Wierd behavior - need help

[Old_Rustic]

I want to reinforce a furniture piece with a hardwood inlay.

I created a 1.5x3" rectangle with 0.125" radius corners in the modeling pane. In the Toolpath pane I then a) cut a 0.375" Pocket and b) an outside Profile using the same vector without "Allowances" in either case, The cutter was a 1/4" endmill. I expected the two to slip together, maybe requiring some sanding.

What I got was a pocket measuring 1.44 x 2.56". and an insert of 1.55 x 3.01". the depth was 0.375" in both cases.

Any ideas where to look for the problem?

Mike

[ohiolyons]

Did you measure the bit?

A 1/4" EM is rarely ever 0.25.

[Old_Rustic]

Yes, and again just now: 0.249" across cutting tips. Not nearly enough undersize to account for the hugh difference I get.

[MiloScott]

Might help to post the design file and gcode. Is this a new problem where the cut size isn't the design size?

[ohiolyons]

Is this a new issue?

Did you check your machine for loose fittings?

What version of the software?

[adze_cnc]

A question to ask: why are 3 of 4 dimensions out by 5 & 6 thousandths but one only 1 thou?

Climb-cut or conventional? Up-cut bit or down? Constant velocity or exact stop?