Sharp inside corners cannot be achieved with traditional milling and require nontraditional machining processes such as electrical discharge machining (EDM).
Recommendations:
-
When designing a three-edge inside corner, one of the inside edges must have the radius of the end mill. A generous corner radius can accommodate a larger milling cutter, which is preferred. Use the radii recommended by fabrication personnel to ensure that tools are easily obtained and maintained.
- If sharp corners cannot be avoided, drill a separate relief hole to allow a male ninety-degree corner to fit. Drill the hole first because drills cannot withstand significant side loading.
