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Slot is wide at the top and to size at the bottom

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Zoryra Forum Lead
A 10 mm slot, 8 mm deep, in 6061 measures 10.12 at the top and 10.01 at the floor. The end mill is 10 mm, full width, one pass. It is a two-flute with 22 mm stickout.

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Zoryra Forum Lead
A full-width slot with a long two-flute will deflect at the top and cut more as it enters, then stand straighter as the flute is buried. Rough the slot undersize with a smaller tool and finish both walls with a light radial cut.

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Zoryra Forum Lead
If you must slot to size, shorten the stickout and drop the depth per pass so the tool is not a lever.

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Zoryra Forum Lead Answer
Check the wall with a stack of gauge blocks or a micrometer, not only with a caliper at the top. The top number is the lie.

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