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Hot take: my old lead hand in Akron told me to always leave 0.01 on the finish pass, and it still bugs me
Back in my first real job around 2009, this old lead hand named Ray told me to always leave a hair of stock for the finish pass, no matter how good the rougher looked. I ignored him for about two weeks because I thought I knew better and could save a pass. Ended up scrapping 4 shafts out of 4340 in one afternoon because my finish cut grabbed and chattered on a part that was already at size. Ray never said a word, just walked over and held up one of the scrap parts. Now I leave 0.01 to 0.015 depending on the material and I cut my scrap rate way down. Curious what stock allowance you all run on your finish passes, and does it change much between aluminum and steel?
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