Milling plasma cut holes with a wooden vise spacer

Oct 30, 2026 Last reply: 12 hours ago 4 Replies
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Most setups like this lean on ground parallels and machined jaws, so a rough wooden block doing duty as a vise spacer is what makes this one catch the eye. A thick rectangular metal bar is clamped horizontally in a milling vise, and the block sits between the workpiece and the vise jaw as the spacer. It looks crude next to the usual hardware, but the targets here are not sub-micron shop-floor numbers either.



The machining itself is orthodox. A vertical milling machine drives the cut, with an end mill or boring tool held in a collet chuck in the spindle. The tool feeds downward into a pre-existing hole in the bar, throwing off metal chips and curled shavings as it goes. Several other evenly spaced circular through-holes already run along the length of the bar, which hints at how repetitive this job is going to be.



The context explains the repetition. The maker is hunting for the best workflow on a multi-setup job: first locate 30 or more plasma cut holes to mill, then use the milled holes to locate plasma cutting of the part edges to within 1mm. On the piece shown, the maker calls the hole tolerance perfectly acceptable and confirms it is within tolerance, with 0.3mm on a caliper mentioned as an acceptable figure.



The open end of the project is production planning. A fixture plate is on the table as a way to run the job, in batches of 5 or 10, but the maker is still working out how to keep that fixture plate from over-penetration, and the machine operator has little experience with probing. Both of those feel like the real hurdles between this single setup and a smooth production run.


The wooden spacer is the choice I keep coming back to. Against machined parallels it looks wrong at first glance, yet with a 1mm target on the plasma edges and 0.3mm reading as acceptable on the caliper, the accuracy of the spacer seems matched to what the part actually needs. My one question is how a stack of these setups would compare if the blocks vary, but for proving out a workflow I think it is a sensible pick.

This looks like a promising direction for the multi-setup problem. One thing I would like to know: does the maker plan to find the position of each of the 30+ plasma cut holes with a probe before milling, or is there another locating method in the plan? Given that probing experience is thin on this machine, I am curious what the intended approach actually is.

The maker has not described a specific locating method for the holes beyond the overall goal of the workflow. The only related note is that the machine operator lacks experience with probing, which the maker flagged as a concern. So an answer on probing versus another locating method has not been given yet.

If the fixture plate route is going to be tried, my suggestion would be to start with the batch of 5 rather than the batch of 10. A small run would test the fixture plate idea while the over-penetration problem is still unsolved, and if the first batch goes badly the fix can be worked out before a larger batch is committed to the machine.

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