Somewhere on lines between N250-N350 is something that kills Mach. Small holes dia 1.3mm using a 1mm dia tool. Code is generated by RhinoCAM. Sometimes earlier I noticed that helix toolpaths killed Mach but after checking "Create full (360 deg) helixes only" and Output each helix individuall" in RhinoCAM Hole Pocketing Mach worked fine without 3D interpolation. Those options are used here too and the only difference is that these are very small holes. I just updated to the latest Mach lockdown .043.022 but that did not make a difference.

N40(BEGIN - StartUp Code)
N50 G00 G49 G40.1 G17 G80 G50 G90
N60 G21
N70(END - StartUp Code)
N80 (Hole Pocketing-dia 1.3mm)
N90 (#025-2FL-D1mm-L10mm-LOC4mm-GARR45010-ER20/3mm)
N100 M901
N110 M6 T25
N120 M900
N130 M904
N140 G00 X6.7995 Y55.2022
N150 G00 Z10.0000
N160 M03 S18143
N170 M1
N210 F635.0
N220 G01 Z1.0000
N230 F600.0
N240 G17
N250 G02 Z-0.4333 I6.7500 J55.2000
N260 X6.7900 Y55.0554 I6.7500 J55.2000
N270 X6.7100 Y55.3446 I6.7500 J55.2000
N280 G01  X6.7995 Y55.2022
N290 G02 Z-0.8667 I6.7500 J55.2000
N300 X6.7900 Y55.0554 I6.7500 J55.2000
N310 X6.7100 Y55.3446 I6.7500 J55.2000
N320 G01  X6.7995 Y55.2022
N330 G02 Z-1.3000 I6.7500 J55.2000
N340 X6.7900 Y55.0554 I6.7500 J55.2000
N350 X6.7100 Y55.3446 I6.7500 J55.2000
N360 G01  X6.7995 Y55.2022
N370 X6.7500 Y55.2000
N380 G00 Z10.0000

All help highly appreciated, I'm getting a bit desperate with this.

Thanks,
/Risto

PS. A small correction to what I said. It does not kill Mach but actually Mach kills the X servo motor and an emergency stop is generated.

I have just run it and it ran fine but that is not a 1.3mm dia hole for me, its about 110mm
There is a jerk in a few places which may be where you are getting the servo fult but I think it i the G1 move, why that is there I am not sure if it is meant to be a circle.
Hood

Are you in Abs IJ mode as that would seem to run it about the size you said.
I have just run it in ABS and again it ran fine so could be your servos tuning is needing looked at.
Hood

Yes, both distance and IJ in abs mode and 'Constant velocity' . Large holes have never been a problem. I think I just read something about small holes being a problem with G02/G03. Anyway, I'll decrease axes accerelations and speeds to see if that helps. Thanks Hood.

/Risto

I would think actually tuning your servo drives may be needed, certainly no issues here running the code.
Hood

Hood, you are right, I decreased accelerations and speeds and now it works. So a tuning problem it is, thanks for revealing the problem.  Will have to tune the axis when I have better time, for now I'll just change the acc/speed settings to get this job done!

Regards,
/Risto

Good news, hopefully you can get some time to tune them soon so you can crank up the accel again 
Hood

Did some testing and there is no way I can get the axes die outside this particular program. The acceleration I'm using is 1000 mm/s^2 and the top speed is 6750 m/s (limited by Mach frq). Everything works nicely when accelerating or stopping to/from full speed. To me it seems as if the dying is somehow related to the helix diameter and the helix height the tool is approaching the hole with. By changing these helix parameters I can find a combination that works.  Anyway, the main thing is that it's not Mach not being able to handle the code, so I just adjust the helix parameters to get this to work.

One more question. This block:

N250 G02 Z-0.4333 I6.7500 J55.2000

is this a 3D move or is Z first run to -0.4333  and after that the circle is completed?

Thanks guys!

/Risto

Are your axis of a similar motor tuning, steps per etc? I seem to remember problems if Z was a lot slower than the others when doing helical paths.

Hood

Did some more testing. Accelerating and decelerating short 0.1 - 0.2 mm travels back and forth rapidly in the helix movement with high speed causes over current fault in the heaviest axis. It seems that it can't be fixed with PID tuning so I need to change the timing belt gear ratio or use slow speeds for those. Thanks Hood.

/Risto