Gotta watch out for those radians!!! :]
You can use a different total depth for the male/female but I haven't actually sat and thought about how to vary the glue gap and saw gap individually like that. It's surely just a matter of the male having a deeper overall cut to start with, but I haven't thought about how the other parameters are affected to achieve the desired glue gap and saw gap. In some instances it would make sense to have them not be the same but I will figure all of that out for the dedicated Male Inlay operation.
The offset for the clearing operations around the male plug geometry is going to be equal to the initial profiling operation's offset that results in the desired glue/saw gap depth. So if your gap depth is 0.1" and your V-bit angle is 60 degrees, then your profiling offset is 0.05" (plus some for the V-carving to cleanup), as well as for 2D milling operations that clear material out around the plug. For an endmill to profile right up against the plug you would add half of the endmill's diameter to the offset as well - because the Profile Milling operation puts the cutter centered along the input contour, rather than differentiating between inside/outside and automatically offsetting the cutter by half of its diameter like the 2D Offset/Trochoidal Milling operations do. So a 1/8" endmill that's profiling the plug to clean everything up right against it would have an offset of 0.05+1/16.
- Charlie