I ran into the *EXACT* problem on a third-hand, worn out CNC machine once years ago, and finally figured it out. After checking everything everybody is talking about above, I noticed that the end mill bit wobbled just a tiny bit when I started up the spindle. There was just a hint of slop in the tool collet, therefore the tool bit wasn't perfectly perpendicular in the machine, therefore the tool wobbled.
Obviously, if your tool wobbles at all, the cut will be bigger than the actual tool size. It's not necessarily the end of the world as the tool is moving down the edge of a cut because the tool is sort of held in place by the material (Yes, there will be more room between the pocket and the inlay than you programmed, but that's a different topic). But, when it gets to the corner, the X and Y axes slow way down to allow for the turn. When it slows down, the tool is allowed to fully wobble and dig in at the corners.
I bought a new collet, and everything was perfect! Hopefully you just have a loose collet, too.
p.s. As far as BobCad goes, I fully vote for v24. I went from v21 to v24, and *MAN* what a difference. I've never used v23, so I don't know how many significant changes they made between v23 and v24.
Obviously, if your tool wobbles at all, the cut will be bigger than the actual tool size. It's not necessarily the end of the world as the tool is moving down the edge of a cut because the tool is sort of held in place by the material (Yes, there will be more room between the pocket and the inlay than you programmed, but that's a different topic). But, when it gets to the corner, the X and Y axes slow way down to allow for the turn. When it slows down, the tool is allowed to fully wobble and dig in at the corners.
I bought a new collet, and everything was perfect! Hopefully you just have a loose collet, too.
p.s. As far as BobCad goes, I fully vote for v24. I went from v21 to v24, and *MAN* what a difference. I've never used v23, so I don't know how many significant changes they made between v23 and v24.
