Hi Rich,
Thanks for the "promotion", but I worked at MIT, didn't graduate from there. Alex is someone I know, I can't quite claim him as a friend, but an acquaintance. He is a friend of Josh's, the guy who owns the company you did the Somerville, MA training in some years ago.
That's just molded plastic, so likely not super-precise. I'd be tempted to scan it, then import the scan and fiddle with it in CAD to mock up the profile.
What's the part do? What sort of loads and speeds?
You should check into post-milling diamond burnishing. Single crystal ball tip, filtered coolant, and just rub that baby smooth...
https://www.google.com/search?client=firefox-b-1-d&q=diamond+burnishing
Think about dust collection and coolant/oil contamination if you have to keep the material clean. Some spindles spit a bit of oil out in normal use and that could be an issue in bonding cut shapes.
I agree, but it's already a lost cause with the buyer doing post-machining welding on this housing. It's now a matter of doing one's best, then if needed trying to bail the customer out after the fact with a sleeve and rebore.
Sucks, but the guy with the money is always right. Right?
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