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Cone angle


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I've found circle paths perpendicular to the cone axis on small cones tend to give bogus results. If you do linear paths parallel to the cone axis you should get results that are more believable. If you didn't need the cone angle, and just needed the feature for say surface profile, I'd recommend using free form surface on small sections of cones. Calypso struggles with small cones or sections of conical features it seems, and free form surface has definitely given me much more plausible results in those circumstances.
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The method he mostly uses for radii less than 180 degrees.

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Also don't forget to turn on Filtering.
Your form value, which is 0.09 mm, is also high. If the points are not good, your production section may be operating at high speed or with a blunt tool.
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