Hi... I wish to cut a "square" hole in a sheet of 1/8" 6061, with the corners of the square hole having a radius as small as possible (ie. .015"); I don't want to resort to EDM/punching/broaching/hand-filing/crazy rhohedral bits etc.
My plan is to:
- rough the square using a .125"dia endmill, which'll give .062" corner radii.
- Then use a .031"dia endmill (or perhaps even smaller?) for finishing, which'll give .015" corner radii - which should be tight enough.
But I need a gcode generator to create the multiple light cuts (.002" each?) so the small endmill doesn't break. In another post someone called this "trichordial" cutting, but I can't find any such tool in Mach3. Can anyone steer me in the right direction?