Took me two days to realize my offsets were wrong on a simple part run

I was running a batch of 50 aluminum brackets last Tuesday and every single one was coming out 0.015" oversized. Chased tool wear, machine leveling, even blamed the coolant. Finally noticed my tool setter had a tiny chip on the probe tip that threw everything off. Has anyone else spent way too long on a stupid simple fix like that?

2 comments

2 Comments

the_james21h ago

Every single one was coming out 0.015" oversized" - I spent THREE hours once trying to figure out why my finish passes looked like garbage on a mold base before I realized I had my chamfer tool loaded in the wrong pocket.

margaretf4017h ago

@the_james I feel you on that, but 0.015 oversized sounds more like a tool offset issue than a wrong pocket thing. A chamfer tool in the wrong spot usually just gives you a bad finish, not a size bump that consistent. Still a pain to track down either way though.