Square Box not Square

You may want to check if maybe you don’t have too much tool deflection ? this can show up as slightly larger/smaller pieces than expected. I have covered it (not well enough) here, but first you could use @gmack calculator and figure out how much deflection you have for your setup/cutting parameters

Or if you don’t feel like learning about this worksheet just yet, just retry your cut with:

  • the endmill stickout reduced to a minimum
  • reduced depth per pass
  • or even better, a roughing pass and then a separate finishing pass
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