Hi Joe - The ball mill will not give you a good finish as I imagine you are using the "end" which has a very small non cutting surface in the middle. Either use a straight mill tool and turn the blade up as Gerry suggests (to cut on the side) or use a small end mill for your roughing (cut on the end). This will give you a good cut and finish.. Then I imagine you draw file to finish? Peter
To discuss - The centreline of a blade is "straight" in its plane so this means if the blade is supported at its intended half angle the cut surface is planar?
(No, after thought) So a very sharp blade is 15degs so support at 7.5degs or a typical sharp blade is 20degs so support at 10degs. Is this what you are doing? As the blade edge is curved I think the only way to do it is to hold it at the half angle as then the cut angle remains the same to the blade irrespective of the shape of the blade & you use the side of a milling tool. Or you can incrementally machine it if the blade is vertical but then it will have steps in it to be removed. Does this make sense? Are you trying to achieve a "hollow" bevel?
Thought this through and its tricky. If you get a 10deg draft cutter you can cut it on the tool side and have the knife vertical. Then the tool path has to follow the "vertical" blade shape or belly. Or you can tilt the machine head but does the Tormach do this? Peter
https://conicalendmills.com/cutting-...pered-end-mill