Still learning this 5-axis malarky at work... This week I learned the hard way although not totally my wrong doing..
1 Roughing tool Skims the platforms of a rather pricey bladed disk (Blisk)
Said tool has a large standout from the holder (70mm) to avoid collision with the blades, The roughing tools are sent for re-grind after every use and the minimum length is (80mm) so that means 10mm clamping material on the holder.. I was in autopilot as I set the tool and this never occurred to me.. I think you can see where this is going...
Instead of the tool snapping due to the cutting force the crappy holders we (used to) use allowed the tool to flex and move at its own accord thus cutting all of the 38 platforms at different depths...

Had to adjust the finishing tools -.028" to clean them up so this one is going to be a very expensive bonnet ornament for my car apparently..
But at least now the minimum length for the regrinds are now 105mm and we now use hydraulic holders instead for a little bit more stability...
Below a picture of the lovely undercuts on the 'finished' platform
