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mattdlr89
in reply to: boyd.sofield

Your first toolpath in that file is leaving 0.5mm stock on everywhere. If you turn that off then you get a proper blend on the corner in the stock simulation with the second toolpath. I think you are correct in adding a -2.5mm offset to the contour. I have only used corner rad tools a few times and I've actually modelled the corner then selected the lower edge (same difference).

 

Also have you checked that your tool is properly defined. You have diameter and shaft diameter both set at 6mm. Diameter is the diameter of the very tip of the tool as shown in the tool graphic when you define it.