Every toolpath takes too much stock off the walls. The roughing only takes about 1 thou too much as I'm trying to leave 3 thou for my finishing passes. Not a big deal, but my finishing passes end up taking off up to .0062" too much. Will my machine actually take too much off or is this just a simulation glitch? I get the same result even with .00001" tolerance +.00002" smoothing.
Attached is my Fusion f3d file.
When you wrap tool path around diameter, tool is aimed at model center point, you need to use pocket bottom as wrap diameter then use ball end mill to detail side walls.
Right now tool is lined up with outside edge of pocket and over cutting bottom edge, take a look at sketch.
Ignore my previous post because I overlooked the fact that it is possible to get things done to near perfection.
Check out last contour in attached file. Basically you use bottom of pockets as wrap diameter to get floor done without over cutting redial walls, this leaves stock on upper edge which starts at zero on lower edge and grows to some volume on upper edge.
To get the remaining stock you must use contour and tool orientation, I used vertical edge of corner fillet, using small lead in and lead out value you can blend contour with corner fillets to achieve near perfect blend.
I have done one side of one pocket just to show result, you make it "perfect" on rest of the part.
Included fillet on top edge of pocket, tool left small intrusion into diameter so leaving .001 axial stock makes it go away, as "perfect" as it gets and my work is done here.
