WOW>>>HAHAHAHA!!! You guys rock! Hood...you were absolutely correct about the speed was too fast. I about jumped out of my shorts when it took off after making the suggestions of the second kind sir! I cut this design, it took 2 hrs 40 minutes. Now I recut, took 4 min 48 seconds! Plastic dust was launching. I was about to do a manual over ride and slow it down but thought heck..let her go and away she went. She cut that baby out super sonic speed. It did break off a few pieces, but I actually don't think the speed was the issue, the rod was an extra one where the inside hole I accidentally bored a touch too big, so the depth of the hole ended up going all the way through the rod and that's why the center of the A disappeared and part of the inside of the M broke off. I will slow it down next time, but not hardly by much. I got the boxes on the top of the two letters perfect too.
This was the suggestion to try in the visual mill and it worked out.
Can you try setting the Co-ordinate output in the post to non-modal and see if this makes any difference?. To edit the post processor, select Set Post Options (2nd button on setup tab), Click edit next to current post processor. This opens up the post processor generator.
On the General tab, clear the check box for Co-ordinate under Modal Output. Save and close the post processor.
Now post process your toolpath.
Setting the co-ordinate to non-modal, outputs X Z and A co-ordinate motions for every line of code.