end-mill between the centers along both edges
- Flip part and repeat step 3
...
I'm thinking:
- Drill the two end holes undersize
- Ream holes to 3/16"
- run a 1/8" end-mill between the centers along both edges
- Flip part and repeat step 3
Being aluminum and not steel will be a big help.