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happens to everyone at one time or another. Clean out the taper in the spindle and clean the taper on the holder. then spray some of that holder lube on it. I can't remember what is in it but your tool rep should be able to handle this.
if you are using solids you may be able to use the 2d HST tool path called 'core mill'. requires two chains. basically the stock boundary and the solid edge chain. there is a video showing it somewhere in the what's new documentation in X3. this is not multiax though. I wonder if you could then utilize the 3 to 5 axis convert?
HTH
line tangent is a great tool. hardest part in conveying this method is convincing someone not to pick a point but the arc instead. ROLL your mouse around and voila, see your line stretch around your arc. X3? Icing on the cake.
if posting operations that are organized in "their own groups" you can select the group and right click/change nc file name. should post out the way you want.
for D2 especially I would go with a high end grade of iscar(inserted cutter). runs like nitro and you iscar rep should know how to apply optimum sp&fd. I personally shocked at how fast I was able to get away with running D2. I asked my rep, "are you sure?", to which he replied "cut it!". I never looked back.
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