3D SURFACING, YOUR BEST GUESS AT THIS PROB

[LouGold]

So, I have successfully surfaced this with a 1/16th ball mill a couple times. All the other times is comes out like this photo attached. Really fuzzy and raspy on the flats.

I am running it at MAX rpm for the mill (11,500. I know 20k or 30k would be better but aint got it.) and at about .0005 IPT chipload and .0035" stepover, attempted with both scallop and raster(parallel) toolpaths. Tried with both 2 and 4 flute endmills and only had success a couple times.

A few questions I have are, given the 3d shapes, how much should I leave for the ball? I've been trying .003 before the final pass but should I do more? .010 or .012? Im stumped... Tried everything.. Maybe more chipload?

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[awerby]

It looks like you've chipped the end of your ball endmill.

[routalot]

How far was he tool projecting from the collet?

[LouGold]

Well.. We're using a brand new ball mill every single time....

The tool is choked up super close to the collet and its using a REGO PG tool holder with almost zero runout

[Algirdas]

I would do an experiment.
Anyway it is long story, requires thorough investigation.
I would machine a piece of surface which goes ( always ? ) good, trying to destabilize the table with hand.
It would be easy indication if table is stable. The next - almost the same destabilization attempt - headstock.
It shows if headstock is stable.
And, of course, I would check static tool runout. Must be less than 1 micron.
The next - a bit bigger ball tool tip.
These experiments will provide many information for discussions.