

Problems with machining delrin/acetal parts
I work for a company where we make small production runs but our main is prototype work...
For a couple of years, lets say once per year we get to make 1500-2000 small plastic wedges that are milled from 140x400x30mm delrin (one part is aprox 6x20x28)
Basicly parts are nested in such way that we run endmill between them to get 2machined parts....
Delrin plate is clamped on vaccum table and 4 screws just in case(previusly we had problems with plates bowing during machining)
problem is chatter, currently we use 4mm 2flute endmill for aluminium with 20mm flute lenght and 30mm reduced shank in shrink fit holder.... runtime is aprox. 3h per plate
I understand that there is massive tool stickout but any bigger endmil and there is more waste than parts.
what endmill would be better choice?
downcut? we take 1mm per pass with air blast so chip packing shuldnt be a problem
4mm with as short as possible flute and then 4mm shank?
or is better to change strategy and add finishing passes?
2-3rough passes then one finish? and repeat?