I did a test pattern of some 5/8 holes to find out what will give me the right clearance in the finished hole.
.66 dia and 15ipm
Test file was used to test and tune. Final product file, test cut, different size. I confirmed that the hole size is the same, and same cut speed.
Correct size
Wrong size.
What am I missing?
I am not that good understanding g-code but it looks like there is a difference in some speed:
Or are those the rapid movements? I see that both have F15 on the second line.
That might be actual program speed, but the cut speed (According to Fire Control) was the 15+/- ipm while cutting.
I cut one file, loaded up the other, and cut it. same observed cut speed, same hole size on both drawings, different size hole after post.
Having said that, I am going to match up all the cut settings 100%…all of them, and see if that gets it.
You know me, I love experiments and research!!! 
I matched them up.
Two different hole sizes.
EDIT - I LIED!
Test was closed chain for hole profile.
Other was face contour.
Someone please verify my findings. A Closed chain cut will result in a larger hole than a face contour cut.
Now that is interesting.
I am meeting the grand kids at the park in a few minutes, otherwise I would try. This is “our” day and night sleepover which my wife is planning to make it a weekly thing. I am already exhausted. 
Want to add 3 more to your weekly sleepovers?
Duct tape and Rum.
I just did the paperwork exercise in Fusion.
This is the model:
I then manufactured using the sketch profile for one gcode and used the body face for another gcode. They are exactly the same:
Sketch profile used for manufacturing:
H1
G3 X-0.6868 Y0.1891 I-0.0282 J-0.0103 F70.
G3 X0.2632 I0.475 J0. F108.
G3 X-0.2168 Y0.6641 I-0.475 J0.
G3 X-0.6867 Y0.1791 I0.005 J-0.475
H0
M5
Face of body used for manufacturing:
H1
G3 X-0.6868 Y0.1891 I-0.0282 J-0.0103 F70.
G3 X0.2632 I0.475 J0. F108.
G3 X-0.2168 Y0.6641 I-0.475 J0.
G3 X-0.6867 Y0.1791 I0.005 J-0.475
H0
M5
Body hole sketch profile.nc (837 Bytes)
Body hole sketch profile.nc (837 Bytes)
This is really wierd. I cannot seem to get the two different gcode files to give the name that I have saved them. So I am not really proving my point.
Body was used for each. One was using Face Contour inner loops, the other using Closed Chain.
I get the same as well if I use a single file. now to try two different files.
Still coming out the same:
Sketch profile used for manufacturing:
H1
G3 X-0.6868 Y0.1891 I-0.0282 J-0.0103 F70.
G3 X0.2632 I0.475 J0. F108.
G3 X-0.2168 Y0.6641 I-0.475 J0.
G3 X-0.6867 Y0.1791 I0.005 J-0.475
H0
M5
Face of body used for manufacturing:
H1
G3 X-0.6868 Y0.1891 I-0.0282 J-0.0103 F70.
G3 X0.2632 I0.475 J0. F108.
G3 X-0.2168 Y0.6641 I-0.475 J0.
G3 X-0.6867 Y0.1791 I0.005 J-0.475
H0
M5
Using closed chain of the body face:
G3 X-0.6868 Y0.1891 I-0.0282 J-0.0103 F70.
G3 X0.2632 I0.475 J0. F108.
G3 X-0.2168 Y0.6641 I-0.475 J0.
G3 X-0.6867 Y0.1791 I0.005 J-0.475
I don’t know. I have awful compelling evidence in front of me that says a chain profile cuts a different size hole than a face contour. All other aspects of the cut settings being the same.
I don’t want to select 24^2 chain cut profiles. Eeeewww.
All I did was delete the face contour and select 3 chains and closed the edit.
Did it again. Same result with another drawing:
Same exact numbers, as you would expect.
Closed Chain:
G0 Z0.06 (Cut Height)
H1
G3 X0.0908 Y0.4502 I-0.0103 J0.0282 F70.
G3 X-0.3842 Y-0.0248 I0. J-0.475 F108.
G3 X0.5658 I0.475 J0.
G3 X0.0808 Y0.4501 I-0.475 J0.
H0
M5
G0 Z1.
Face:
G0 Z0.06 (Cut Height)
H1
G3 X0.0908 Y0.4502 I-0.0103 J0.0282 F70.
G3 X-0.3842 Y-0.0248 I0. J-0.475 F108.
G3 X0.5658 I0.475 J0.
G3 X0.0808 Y0.4501 I-0.475 J0.
H0
M5
G0 Z1.
Face.nc (852 Bytes)
Closed Chain.nc (852 Bytes)
Are you, by chance applying a template?
No. As I said above when I suspected something amiss. I deleted my face contour cut path only, selected 3 holes as chains for a test then clicked OK, post processed it, fixed the program speed (PS0) in the gcode last line (known post processor bug) and ran it.
Those 3 holes were larger than the other ones I just cut from the same design. By larger I mean my 5/8" tooling fit in the holes, whereas the others were too tight by a lot.
Same cut speed for both.
I know you confirmed that the larger holes were, indeed, cutting on the inside of the holes?
(Don’t hit the messenger…only asking for a friend. 
)
Yup. CCW cuts on both and on the inside (lead/out in were correct)
That’s what I told him!
We need input from some of the Fusion 360 wizards!
You guys have a backdoor lounge conversation going on?
