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We do a LOT of plunge cutting, nearly every part we make has at least a few plunge cuts. I've been using Ingersoll DHU series insert mills for 1" and up (going about 17-18 IPM in 495B with with about .1XD WOC) and used flat bottom drills for 1/2"-3/4" (similar MMR). They do alright for our purposes, but there's always room for improvement. Any suggestions?
I've already tried using HSM practices just rotating the part off in B axis and cutting with a BNEM, but plunge cutting is faster given that there's no need for A axis indexes, our machines are S L O W 3+2 axis HMCs).
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