Need Help! Error in Z level finish depth

I'm running into a major problem with final cut depth in both madCAM v4.3 (in Rhino 4/5) or the latest v5 beta in Rhino 5. The Render.jpg and Render Step.jpg images show this error where the Z level finish tool, a long 0.25" diameter ball mill does not reach the flats. I originally found this while using a 15 degree taper ball mill on the same model.

Profile.jpg shows all the toolpaths and the Z Finish Depth.jpg shows the toolpath above 0.125" (tool radius). Grid spacing is 0.125". I've attached the sample 3dm (from Rhino 5).

The Roughing toolpath also shows a problem (0.25" diameter flat, and stock to leave set to 0) as it does not reach the flat on the lower right side.

I've experimented with Z finish Step Down /Angle Limit / Link Method / Toolpath Corners, Region Curves to bound the Z finish, Pencil Tracing and Re-Machining, bit diameter 0.001" smaller, model with no corner radii, etc. with no change. I've even tested the model in an older version of RhinoCAM - is OK.

Any thoughts as to how to solve this depth error?

Thanks, Ed

Attached Images

• Profile.jpg‎ (44.9 KB)
• Render.jpg‎ (22.3 KB)
• Z finish depth.jpg‎ (18.9 KB)
• Render step.jpg‎ (45.2 KB)

Attached Files

• CNCz sample.zip‎ (288.7 KB)