Method of cutting a hole in a composite material workpiece

A method for cutting a hole of a hole size in a composite material workpiece, the method comprising the steps of:

• providing the composite material workpiece;
• selecting a milling cutter having an effective cutter size less than the hole size;
• mounting the composite material workpiece in operable relation to the milling cutter wherein the step of mounting includes the steps of
• providing a backing fixture, and
• affixing the composite material workpiece to the backing fixture with an adhesive material;
• rotating the milling cutter about an axis of rotation;
• advancing the milling cutter longitudinally into the composite material workpiece parallel to the axis of rotation at a rate of longitudinal advance, while laterally moving the milling cutter perpendicular to the axis of rotation to interpolate the hole, the step of advancing including the step of controlling the rate of longitudinal advance such that the hole has a substantially constant depth over its entire area as it is cut;
• and, after the hole is completed,
• removing the composite material workpiece from the backing fixture.