Solution – limit the arc of engagement
Use a programmed radius (circular milling) to reduce the arc of engagement and a radial cut to reduce the vibration tendencies, which will allow higher depths of cut and feed rates when milling inside corners.
- Mill a bigger corner radius than stated in the drawing. This can sometimes be favourable, as it allows the use of a bigger cutter diameter in roughing, which maintains high productivity
- Alternately use a smaller DC cutter to mill the desired corner radius
Mill a bigger component radius,
Corner radius = 75% x DC
Use a smaller cutter,
Corner radius = 100% x DC
A programmed radius of 50% DC is optimal.
For finishing, it is not always possible to have such a large radius; however, the cutter diameter should be no larger than 1.5 x component radius, e.g. corner radius 10 mm (0.394 inch) = max 15 mm (0.591 inch).