garyhlucas,
I'm really not missing steps, I was only mentioning AC servo's in the event that the steppers need to be replaced, might as well as go with the best, but yes the current steppers work fine.
One of the things I am unhappy with is G02 and G03 circular cut feed codes run incredibly slow. G01 cuts in a straight path at appropriate feeds, but when I give it an arc cut it never cuts faster than maybe 3 IPM. If I use my CAM software to only output line segments and no arcs in the GCODE, it gets better, but then there is a small delay between each line segment. I have a suspicion that the controller software is taking G03 codes and feeding the controller very small line segments at a high resolution, resulting in the code buffer being empty most of the time and the PC thinking too hard. Also, even when the line segments are longer and straight it still seems like there is delay (300ms maybe) between line executions. I am suspecting that the software is spoon feeding the buffer too slow on the card.
Also, I know the card supports helical cuts, but the control software does not. I cannot spiral down to plunge, or do helical moves for 3d surfacing.
Last but not least, occasionally (maybe once every few months) the machine will rise against the human race and act contrary to the codes it was given. This could be as simple as it forgot to retract between 2 pockets. Sometimes the software gets into a weird state and glitches happen, it almost never glitches the same twice (excluding a few specific things), its like lightning, this is solved by re installing the software.
Bottom line is we are buying SolidCam 3DiMachining with 4th axis simultaneous, but our machine can't take advantage of this upgrade as is.
The PC is an Intel Core2duo with 1GB Ram, WinXP SP3, no network, nothing else installed, no MP3's or anything of that sort. PC is dedicated to this machine.