CMStewart

3 hours ago, Prostheta said:

No worries. Start a thread documenting your process, @ me in and start a discussion. It both helps others understand the process and also provides an opportunity for others to weigh in and help you through to the result you need.

Will do. I just have one last quick question. Harvey tool has a lot of options for long flute micro end mills, but they all seem to be 3-flute. Is there a downside to 3 flutes vs 2 flutes?

11 hours ago, Prostheta said:

Zombie thread! I would say that it depends on your CNC. If your spindle has significant runout or there is flex in the cutter, that 0,027" cutter might end up cutting a much wider slot than you want. A hair over the tang width is fine, so 0,027" would be correct in theory. In reality, I would consider having one or two finer cutters in case your spindle does want to cut wider than the endmill actually is. You'll probably find that if this is the case, you'll have a larger incidence of breakage from asymmetrical load.

Do tests and establish what you're able to achieve, and that should help you develop a working strategy.

That sounds like some very reasonable tips. I really appreciate it!!

On 7/26/2016 at 3:21 PM, DC Ross said:

Sorry I can't help with your MeshCAM issues, but I'd be surprised if there's no "Groove" or "Slot" operation that allows you to choose a 3D path for it to follow...

I've modified my approach somewhat since that post from Dec. 2014. I now use a 2-flute .027" diameter (.025" for non-ebony) carbide bit, at 20,000 rpm, going 30IPM, and cutting .01" deep passes, and it poses no problems at all. 

Hey DC. I am looking to use the Jescar 47095 fretwire (0.021" tang with 0.035" barbs), and was wondering which bits you would recommend for that size? I see you use 0.027", but I wasn't clear what size fretwire you use. And what manufacturer do you recommend for the bits? I appreciate the help a ton!

- Colby