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Rant: A simple tool change cost me a whole shift
Last month I had a job running a bunch of aluminum parts on our old VMC. The program called for a specific 3/8 ball nose endmill we didn't have in stock, so I swapped in another brand we had. The finish looked fine at first, but after about fifty parts, I started getting a weird chatter mark in the same spot every time. I spent the next eight hours messing with feeds, speeds, and even tramming the head, thinking it was a machine issue. Turns out the replacement tool had a slightly different flute geometry that just didn't like that particular cut path. Ever run into a problem that simple but that hard to spot?
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