Ball milling 45* bevel error.

[dkp_design]

So. I'm trying to make a bevel plate. .356" thick. 2.250 wide at the widest. A 45* bevel on both sides. Now I make the plate great. Finish is awesome and true. But my bevel width is .050" too small. Drawing in fusion is right. Roughing passes with 1/2" end mill are right. The ball is cutting .025" more off each side. It is a 1/8" Helical 17030 2flt ball mill. Milling in X axis. Y axis only has .001" backlash. My math, even though it's a ball mill. To be .025" too narrow. It has to be .025" too deep for a 45* angle. Simple geometry. That should hold true for the ball mill cutting edge right? Or does ball mills do something different on the radius? Drawn in fusion 360. I know I can re cad part .050 wider. But I want to find what is causing this error. All my end mill made parts come into my acceptable tolerances. But this piece is a part for a TAIG dovetail headstock mount and needs to be proper width.


Any help be awesome. .025 per side is a rediculous amount of error. Even for a bad backlash machine. And Helical tooling is usually some good stuff. It appears a smooth radius under my loupe

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[dkp_design]

Ugh. Disregard that whole post and question. I am such a dummy. I revised my sketch dimensions the night before. And forgot to redo the cad and upload to mill. Was running wrong g code. Ugh. Came to me at 2am.

[Superman]

Ugh. Came to me at 2am.

Nightmares.... everyone has 'em, one time or another.