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I generally try and avoid inserting any thing manually after posting. Should you need to re-post for any reason and forget that crucial line you're dead. I faced the same situation with an undercut...

algorithms can disappoint...can you upload the MCX file?

Ken

Superman"s methods are what you're stuck with in X5, but should you ever get your hands on X6 or later, there's a much easier way using the stock model/opti-rest combination. I finally got it...

Ken

The stock you define at the outset under Machine Group-1/Properties-3-AXIS VMC has no effect on toolpaths (that I can see). I think the answer you're looking for is in the mill toolpath "Stock...

Hey Ken

I opened your file in X7 to see what kind of functionality MC has these days. There is a "toolpath" called "stock model" where you can select your stock solid and reference selected...

I should have included a caveat that it was programmed at lunch in haste and that I haven't been on MC in years. Jay caught one mistake, I'm sure there were more. Hope I didn't screw you up.

As...

You're right, good catch. Shows what haste will get you.

I don't have MC available right now but I believe I pre-drilled for Dynamic milling routine.

Something to get you started...

Can you mill the slot 1/2 way from each side? Drill some entry holes, dynamic mill pocket, maybe ramp mill deep portion of slot.

They keep saying its on "critical maintenance" so I put off learning it. It comes in handy though in certain situations where CP bombs out. The problem is, when it doesn't work there's not much...

You're right about the material at the bottom

By the way, do you know how to get sequential mill to output motion similar to contour profile. By which I mean keep the cutter tangent to drive while...

two operations, one flanks the chamfer, the other drives normal to cylinder, both 4 axis. To confirm look at IJKs

Head-to-head: Mastercam Dynamic Milling vs. Traditional Toolpaths | Macdac Engineering