Getting a nice finish in pockets

[flannman]

If all the components are in aluminium you could mix up a strong solution of caustic soda and carefully fill the cavity and let it etch the surface for about twenty minutes or so. This will give a nice even matt finish although you have to careful not to get the solution on the top face as it will stain. You could use a syringe to fill the logo and then just wash it off with water when its done.

[tikka308]

flannnman - you've got my interest. I have no experience with caustic soda; any recommendations based on your experience? Does something like Dow's caustic soda work? (http://www.dow.com/causticsoda/index.htm)

[flannman]

Caustic soda is found in commercial drain cleaners and can be found in most DIY stores. I live in the uk and there are many brands available but I believe in the States a popular one is called "Lye". You will need to experiment with the strength although it should be quite strong as it wont take very long to etch then although you have to be careful not to leave it overnight as it will do some damage. I have done exactly what you are trying to do in the past and if you are careful you can get a really nice matt finish which when anodised the same colour as the rest of your machined component will give a very good transition effect that will make your logo stand out. Hope this helps and let me know how you get on.

[mc_n_g]

Looks like you are trying to push it too hard. There does not appear to be enough overlap onthe cuts. I would overlap the cuts by at least half. Rough out with a .125 or .093 mill first and only use the 1/32 for the final passes. Looks like you final passes on the outside were heavy and too fast.
Did you cut from outside to in or the opposite. Did you climb mill?

mc_n_g

[big_mak]

Try perhaps using a solid carbide endmill. They will be stiffer than HSS you should be able to rough and finish with the same tool. I don't know what machine you use but some of the little machines toolchanges can be a pita, and you want to do as much with one tool as you can.

[teamtexas]

I agree with MC, looks like the stepover for the end mill is set way too high. I would try about a third of the diameter. it will take more steps but is should smooth out alot.

Dan

[big_mak]

Personally for productivity sake, I wouldn't go any less than a 50% step over, unless of course you are try to maximize your DOC then you may go down to some thing like 10% but then you better be using a 1x Ø DOC!!!!!