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Originally Posted by sanddrag
EDIT: If you use this method to make a keyway, make sure you are using a center cutting endmill.
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Something I've been known to try is to give the mill table a little horizontal motion as the tip of the end mill is being very lightly plunged into contact with the workpiece (it helps to mill a small flat on the top of the piece first, to avoid trying to do this on the rounded surface). Where very fine precision isn't necessary, this can produce acceptable results. I've done it with 1/8" and 9/64" keyways, with three-fluted non-centre-cutting endmills, and it works well enough. Workpiece materials were 416 stainless, if I remember correctly.
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Edit: For a non-centre-cutting endmill like the one that I described above.) Work slowly, and remember to never try to plunge the end mill straight down, even after the cut starts. Let it cut at an angle.