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moldmakingtechnology.com 19 a previous stepover. Sometimes it is necessary to reduce the depth of each stroke when taking multiple steps, so the tool does not contact the floor, which would require material to be removed in another semi-roughing operation. Whether using a drill or milling tool, the toolholder is just as important. Tool stability is critical to eliminate deflection that can cause tool failure during plunging. Milling tools have a larger body with a large core that is very stable and can be mounted solidly to a spindle adapter. A good rule of thumb is to avoid using a tool that is larger than the diameter of the spindle taper at the spindle nose. This ensures that the forces remain toward the spindle centerline. For example, using a large 6-inch-diameter tool to plunge a com- ponent with a CAT40 spindle would create excessive loads too far from the spindle centerline and would most like- ly deflect, chatter and break inserts. Since indexable drills have flutes that continue to a certain length up the tool, they are a little weaker by design. This is where the tool connection becomes important. A flange on the tool that will act as a positive stop on the holder is a requirement. However, on traditional straight-shanked tools with a flange, that feature only stops axial movement and does not add any significant radial stiffness. In modular connections, the connection diameter is much larger, and there is a signifi- cant increase in radial stiffness even in long projections due to the unique clamping style of the modular connection. Plunge roughing can be a great alternative to traditional rough machining strategies. It stands out in setups with poor stability in which cutting with axial tool pressure is a much better option. With good operation planning and some time spent optimizing the cutting tools in the system, plunging can be the most productive and stable choice for high-volume material removal. FOR MORE INFORMATION KOMET of America 800-656-6381 cullen.morrison@kometgroup.com komet.com CONTRIBUTOR Cullen Morrison is business development manager for KOMET of America. VIDEO: Milling in Slow Motion short.moldmakingtechnology.com/ slowmotion MOLDING STANDARDS Now you can get to root cause solutions with science-based technologies that are revolutionizing injection molding. - MeltFlipper® Rheological Control - Mold Filling Simulation - Therma-flo™ Material Characterization Learn more at Beaumontinc.com or call us today at 814 899-6390 ext 130. CHALLENGE INJECTION