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? Why not use the program WPC? And try leaving out the g43. I have my machine parameters set for the control to read the tool data from the tool file. I forget which parameter to set, but it will be...

Using a downward path of 5 degrees would be figured by:
P=0.137*(D-d) where D is the diameter of the hole and d is the diameter of the end mill. If this is too aggressive then use a smaller...

I once had a similar mishap with a Phillips driver. My scar is on my left thumb, but is on the bottom ... the driver went thru the thumb. Damn! 50 years ago and I still remember the pain.

The radius has nothing to do with flatness. The spec means just what it says, nothing about radii. The best you can do is measure over a 4' length and expect </= 0.008" total deviation.

Helical bore the holes with a 3mm rad 18 mm bull nose mill. Relieve the upper outside cutting teeth leaving the bottom 3/16 or so of cutting teeth alone. 1500 rpm, spiral down at no more that 0.04"...

You give s/f details for drilling but no info at all for the s/f of the tap.

Lose the spray mist. Use a brush and apply high sulfur cutting oil (available at Lowe's, Home Depot, etc.) to the tap....

Never heard of them, but they look pretty good. My question would be regarding how to REMOVE the collet from the holder. Perhaps someone familiar with these can answer both our concerns.

What I.D. do you need? Your terminology indicates you are looking for 5/8 O.D. die buttons.

" ... The books said clearance constant for aluminum over 1/8" is 8, so .375 divided by 8 is about 48 thousandths, divide that by two so my clearance is 24 thousandths per side...

Why divide by...

McMaster offers 1" dia x 36" long inco 625 for 365.71 ... just sayin'

Try honing I.D. first, then grind O.D., on freshly ground arbor if you can.
I have ground O.D.'s with al-oxide wheels. Since you are only removing a tenth or two per side you should have no trouble.

Not familiar with that mill, but an 8 or 10 mm pilot drill should help drill on size and lower power requirements.

As Litlerob1 says, increase your finish pass material. I have found leaving 0.05 (0.025 per side) for finish works well with C1018

If someone else has this problem, it can be machined with the "Spiral" machining option. Have to write a manual program to use it as it is an EIA option, but it does work just fine.

I've been running Mazak even longer than Philabuster and have no clue what 'negative tool pressure' is . . . don't touch the part?

360 degrees divided by number of teeth yields degrees per tooth. Divide this by two to get degrees per 1/2 tooth. This is the angle to rotate one keyway relative to the other.

Sounds like a dull tool putting excess pressure on the part.

Sunnen has always been very helpful when you call them with questions. Just give them a call.

What Gobo said ... BUT most work I see can be done easily with Mazatrol.

Set spindle speed to 100 and see if it smooths out.

Try one of those 'sheet metal' drills with stepped diameters. For 3/16" should work fine.

Both sizes/pitches are standard MSC taps, spiral pointed, and 70 mm OAL. Grind your own shank relief and tap without pecking.

Lathe will be fine. BORE the tube I.D. to the max minor thread diameter (bore to get the I.D. concentric!)
MSC lists over 200 spiral point taps ... you should not select the cheapest one!

Not a parameter; try M code 19

A 1/4" capacity shear would likely require a hefty motor. What does your motor tag list as full load amps? (Often listed as FLA)

What is the breaker protecting? Phase converter?