by l0ckcr4ck3r » 2 May 2015 11:09
I can see what you mean about the keys not looking correct, they don't have the "factory-cut" look to them with that additional radius; I suspect it was a deliberate design change to make the cutter stronger.
When you chip a milling cutter machining, 9 times outta 10 its the corner of the end mill you loose. Its basically because thats the weakest point and you have been trying to feed the material too fast and talking too big of a "bite"
To avoid this, you can use a radius or "Bull nosed" end mill which is a much stronger design. A manual duplicator requires the operator to feed the key into the cutter at a reasonable rate and control the "chip load" or size of the "bite" and thats why they probably changed the design.
maybe if you looked for a similar cutter that is designed for a cut-to-code or automatic cutter, they would have a sharper/smaller radius corner?
