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Re: Hex vs. Key
A manual lathe is perhaps preferable to a CNC one, since you can judge the cut and chatter, backing off as necessary. Take a light cut, and cut the shaft speed down about 30% from normal. It's possible to break the tool, so have spares on hand, and take a lighter cut.
The key is an even feed rate sideways, so if you have a screw-cutting lathe, use the finest feed rate (usually about 0.001" available.
An alternative is to grind away some of the points first, just don't overdo it.
Don
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