A 2 mm internal fillet is called on a floor-to-wall. The rest path keeps trying to drive a 6 mm ball into it and leaves a cusp the drawing will not accept. The programmer says the ball is what we have.
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A 6 mm ball cannot cut a 2 mm fillet. Rest machining will not invent a smaller tool. Either model a larger fillet the buyer accepts, or put a 3 mm or smaller tool in the crib and in the program.
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If the fillet is a tool-radius leftover and the print does not require it, say so and stop forcing the ball into the corner. The cusp you leave on purpose is fine. The gouge from trying is not.
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Write the minimum internal radius on the quote from the tool you will actually run. CAM does not negotiate the print.
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