Ted, I fully relate to your story. I ended up machining my own parts and soon cutters, from just the type of experiences you mention. Many metal heads tend to think woodwork is "easy" or "does not really need to be *that* precise" until they try it at a professional level to specified standards. Don't even think about AWI specs.
On the solid cutters, my comments about face sharpening were part of my musings to try to understand your objectives. In the recent "old days" (40 yrs? and back) before flat insert tooling, solid body cutters were sometimes made as I described, for long production runs. They tend to be a very expensive way to make a cutter.
Coincident, and still made, some cutter bodies employ replaceabe/re-settable lug bits, where only the bits are profile ground and set to be face sharpened. These used to be somewhat common on tenoners, and things like flooring mills where thousands of miles of moulding (T & G, e.g.) were run, but all had to match up more or less precisely. Again these tend to be quite expensive tooling solutions, but on a cost of cuts per mile, very cheap.
Getting back to your question; no, a standard grind with hook and clearance to suit, will not automatically give the benefits of a developed cam ground tooth form. But it will be a heck of a lot cheaper. Then when it is resharpened, all the surfaces will be touched up, but lightly. Probably more economical, given the volume of cutting for your application. I was just exploring the "why" question.
Have you made similar successful cuts with that cutter, or with any other tooling? What specifically was unsatisfactory?
How do you support the end of the part, where the cutter runs out, or is that proprietary info
? I'm thinking the part must be over long, profiled in to depth and length, but a little left for handwork, and then cut off later? Or do you use a full round shop made steady rest with a cutout on the cut side to let it pass?
(I'm just all full of surmisals, hunh?
)
Can you make or sharpen tooling?
As a point of curiosity, do you bandsaw the mating form on the cue butt as was tradtional? or is there another way to do it these days?
smt