How about machining a tall thin wall? This is a notoriously chatter-prone situation that may be partially amenable to plunge milling. If that’s the case, plunge milling is even more likely to give you the best material removal rates. But, if your spindle RPM is the limiting factor, you may not be able to take full advantage of high-speed machining. Plunge feeds and speeds may be a little slower than straight up high-speed machining. ![]() Plunge milling can also be just the ticket when your machine’s spindle power is limited, according to Sandvik.Īnother way plunge milling can help overcome a machine’s limitations is when spindle speed is limited. How about a mill-turn situation where your live tooling is not nearly as rigid as on a pure milling machine? Here again, you may find plunge milling is just the ticket. Sandvik says plunge milling is advantageous any time overall tool stick out is more than four times tool diameter. plunge milling seems tailor-made for the limited rigidity and performance of hobby CNC machines too, for example.Īnd speaking of a lack of rigidity, plunge milling can be ideal for those really deep pockets where side forces are causing so much tool deflection you can hardly make progress at all. Older (or cheaper) CNC milling machines that have more slop in the XY axes, less precise interpolation, or slower spindle speeds may also benefit from exercising the Z-axis more via plunge milling. Or, you may be able to overcome a chatter problem that’s due to a lack of rigidity. By taking advantage of the greater rigidity your machine will have in the Z direction, you may be able to get higher material removal rates. Perhaps you have a relatively lightweight or less rigid machine. Taken together, it’s pretty easy to see where plunge milling could turn into your secret weapon. ![]() By changing forces from side forces (XY plane) to axial (Z) up and down forces, we get much more rigid cutting.
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