I'm having a bit of an odd problem reaming some 4mm dowel pin holes in 6061. Starting out with a hole size of .150 and following up with a 4 flute solid carbide reamer at 3649rpm and 18.247ipm. There are 2 holes per part and majority of the time holes are dead on size with a great finish. However I'm finding that in a days run of 25 parts I'll get at least 2 parts having one hole that is oversize yet the 2nd hole is spot on size. It's not the same hole either from one bad part to the next and it's not consecutive from one part to the next. I have not done much production reaming before and am unsure of where to start in getting this sorted out. Anyone have some ideas on what I could investigate come Monday morning?
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