The $9 sanding block that wrecked my G-code routine

Ngl, I spent 6 months dialing in feeds and speeds on a stubborn aluminum job, tweaking cutter paths like it was the secret sauce. Then one slow Friday I swapped my worn out carbide end mill for a cheap HSS one from the drawer just to test something. The finish was smoother and the cycle time dropped by 11 minutes on a 40 part run. Took me way too long to realize the tool geometry mattered more than any code tweak I was obsessing over. Now I check the actual cutter specs before I touch the post processor. Has anyone else chased the program when the real fix was just grabbing a different bit?

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