Deep profile milling can present some serious chatter problems especially on lighter duty machines. One trick that I have found when all else fails, is to spin down about .020 - .030 on the diameter of the endmill leaving only enough cutting edge length to allow optimal milling performance. This will get the cutting edges of the endmill away from material that has already been cut and eliminate any chatter patterns generated by cutting edges that are in contact with the material above the cut. This works for roughing as well as finishing endmills and it looks like this. The photo shows a 1" roughing endmill that has been hand ground (way more than .020 - .030 but it works just fine).

Click back arrow on your tool bar to return to Helpful Hints page.