Thanks for the thoughts guys. I don't think there is any issue with the surfaces as they were sketched and extruded in SolidWorks, not imported (assuming that the translations between programs are working correctly).
Will try simulating the program to see if it runs OK (that should help identify if curves are being poorly approximated).
Will also check for backlash under load. The X and Y gibs are nice and snug. Haven't checked the Z for a while...
The pockets are all at least 2.1mm wide at the narrowest point so I would expect that a 2mm cutter is fine for the geometry. I set the feed rate myself and the machine ran fine with no visible stress/overload.
I'll post back as the investigations continue...
Last edited by Clot; 09-28-2008 at 04:31 PM.
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