Taper problem

[machinedudester]

I am machining a .250" thick wall that varies in height for 1.2" to 2.5" and has a 87 degree taper at the bottom. The material is 2024 T4 and I am holding from bottom with dove tails. I have tried several different approaches and every time the top ends up .010"-.030" thinner than the bottom at the highest point. I am currently using a rough pocket with a 3/4" flat end mill then a 1/2" ball end mill(because there is a 87 degree corner with a .188 radius at the bottom) 3D contour to finish it. I come back with a 3/8" ball end to finish the radius on the bottom. Any suggestions would be greatly appreciated.

[Rick Henrickson 65]

after rough leave .15 a side the finish the wall stepping down in an uneven pattern. like .25 deep on one side then .5 on the other and keep the overlap all the way down to support the opposite sides cut

[crazy^millman]

Got a sample part? Are you letting the material normalize between roughing and finishing? Do you have the correct chip load and speeds and feeds for the material? Are you using positive style cutting tools? Are you roughing it wit ha rougher putting stress into the part? A lot of questions I can ask. I guess it would be good to know exactly what you have tried.

 

Welcome to the forum.

 

HTH

[Rick Henrickson 65]

good point Ron guess I just thought they would be using the right tooling