Hello all,

Suppose one needs to remove 1/2 inch of acrylic from a 2x1 inch (in
cross section) block. The goal is to end up with roughly the following:

+----+
| |
| |
| +-----------+
| |
| |
+----------------+

I find that with deep cuts, there is some risk of breaking off material
as the endmill reaches the end of the part. Slowing the feed rate near
the end helps, but does not eliminate it. Lots of light fast passes
seems to work.

What _should_ I be doing? Out of curiosity, would it change if the
material were Aluminum?

The part is a little long to stand on end in my bandsaw. With a
suitable jig, that might work. But if it must be roughed on a mill,
what is best approach?

Bill