Decorative Architectural Column, Pilaster, and Corner

[rgreever]

I am currently working on a project where I need to make this (pilaster example):
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The material is vertical grain douglas fir and the overall dimensions of each piece is 8' 5" by 11" wide. There will be a few single-sided pilasters, corners, and columns that need to be created. Each piece will be back-mitered and fit together on-site made to look like solid wood. (Made to fit around steel structural beams, where applicable.)

I have set up the job such that first I cut out the 'VEEs' using a 110-deg v-bit. Then, I cut out the 3D 'swoops' using a roughing pass with a 1/2" straight end mill, rastering in the Y-axis. Next, I plan on using a 1/2" ball end mill, rastering in the X-axis to do the final 3D detailed pass for the 'swoop'.

Attached are a few pics of the Vees and the rough cut swoops:
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Before I go any farther, I'd like to know if there's an easier/better way for me to accomplish this. Better technique? Anything else to consider? Etc? What would you do, if you were in my shoes?

[rgreever]

Here's a pic of the finishing pass:
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Came out pretty sweet using a 1/2" ball-nose rastering along the x-axis.

When I'm using the 110 deg V-bit to cut out the horizontal v channels, I am getting pretty bad tear out on one side. This vertical grain douglas fir is pretty bad for that, but I was able to control the tear out by fastening a sacrificial board to the outside edge. Seems to keep the tear out to a minimum.

[rgreever]

Can anyone help diagnose this issue?

Here are a couple pictures of the detailed inlay:
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These are 1/2" diameter circles that I'm pocketing with an 1/8" end mill. They are not coming out round, more like slightly ovalized in the x-axis. I have a feeling there's a minute bit of play in my machine somewhere. I thought I adjusted the v-roller bearings on the YZ car correctly, so I don't think it's that, although I'm not sure.

What else can I check? I was cutting at 2 in/sec, so I may slow it down to a creep when doing the circles, to see if that will help.
Edit: Going to check my x motor pinions...

[chiloquinruss]

Thinking out loud here, but looks like you might be getting a bit of flex in that 1/8 inch bit. Is there a pass somewhere else on the design where you use a bigget bit that you might hog out the holes with? Then you could come back with the 1/8th inch for the final pass. I don't think it's your machine as all of the cuts would be off in the same direction not just the holes. My 2 cents, spend wisely! LOL Russ

[rgreever]

I had a little play in the x motor control box side, and the pinion was, in fact, a little loose. I tightened her up, and we'll see what happens on the next board. I'll probably slow it down to 1"/sec as well, to see if that makes any difference. Thanks for your input, Russ

[gc3]

I would...ck the nodes on the vectors, use offset for the pocket and cut no more than 2mm per pass @13k with a straight flute bit

[MogulTx]

I like the work you are doing! Good job. You'll figure out the detail... and it will be great!

[jerry_stanek]

I had one of my x motors not plugged in and got the same kind of cuts