Well, that's embarrassing, I changed the insert for a new one and the
part came out fine. I guess the lesson here is that you can get away
with allot more when machining aluminum. I wonder if making a Delrin
part could be used as a means for optimizing machining aluminum. BTW,
the tool I am using looks just like this:

http://littlemachineshop.com/products/product_view.php?ProductID=1669

with an included circle of .250 and points only on the top. This one
looks it might be better:

http://www.pgstools.com/servlet/the-16356/TCGT-21.52-dsh-AK-Insert-for/Detail

... 

I think this is the winner:

http://www1.mscdirect.com/CGI/NNSRIT?PMPXNO=8095371&PMT4NO=45689204

Darn, not in stock.
-- 
Kirk Wallace (California, USA
http://www.wallacecompany.com/machine_shop/ 
Hardinge HNC/EMC CNC lathe,
Bridgeport mill conversion, doing XY now,
Zubal lathe conversion pending
Craftsman AA 109 restoration
Shizuoka ST-N/EMC CNC)


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