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I have a tiny bit to add here. One, I've used a 1/4" ball end mill to cut grooves for ladder pattern Damascus with some success. Two, I typically do my guards one at a time and use a 1/2" or 3/4" mill and come in from the side. Haven't tried to do a big bar like you've described. You'd have to go ball end for that.
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The algorithm of ball-end mill gashing can be verified by the 3D simulation system. Result shows that the algorithm presented in this paper provides a practical and efficient method for the manufacture of a ball-end mill gashing. Keywords: CNC grinding, ball-end mill, gash out, grinding wheel. 1. INTRODUCTION
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