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« on: July 29, 2017, 11:58:54 AM »
Rather than spending time manipulating G-code and exploring the various methods you are looking at, you would, as Rich eludes, be better served by exploring different drafting and CAM techniques. Since you are using a rack method already you should model the rack, then duplicate the part you are machining in each of the rack spaces. At which point you can either remove the rack for CAM or leave it in if your CAM package allows you to do so. Once all of this is completed you should be able to optimize your tool changes so that the first operation will be completed on all parts with the first tool, no changes required. Once you load the second tool, the second operation on all parts will be completed, and so on and so forth. So even if you don't use a tool library with stored tool length offsets you are at a minimum reducing your tool changes and z-height settings to the number tools. That said, with a touch plate or even a light up touch block and some modifications to Mach 3 you can easily go to a tool library with stored tool length offsets and that will completely eliminate setting your offsets after that initial setup assuming you use repeatable length tool holders.
Obviously all of that is easier said than done, mainly you are looking at learning new CAD/CAM packages, but once through that learning curve the speed at which your production times will be a fraction of what they are now. My recommendation would be Fusion 360 (it's free for most) because the CAD is great and the integrated CAM is probably even better. That said, you understand your needs better than anybody so you'll have to do some shopping.
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