For the prototyping of a new product, due to structural constraints, a T-slot cutter was required to machine the internal bottom surface. The design specified a transition radius of R1.5 between the bottom and sidewalls. However, using a bull-nose cutter was not feasible due to interference issues. Customizing a non-standard T-slot cutter would have been too expensive and time-consuming.
Instead, we utilized an existing T-slot cutter and created an R1.5 prototype. After confirming its compliance through projection inspection, we proceeded to manually grind the bottom tooth profile of the T-slot cutter. After four rounds of grinding and test cuts, the projection inspection confirmed that the part met all requirements, successfully resolving the issue.
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