What is successful plunge milling?
In plunge milling, the cutting is performed at the end of the tool instead of at the periphery, which is advantageous due to the change in direction of the cutting forces from predominately radial to axial. In general, plunge milling is an alternate method when side millling is not possible due to vibrations.
- When the tool overhang is greater than 4 x DC
- When the stability is bad
- For semi-finishing of corners
- For difficult to cut materials such as titanium
It can also be an alternative when machine power or torque is a limitation.
Note: Under favorable conditions plunge milling is not the first choice due to a lower metal removal rate.
Choice of tools
Cutter selection is determined primarily by the diameter.
Plunging with drilling tools can be more effective up to approx. DC = 35 mm, see Drilling.
How to apply plunge milling operations
Plunge milling operations vary considerably from traditional milling. It uses the end of the tool to cut instead of the periphery, which beneficially changes the direction of the cutting forces from predominantly radial to axial. It can be compared to a boring operation with interrupted cuts.
Power consumption and noise are low.
Plunge milling = interrupted boring.
Axial cutting forces.
Mainly radial forces.
= program table feed = rapid traverse
Avoid re-cutting on return stroke. Gradually decrease plunge depth.
Power consumption calculation.