Why was my rectangle not completely square? I do not mean in the corners where a round emdmill necessarily guarantees the corner will be limited by the diameter of the endmill. Then I watched the endmill cutting circles. It was definitely bending.
This is a Kodiak 1/8" diameter, 3" long endmill, made in USA. This is a tradeoff issue. The extra length means deeper reach, but also it can bend a little. This also makes it less likely to break when overloaded. I am now using my Taiwanese Speed Tiger end mills which are 1" long. They seem to flex less. Again, this is a question that requires a level of knowledge by the machinist that I just starting to reach. Do you need the deeper reach? If so, slower feed rates to reduce flex, or a shorter endmill.
The flex doubtless increases vibration, making the endmill holder set screws less effective. I need to put a flat on the SpeedTiger endmill shank too.
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