Seems to work in simulation, all the steps now make sense and total time in Mach3 was about 6m plus a tool change, not bad I think. :)

How do you figure plunge rate? Same as cut, half as much etc??

Its fascinating seeing the difference in manual machining and CNC, a real eye opener and I haven't even got to cutting a part yet;)

I settled on 0.6mm DOC for the 2mm tool when pocketing the fine parts and 2mm DOC on the 5mm tool for hogging out the holes and roughing outside, then the final pass on the 2mm tool at 4.9mm DOC.

I have high-helix carbide tools listed as suitable for aluminium etc.

Hopefully good to go as soon as she's finished :)