Thanks for the quick reply. I am using a caliper to measure the diameter. Yes, .005 may not be much, but I had tried larger numbers. I have been checking the machine since all my holes fall short some .020 from the set diameter. I've checked for backlash, I've changed bearings, and it all seems ok. I've changed router and bits as well. Finally, I had decided( for production purposes) that I had to get things moving again, thus the wear comp. Here's my example.... a .375 hole comes in at .355. If I enter .100 in the tool diameter table, I should get a hole larger than .355. It doesn't. If, on the other, I enter a -.020, Mach 3 opens the hole.
I've spent two days on this before seeking help, given that at this point I've exhausted all possibilities. The holes are round, but they always come in small. Yes, I measured the tool diameter and it's .125. I've reduced acceleration and velocity settings and calibrated the steps. A micrometer shows accuracy within .001".
The only thing that I have not tried is a multipass in addition to a multi depth code. I notice that the wear correction barely travels one turn. Also, when in tool wear compensation mode, Mach 3 shows a spiral pattern despite the machine cutting correctly.
tc