Machsupport Forum
Mach Discussion => General Mach Discussion => Topic started by: SWATH on March 23, 2011, 12:28:07 AM

Hello.
I keep getting errors in the arc lines that my CAM software spits out and I'm not sure how to fix the post processor or Mach itself to get them to work.
Here are the details:
CAM software is RhinoCAM using Mach3Inch.spm post processor
In the circle tab I have the following options
Output Format
I,J,K and Radius
I,J,K only <this one is selected
Radius only
Arc Center (I,J,K)
Absolute <this one is selected
Vector from Center to Start
Vector from Start to Center
Unsigned Vector from Start to Center
Here is the circle block format:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]
RhinoCAM also has the following options that can be checked:
Output arcs as linear segments <I have this one unchecked but I'm not sure what I should do with the other two.
Output spiral motions as linear segments
Output helix motions as linear segments
Now in Mach I tried both absolute and incremental but I keep getting these two errors:
In IJ mode Absolute I get this error:
Zero radius arcLine 140
140:G03X1.1733Y0.5598I0.8561J0.9783
In IJ mode Incremetal I get this error:
Radius to end of arc differs from radius to startLine 942
942:G02X1.6663Y0.4917I0.3265J0.4175
These are just the first ones to pop up in reality almost every arc line gets an error.
Sorry can someone help me get this straightened out?
I would much rather cut arcs than line segments.

Do you have a setting to or can you find out what the setting is for precision.
Sometime, this can be only because you post output value like 2.1234 and the real value is 2.123
Normally, you would choose incremental value for center of arc.
Check the value in your cad or cam program and check what it is output by the post.
Jeff

Please post your Gcode using the "Additional Options" when posting a reply.

Thanks for the tip, I think you may be right. I remember someone telling me that the arc tolerance must be less than the global tolerance and I had it equal in a couple of places. I set both the post processor and Mach to Absolute because the post processor didn't have incremental as an option for arcs, only for motion (G91), then I set the global tolerance to .0001 and the arc fitting tolerance to .001 and that seemed to do the trick.
Can Mach handle arcs in spiral or helix motions? I had heard it was one or the other but I can't remember which. Could it be both?

Now I'm getting a new error:
"K word given for arc in xy plane 9"
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3G43 H3
S5000M03
G00Z0.2500
X0.1249Y0.0042
G01Z0.2960 F7.3
G17
G03X0.1250Y0.0000Z0.5473I0.0000J0.0000K0.2500 F10.0
I can't seem to change anything in the settings that eliminates the K even when outputting all in linear segments. Is this something I'm going to have to edit in the block format?
Helical Interpolation:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]K[HELIX_LEAD]
Circular Interpolation:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]Q[SPIRAL_LEAD]

K is for XZ plane.
I and J are for XY plane
Maybe you do not work on the right plane with your cam software.
Or is there a setting in the Cam software to not output arc on the XZ and YZ plane, only on the XY plane.
Just a tough, I don't use Rhino but I know Mastercam has that option.
Jeff

Thanks I found the setting I have spiral interpolation set to G17 XY plane but do I set Helical interpolation to G18 XZ plane or G19 YZ plane? It seems to me a Helix is both XZ and YZ.

I'm thoroughly confused now. I can't seem to get Mach to read the file with any of my settings. I know that G17 followed by the K is causing problems but I can't seem to fix it so I'm going to post all the info I can and hopefully someone way smarter than me can spot the problem and tell what settings should be what.
Here is a sample toolpath that gives errors in Mach:
(http://img832.imageshack.us/img832/3476/toolpathspiralarcs.jpg)
Here is the machining preferences settings in RhinoCAM:
(http://img834.imageshack.us/img834/5182/machiningpreferences.jpg)
Here are the relevant tabs in the post processor:
(http://img17.imageshack.us/img17/7460/circlemotion.jpg)
(http://img810.imageshack.us/img810/4177/helicalspiralmotionheli.jpg)
(http://img847.imageshack.us/img847/2702/helicalspiralmotionspir.jpg)
Here is the GenConfig page in Mach:
(http://img847.imageshack.us/img847/6272/generalconfig.jpg)
Here is the gcode produced:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1249Y0.0042
G01Z0.2960 F7.3
G17
G03X0.1250Y0.0000Z0.5473I0.0000J0.0000R0.125K0.2500 F10.0
X0.1774Y0.7284I0.0000J0.0000R0.7497Q0.3500
X0.1774Y0.7284I0.0000J0.0000R0.7497
X0.1774Y0.7284I0.0000J0.0000R0.7497
G01X0.1250Y0.0000
X0.1035Y0.0700
G03X0.1250Y0.0000Z0.7737I0.0000J0.0000R0.125K0.2500
X0.1774Y0.7284I0.0000J0.0000R0.7497Q0.3500
X0.1774Y0.7284I0.0000J0.0000R0.7497
X0.1774Y0.7284I0.0000J0.0000R0.7497
G01X0.1250Y0.0000
X0.1035Y0.0700
G03X0.1250Y0.0000Z1.0000I0.0000J0.0000R0.125K0.2500
X0.1774Y0.7284I0.0000J0.0000R0.7497Q0.3500
X0.1774Y0.7284I0.0000J0.0000R0.7497
X0.1774Y0.7284I0.0000J0.0000R0.7497
G01X0.1250Y0.0000
X0.0000
G00Z0.2500
M5 M9
M30

Ok the forum is not letting me edit the previous post but that is not the correct gcode to go with those settings.
This one is:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1249Y0.0042
G01Z0.2960 F7.3
G17
G03X0.1250Y0.0000Z0.5473I0.0000J0.0000K0.2500 F10.0
X0.1774Y0.7284I0.0000J0.0000Q0.3500
X0.1774Y0.7284I0.0000J0.0000
X0.1774Y0.7284I0.0000J0.0000
G01X0.1250Y0.0000
X0.1035Y0.0700
G03X0.1250Y0.0000Z0.7737I0.0000J0.0000K0.2500
X0.1774Y0.7284I0.0000J0.0000Q0.3500
X0.1774Y0.7284I0.0000J0.0000
X0.1774Y0.7284I0.0000J0.0000
G01X0.1250Y0.0000
X0.1035Y0.0700
G03X0.1250Y0.0000Z1.0000I0.0000J0.0000K0.2500
X0.1774Y0.7284I0.0000J0.0000Q0.3500
X0.1774Y0.7284I0.0000J0.0000
X0.1774Y0.7284I0.0000J0.0000
G01X0.1250Y0.0000
X0.0000
G00Z0.2500
M5 M9
M30

I believe if you want Incremental IJ, it would be Vector from Center to Start.
I'd try changing these:
Helical Interpolation:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]K[HELIX_LEAD]
Circular Interpolation:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]Q[SPIRAL_LEAD]
To these:
Helical Interpolation:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]
Circular Interpolation:
[CIR_PLANE]
[G_CODE][NEXT_X][NEXT_Y][NEXT_Z][NEXT_I][NEXT_J]
And the Helical plane should still be G17.
I've never used RhinoCAM, though.

I think your right, Gerry. The K and Q values are not normally needed. The key is finding out what setting makes use of the I and J instead. Would be allot easier to troubleshoot it "hands on". Also, you need to make sure that you set the incremental/absolute mode in Machs "general logic config" within your gcode, instead of the check boxes. In the PP generators 'circle' tab, I would check the 'limit arcs to angle' check box, just to be on the safe side and avoid any potential unrelated errors that you don't need right now. When you get everything sorted and working right, you can uncheck it and see how it jives. Here is how a helix format could look, to give you at least some reference to go by.....
%
O0000
G20
G0 G17 G40 G49 G80 G90 G91.1
T1 M6
G0 G90 G54 X.2492 Y.301 S1000 M3
G43 H1 Z1.25
Z1.2
G1 Z1.1 F500
G2 Z.9354 I.3992 J.301
Z.7707 I.3992 J.301
Z.6061 I.3992 J.301
Z.4414 I.3992 J.301
Z.2768 I.3992 J.301
Z.1121 I.3992 J.301
X.0443 Y.4887 Z0. I.3992 J.301
M30
%
Also, when your posting a reply, there is an 'additional options' link southwest of the text input box, that will allow you to post your pics without the need to upload them to a separate server, and that mess. Use it if you like, it's much more convenient.

Thanks for the input. Alright I edited the block format to what was suggested and that has eliminated the K word error but now I keep getting the error:
"Radius from end of arc differs from radius to startLine 10"
I've played with the tolerance settings but it doesn't eliminate the error.
I'm not sure how to change general config logic within the gcode instead of check boxes.

Just add G90.1 for Abs, or G91.1 for inc. Since you've already got it defaulted to abs in the config page, you likely just need to add G91.1 to the code to make it switch to inc. See the code I posted earlier for an example.

I changed from "absolute" to "vector from center to start" in the post processor and "incremental" in mach and here is the gcode:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1248Y0.0044
G01Z0.2960 F7.3
G17
G03X0.1250Y0.0000Z0.5473I0.1248J0.0044 F10.0
X0.2186Y0.7171I0.1250J0.0000
X0.2186Y0.7171I0.2186J0.7171
X0.2186Y0.7171I0.2186J0.7171
G01X0.1250Y0.0000
X0.1036Y0.0699
G03X0.1250Y0.0000Z0.7737I0.1036J0.0699
X0.2186Y0.7171I0.1250J0.0000
X0.2186Y0.7171I0.2186J0.7171
X0.2186Y0.7171I0.2186J0.7171
G01X0.1250Y0.0000
X0.1036Y0.0699
G03X0.1250Y0.0000Z1.0000I0.1036J0.0699
X0.2186Y0.7171I0.1250J0.0000
X0.2186Y0.7171I0.2186J0.7171
X0.2186Y0.7171I0.2186J0.7171
G01X0.1250Y0.0000
X0.0000
G00Z0.2500
M5 M9
M30
I am no longer getting K word errors instead I'm getting:
"Radius from end of arc differs from radius to startLine 10"
10:X0.2186Y0.7171I0.1250J0.0000
which I think is progress because now we are just dealing with math errors instead of syntax.
I'm not sure how to deal with this problem though. Adding G90.1 or G91.1 doesn't help
BTW, what the heck is G40.1?

BTW, what the heck is G40.1?
It is 1/10 more than a G40 ;D ;D ;D ;D
Jeff

"Radius from end of arc differs from radius to startLine 10"
That's usually an incorrect IJ mode.
If you changed it to what I said, you should need incremental now.

Attached is the current setting I'm using:
Here is the code produced from these settings:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1250Y0.0002
G01Z0.2960 F7.3
G17
G03Z0.5473I0.1250J0.0002 F10.0
X0.2173Y0.7175I0.1250J0.0002
X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z0.7737I0.1250J0.0002
X0.2173Y0.7175I0.1250J0.0002
X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z1.0000I0.1250J0.0002
X0.2173Y0.7175I0.1250J0.0002
X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
X0.0000Y0.0000
G00Z0.2500
M5 M9
M30
I'm still getting the error:
"Radius from end of arc differs from radius to startLine 10"
10:X0.2173Y0.7175I0.1250J0.0002
Adding G90.1 or G91.1 to the beginning of the code doesn't do anything.

Make sure you're using helical interpolation, and not spiral interpolation. It appears you should be using one or the other, and not both?
Looking at it again, I think it should be Vector from Start to Center.

Interesting. When I change to "Vector from Start to Center" I still get the error. but when I change RhinoCAM to "Output spiral motions as linear segments" it outputs code in long form but Mach will read it. I had heard that Mach does not do spiral arcs so could this be the issue? Is that true?
Here is the code:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1250Y0.0002
G01Z0.2960 F7.3
G17
G03Z0.5473I0.1250J0.0002 F10.0
G01X0.1327Y0.0231
X0.1358Y0.0491
X0.1336Y0.0768
X0.1257Y0.1051
X0.1118Y0.1328
X0.0920Y0.1586
X0.0664Y0.1813
X0.0356Y0.1996
X0.0004Y0.2125
X0.0382Y0.2189
X0.0789Y0.2181
X0.1204Y0.2095
X0.1612Y0.1929
X0.1997Y0.1682
X0.2343Y0.1359
X0.2634Y0.0964
X0.2858Y0.0509
X0.3000Y0.0006
X0.3051Y0.0532
X0.3004Y0.1087
X0.2854Y0.1640
X0.2600Y0.2173
X0.2246Y0.2666
X0.1797Y0.3100
X0.1265Y0.3456
X0.0663Y0.3719
X0.0007Y0.3875
X0.0682Y0.3913
X0.1385Y0.3827
X0.2076Y0.3612
X0.2735Y0.3271
X0.3335Y0.2810
X0.3857Y0.2236
X0.4278Y0.1566
X0.4580Y0.0817
X0.4750Y0.0009
X0.4782Y0.0428
X0.4773Y0.0870
X0.4723Y0.1314
X0.4631Y0.1756
X0.4498Y0.2192
X0.4323Y0.2618
X0.4108Y0.3030
X0.3854Y0.3425
X0.3561Y0.3798
X0.3232Y0.4146
X0.2869Y0.4466
X0.2474Y0.4753
X0.2051Y0.5005
X0.1602Y0.5220
X0.1131Y0.5393
X0.0642Y0.5524
X0.0138Y0.5611
X0.0376Y0.5650
X0.0896Y0.5643
X0.1418Y0.5587
X0.1937Y0.5483
X0.2449Y0.5330
X0.2949Y0.5129
X0.3432Y0.4882
X0.3895Y0.4588
X0.4332Y0.4250
X0.4740Y0.3871
X0.5114Y0.3452
X0.5451Y0.2997
X0.5748Y0.2509
X0.6000Y0.1992
X0.6206Y0.1450
X0.6362Y0.0887
X0.6467Y0.0307
X0.6519Y0.0285
X0.6516Y0.0883
X0.6459Y0.1483
X0.6345Y0.2080
X0.6176Y0.2669
X0.5952Y0.3244
X0.5675Y0.3800
X0.5345Y0.4332
X0.4966Y0.4836
X0.4538Y0.5306
X0.4066Y0.5738
X0.3553Y0.6128
X0.3003Y0.6471
X0.2419Y0.6765
X0.1806Y0.7006
X0.1170Y0.7192
X0.0514Y0.7319
X0.0154Y0.7386
X0.0831Y0.7392
X0.1510Y0.7335
X0.2173Y0.7175
G03X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z0.7737I0.1250J0.0002
G01X0.1327Y0.0231
X0.1358Y0.0491
X0.1336Y0.0768
X0.1257Y0.1051
X0.1118Y0.1328
X0.0920Y0.1586
X0.0664Y0.1813
X0.0356Y0.1996
X0.0004Y0.2125
X0.0382Y0.2189
X0.0789Y0.2181
X0.1204Y0.2095
X0.1612Y0.1929
X0.1997Y0.1682
X0.2343Y0.1359
X0.2634Y0.0964
X0.2858Y0.0509
X0.3000Y0.0006
X0.3051Y0.0532
X0.3004Y0.1087
X0.2854Y0.1640
X0.2600Y0.2173
X0.2246Y0.2666
X0.1797Y0.3100
X0.1265Y0.3456
X0.0663Y0.3719
X0.0007Y0.3875
X0.0682Y0.3913
X0.1385Y0.3827
X0.2076Y0.3612
X0.2735Y0.3271
X0.3335Y0.2810
X0.3857Y0.2236
X0.4278Y0.1566
X0.4580Y0.0817
X0.4750Y0.0009
X0.4782Y0.0428
X0.4773Y0.0870
X0.4723Y0.1314
X0.4631Y0.1756
X0.4498Y0.2192
X0.4323Y0.2618
X0.4108Y0.3030
X0.3854Y0.3425
X0.3561Y0.3798
X0.3232Y0.4146
X0.2869Y0.4466
X0.2474Y0.4753
X0.2051Y0.5005
X0.1602Y0.5220
X0.1131Y0.5393
X0.0642Y0.5524
X0.0138Y0.5611
X0.0376Y0.5650
X0.0896Y0.5643
X0.1418Y0.5587
X0.1937Y0.5483
X0.2449Y0.5330
X0.2949Y0.5129
X0.3432Y0.4882
X0.3895Y0.4588
X0.4332Y0.4250
X0.4740Y0.3871
X0.5114Y0.3452
X0.5451Y0.2997
X0.5748Y0.2509
X0.6000Y0.1992
X0.6206Y0.1450
X0.6362Y0.0887
X0.6467Y0.0307
X0.6519Y0.0285
X0.6516Y0.0883
X0.6459Y0.1483
X0.6345Y0.2080
X0.6176Y0.2669
X0.5952Y0.3244
X0.5675Y0.3800
X0.5345Y0.4332
X0.4966Y0.4836
X0.4538Y0.5306
X0.4066Y0.5738
X0.3553Y0.6128
X0.3003Y0.6471
X0.2419Y0.6765
X0.1806Y0.7006
X0.1170Y0.7192
X0.0514Y0.7319
X0.0154Y0.7386
X0.0831Y0.7392
X0.1510Y0.7335
X0.2173Y0.7175
G03X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z1.0000I0.1250J0.0002
G01X0.1327Y0.0231
X0.1358Y0.0491
X0.1336Y0.0768
X0.1257Y0.1051
X0.1118Y0.1328
X0.0920Y0.1586
X0.0664Y0.1813
X0.0356Y0.1996
X0.0004Y0.2125
X0.0382Y0.2189
X0.0789Y0.2181
X0.1204Y0.2095
X0.1612Y0.1929
X0.1997Y0.1682
X0.2343Y0.1359
X0.2634Y0.0964
X0.2858Y0.0509
X0.3000Y0.0006
X0.3051Y0.0532
X0.3004Y0.1087
X0.2854Y0.1640
X0.2600Y0.2173
X0.2246Y0.2666
X0.1797Y0.3100
X0.1265Y0.3456
X0.0663Y0.3719
X0.0007Y0.3875
X0.0682Y0.3913
X0.1385Y0.3827
X0.2076Y0.3612
X0.2735Y0.3271
X0.3335Y0.2810
X0.3857Y0.2236
X0.4278Y0.1566
X0.4580Y0.0817
X0.4750Y0.0009
X0.4782Y0.0428
X0.4773Y0.0870
X0.4723Y0.1314
X0.4631Y0.1756
X0.4498Y0.2192
X0.4323Y0.2618
X0.4108Y0.3030
X0.3854Y0.3425
X0.3561Y0.3798
X0.3232Y0.4146
X0.2869Y0.4466
X0.2474Y0.4753
X0.2051Y0.5005
X0.1602Y0.5220
X0.1131Y0.5393
X0.0642Y0.5524
X0.0138Y0.5611
X0.0376Y0.5650
X0.0896Y0.5643
X0.1418Y0.5587
X0.1937Y0.5483
X0.2449Y0.5330
X0.2949Y0.5129
X0.3432Y0.4882
X0.3895Y0.4588
X0.4332Y0.4250
X0.4740Y0.3871
X0.5114Y0.3452
X0.5451Y0.2997
X0.5748Y0.2509
X0.6000Y0.1992
X0.6206Y0.1450
X0.6362Y0.0887
X0.6467Y0.0307
X0.6519Y0.0285
X0.6516Y0.0883
X0.6459Y0.1483
X0.6345Y0.2080
X0.6176Y0.2669
X0.5952Y0.3244
X0.5675Y0.3800
X0.5345Y0.4332
X0.4966Y0.4836
X0.4538Y0.5306
X0.4066Y0.5738
X0.3553Y0.6128
X0.3003Y0.6471
X0.2419Y0.6765
X0.1806Y0.7006
X0.1170Y0.7192
X0.0514Y0.7319
X0.0154Y0.7386
X0.0831Y0.7392
X0.1510Y0.7335
X0.2173Y0.7175
G03X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
X0.0000Y0.0000
G00Z0.2500
M5 M9
M30

Yes, that's why I said to use helical instead of spiral.

I was thinking you mean in the post processor. Anyway it's a bummer that the code will end up so long from the spirals but at least it works and clears up some of my confusion. Thanks for the help.
To recap for future inquiries attached are the settings to use with RhinoCAM with incremental arcs.
Toolpath with a helix, spirals, and circular arcs:
(http://img832.imageshack.us/img832/3476/toolpathspiralarcs.jpg)
RhinoCAM:
Output Spiral motions as linear segments checked.
(http://img8.imageshack.us/img8/6683/spiralsaslinear.jpg)
Post Processor:
set arc format to Vector from Center to Start (incremental)
delete K and Q words from the block format of Spiral and helix
(http://img151.imageshack.us/img151/9008/vectorfrostarttocenter.jpg)
(http://img824.imageshack.us/img824/2241/helixwithkdeleted.jpg)
(http://img847.imageshack.us/img847/8946/spiralwithqdeleted.jpg)
Mach3:
Check arc format as incremental
(http://img846.imageshack.us/img846/9622/newestmachincremental.jpg)
Here is the Gcode produced with these settings:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1250Y0.0002
G01Z0.2960 F7.3
G17
G03Z0.5473I0.1250J0.0002 F10.0
G01X0.1327Y0.0231
X0.1358Y0.0491
X0.1336Y0.0768
X0.1257Y0.1051
X0.1118Y0.1328
X0.0920Y0.1586
X0.0664Y0.1813
X0.0356Y0.1996
X0.0004Y0.2125
X0.0382Y0.2189
X0.0789Y0.2181
X0.1204Y0.2095
X0.1612Y0.1929
X0.1997Y0.1682
X0.2343Y0.1359
X0.2634Y0.0964
X0.2858Y0.0509
X0.3000Y0.0006
X0.3051Y0.0532
X0.3004Y0.1087
X0.2854Y0.1640
X0.2600Y0.2173
X0.2246Y0.2666
X0.1797Y0.3100
X0.1265Y0.3456
X0.0663Y0.3719
X0.0007Y0.3875
X0.0682Y0.3913
X0.1385Y0.3827
X0.2076Y0.3612
X0.2735Y0.3271
X0.3335Y0.2810
X0.3857Y0.2236
X0.4278Y0.1566
X0.4580Y0.0817
X0.4750Y0.0009
X0.4782Y0.0428
X0.4773Y0.0870
X0.4723Y0.1314
X0.4631Y0.1756
X0.4498Y0.2192
X0.4323Y0.2618
X0.4108Y0.3030
X0.3854Y0.3425
X0.3561Y0.3798
X0.3232Y0.4146
X0.2869Y0.4466
X0.2474Y0.4753
X0.2051Y0.5005
X0.1602Y0.5220
X0.1131Y0.5393
X0.0642Y0.5524
X0.0138Y0.5611
X0.0376Y0.5650
X0.0896Y0.5643
X0.1418Y0.5587
X0.1937Y0.5483
X0.2449Y0.5330
X0.2949Y0.5129
X0.3432Y0.4882
X0.3895Y0.4588
X0.4332Y0.4250
X0.4740Y0.3871
X0.5114Y0.3452
X0.5451Y0.2997
X0.5748Y0.2509
X0.6000Y0.1992
X0.6206Y0.1450
X0.6362Y0.0887
X0.6467Y0.0307
X0.6519Y0.0285
X0.6516Y0.0883
X0.6459Y0.1483
X0.6345Y0.2080
X0.6176Y0.2669
X0.5952Y0.3244
X0.5675Y0.3800
X0.5345Y0.4332
X0.4966Y0.4836
X0.4538Y0.5306
X0.4066Y0.5738
X0.3553Y0.6128
X0.3003Y0.6471
X0.2419Y0.6765
X0.1806Y0.7006
X0.1170Y0.7192
X0.0514Y0.7319
X0.0154Y0.7386
X0.0831Y0.7392
X0.1510Y0.7335
X0.2173Y0.7175
G03X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z0.7737I0.1250J0.0002
G01X0.1327Y0.0231
X0.1358Y0.0491
X0.1336Y0.0768
X0.1257Y0.1051
X0.1118Y0.1328
X0.0920Y0.1586
X0.0664Y0.1813
X0.0356Y0.1996
X0.0004Y0.2125
X0.0382Y0.2189
X0.0789Y0.2181
X0.1204Y0.2095
X0.1612Y0.1929
X0.1997Y0.1682
X0.2343Y0.1359
X0.2634Y0.0964
X0.2858Y0.0509
X0.3000Y0.0006
X0.3051Y0.0532
X0.3004Y0.1087
X0.2854Y0.1640
X0.2600Y0.2173
X0.2246Y0.2666
X0.1797Y0.3100
X0.1265Y0.3456
X0.0663Y0.3719
X0.0007Y0.3875
X0.0682Y0.3913
X0.1385Y0.3827
X0.2076Y0.3612
X0.2735Y0.3271
X0.3335Y0.2810
X0.3857Y0.2236
X0.4278Y0.1566
X0.4580Y0.0817
X0.4750Y0.0009
X0.4782Y0.0428
X0.4773Y0.0870
X0.4723Y0.1314
X0.4631Y0.1756
X0.4498Y0.2192
X0.4323Y0.2618
X0.4108Y0.3030
X0.3854Y0.3425
X0.3561Y0.3798
X0.3232Y0.4146
X0.2869Y0.4466
X0.2474Y0.4753
X0.2051Y0.5005
X0.1602Y0.5220
X0.1131Y0.5393
X0.0642Y0.5524
X0.0138Y0.5611
X0.0376Y0.5650
X0.0896Y0.5643
X0.1418Y0.5587
X0.1937Y0.5483
X0.2449Y0.5330
X0.2949Y0.5129
X0.3432Y0.4882
X0.3895Y0.4588
X0.4332Y0.4250
X0.4740Y0.3871
X0.5114Y0.3452
X0.5451Y0.2997
X0.5748Y0.2509
X0.6000Y0.1992
X0.6206Y0.1450
X0.6362Y0.0887
X0.6467Y0.0307
X0.6519Y0.0285
X0.6516Y0.0883
X0.6459Y0.1483
X0.6345Y0.2080
X0.6176Y0.2669
X0.5952Y0.3244
X0.5675Y0.3800
X0.5345Y0.4332
X0.4966Y0.4836
X0.4538Y0.5306
X0.4066Y0.5738
X0.3553Y0.6128
X0.3003Y0.6471
X0.2419Y0.6765
X0.1806Y0.7006
X0.1170Y0.7192
X0.0514Y0.7319
X0.0154Y0.7386
X0.0831Y0.7392
X0.1510Y0.7335
X0.2173Y0.7175
G03X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z1.0000I0.1250J0.0002
G01X0.1327Y0.0231
X0.1358Y0.0491
X0.1336Y0.0768
X0.1257Y0.1051
X0.1118Y0.1328
X0.0920Y0.1586
X0.0664Y0.1813
X0.0356Y0.1996
X0.0004Y0.2125
X0.0382Y0.2189
X0.0789Y0.2181
X0.1204Y0.2095
X0.1612Y0.1929
X0.1997Y0.1682
X0.2343Y0.1359
X0.2634Y0.0964
X0.2858Y0.0509
X0.3000Y0.0006
X0.3051Y0.0532
X0.3004Y0.1087
X0.2854Y0.1640
X0.2600Y0.2173
X0.2246Y0.2666
X0.1797Y0.3100
X0.1265Y0.3456
X0.0663Y0.3719
X0.0007Y0.3875
X0.0682Y0.3913
X0.1385Y0.3827
X0.2076Y0.3612
X0.2735Y0.3271
X0.3335Y0.2810
X0.3857Y0.2236
X0.4278Y0.1566
X0.4580Y0.0817
X0.4750Y0.0009
X0.4782Y0.0428
X0.4773Y0.0870
X0.4723Y0.1314
X0.4631Y0.1756
X0.4498Y0.2192
X0.4323Y0.2618
X0.4108Y0.3030
X0.3854Y0.3425
X0.3561Y0.3798
X0.3232Y0.4146
X0.2869Y0.4466
X0.2474Y0.4753
X0.2051Y0.5005
X0.1602Y0.5220
X0.1131Y0.5393
X0.0642Y0.5524
X0.0138Y0.5611
X0.0376Y0.5650
X0.0896Y0.5643
X0.1418Y0.5587
X0.1937Y0.5483
X0.2449Y0.5330
X0.2949Y0.5129
X0.3432Y0.4882
X0.3895Y0.4588
X0.4332Y0.4250
X0.4740Y0.3871
X0.5114Y0.3452
X0.5451Y0.2997
X0.5748Y0.2509
X0.6000Y0.1992
X0.6206Y0.1450
X0.6362Y0.0887
X0.6467Y0.0307
X0.6519Y0.0285
X0.6516Y0.0883
X0.6459Y0.1483
X0.6345Y0.2080
X0.6176Y0.2669
X0.5952Y0.3244
X0.5675Y0.3800
X0.5345Y0.4332
X0.4966Y0.4836
X0.4538Y0.5306
X0.4066Y0.5738
X0.3553Y0.6128
X0.3003Y0.6471
X0.2419Y0.6765
X0.1806Y0.7006
X0.1170Y0.7192
X0.0514Y0.7319
X0.0154Y0.7386
X0.0831Y0.7392
X0.1510Y0.7335
X0.2173Y0.7175
G03X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
X0.0000Y0.0000
G00Z0.2500
M5 M9
M30

I didn't realize what was happening with the spirals. Mach3 can do spirals, but it's very picky about how you do it, and it's undocumented. I would think that very few controls can do G2/G3 spirals.

Yeah the lines that kept giving me the errors were always the first line of a spiral. If you can think of a way around using a ton of line segments let me know.

Not really been following this as I am not good at code, get easily confused ;)
Actually may be getting confused with this as well but if you use the circular pocket wizard it produces a spiral toolpath, is that the type f thing you are trying to do?
Might be worth looking at the code it produces and maybe you can find a way to get your CAM to output similar, if that is what you are wanting..
Hood

I think you might be on to something there.
I edited the Spiral motion output to something Mach can read by making the [spiral_Lead] R instead of Q and just using X and Y for coordinates as the wizard does. Here is the tool path in Mach from the wizard:
(http://img826.imageshack.us/img826/5256/wizardspiral.jpg)
And here is the code:
G0 G49 G40 G17 G80 G50 G90
M6 T0(TOOL DIA.10)
G64
G21 (mm)
M03 S0
M08
G00 G43 H0 Z2
X0 Y0
G01 Z10 F20
G2 Y0 X5 R2.5 F30
Y0 X5 R5
Y0 X10 R7.5
Y0 X10 R10
Y0 X15 R12.5
Y0 X15 R15
Y0 X20 R17.5
Y0 X20 R20
X20 Y0 R20
Y10 X10 R10
G00 Z2
X0 Y0
G01 Z20 F20
G2 Y0 X5 R2.5 F30
Y0 X5 R5
Y0 X10 R7.5
Y0 X10 R10
Y0 X15 R12.5
Y0 X15 R15
Y0 X20 R17.5
Y0 X20 R20
X20 Y0 R20
Y10 X10 R10
G00 Z2
X0 Y0
G01 Z30 F20
G2 Y0 X5 R2.5 F30
Y0 X5 R5
Y0 X10 R7.5
Y0 X10 R10
Y0 X15 R12.5
Y0 X15 R15
Y0 X20 R17.5
Y0 X20 R20
X20 Y0 R20
Y10 X10 R10
G00 Z2
M5 M9
M30
Now here is the toolpath in Mach for my pocket from RhinoCAM:
(http://img233.imageshack.us/img233/5420/spirallead.jpg)
As you can see the arc and helix output fine but the spiral does not. The X and Y value for the spiral is the beginning point and end point whereas in the wizard it is divided into half circles. The radius is applied to the entire arc instead of segments of increasing radius. Here is the code:
G00 G49 G40.1 G17 G80 G50 G90
G20
(Hole Pocketing)
M6 T3 G43 H3
S5000M03
G00Z0.2500
X0.1250Y0.0002
G01Z0.2960 F7.3
G17
G03Z0.5473I0.1250J0.0002 F10.0
X0.2173Y0.7175R0.3500
X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z0.7737I0.1250J0.0002
X0.2173Y0.7175R0.3500
X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
G03Z1.0000I0.1250J0.0002
X0.2173Y0.7175R0.3500
X0.2173Y0.7175I0.2173J0.7175
X0.2173Y0.7175I0.2173J0.7175
G01X0.1250Y0.0002
X0.0000Y0.0000
G00Z0.2500
M5 M9
M30
Anyone know how I can get the X and Y coordinated to output half circles?

You don't need to use half circles. You just need the start and endpoint to not be more than 1/2" apart. I think actually, the radius from the start to the end can't be more than 1/2" different.
G20 G40 G90
G91.1
S5000
M3
G0 Z0.0500
G0 X0.0000 Y0.6500 Z0.0500
G1 X0.0000 Y0.2167 Z0.2500 F75
G2 X0.0000 Y0.2167 Z0.2500 I0.0000 J0.2167 F80
G2 X0.0000 Y0.4333 Z0.2500 I0.00 J0.2167
G2 X0.0000 Y0.6500 Z0.2500 I0.00 J0.4333
G2 X0.0000 Y0.6500 Z0.2500 I0.00 J0.6500
G0 Z0.0000
G0 X0.0000 Y0.7500 Z0.0000
G2 X0.0000 Y0.7500 Z0.2500 I0.0000 J0.7500 F80
G2 X0.0000 Y0.7500 Z0.2500 I0.0000 J0.7500
G0 X0.0000 Y0.7500 Z0.0500
M5
M30

Your right that is what is screwing my spiral arcs. I have the right format XYZIJ but the values don't work unless I tweak the X and Y values to be lower. Why is the limit .5"? That seems so arbitrary. Is there any way around this .5" limit?

So just playing around, using .5" flat mill a I can do a 1.4999 hole pocket with spiral arcs but not a 1.5. That just seems like a weird cut off point and I would venture that it could be changed somewhere if it is just an arbitrary value.