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Anonymous
in reply to: mathew.hutton

One possible solution would be to make form tool that confirms to groove profile, start cut in X axis at point where groove is full width, then drive C and Z axis to the other end using pitch as driving distance of Z axis for every C axis revolution, stopping short of entering narrow groove area.

This would have to be repeated in several depths to avoid overloading and breaking tool, (material type !!!???).

Perhaps roughing with standard ball end mill then follow with form tool, you would have to create drive curve along middle of grooves with specific entry and exit points to avoid narrow part of the grooves.

 

Without releasing part from chuck, detail front and back narrow areas of the grooves using small diameter ball end mill and machine flat detail, bore ID, broach key way and groove ID.

If you do consider form tool, same thing can be done on mill faster.