Cutting a slot in copper

[jheinen]

Push cutter fully in so cutting at shortest bit length.

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Do you mean push it fully up into the quill so as to leave as little as possible out?

 

[GL]

Hate to answer for tq60, but maybe to clarify, insertion depth should be no further than the shank depth, even if you can poke it deeper in the collet. My experience with small diameter end mills is they break off at the transition from the, say 1/4" shank to the 1/8" cutter about where the cutter flutes start. Then you turn it over, since small mills are often double ended (which reduces the cursing volume by about half, the first time). Then you grind it into some other cutter at a later date and compliment your cleverness/thriftiness. You are looking to get the tool as rigid as you can in the collet, but in this case the most flex you get is in the cutter - too much and it fatigues, in the bend the paper clip too many times kind of way. You indicated before that the Gwizard tool said you would have a bunch of deflection, breaking cutters is the result of leaning on it too hard.