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Martin Dowing	04/12/2020 17:17:14
356 forum posts 8 photos	Posted by Phil P on 04/12/2020 16:06:52: Why not use a long series drill for most of the hole depth, then finish it with a D bit which can easily be made. Phil Chinese are selling 6 mm carbide mills with 150 mm long shank rated for 45HRc for 12 queeds including p&p so they are essentially given for free. Easy enough to order via Aliexpress. But you have to wait 2-3 weeks before one arrives.
Martin Dowing	10/12/2020 16:20:33
356 forum posts 8 photos	Hi, So I have done these counterbores for screws. 130 mm long 8mm diameter surface hardened bar was drilled & reamed to H7 tolerance, 6mm Chinese solid carbide mill was glued in with Loctite 638. Next day it was fitted in the collet and counterbore drilled directly in my part (45 HRC). There was already predrilled 4mm hole there and center was fould with aid of straight and ground 4mm bar in usual way. Mill was not tending to wander much so only slight taper resulted (6.2mm on the top and 6.1mm on the bottom of counterbore. But for this application it is OK.
old mart	10/12/2020 19:48:33
4655 forum posts 304 photos	For tight tolerances, it is useful to know that a slot drill, or endmill will not produce a perfectly square counterbore. This is because the end cutting edges are not square to the tools axis. The counterbore will be slightly deeper at the outer diameter than the inner. This probably does not matter if a screw is to be fitted in the counterbore.

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