While trying to troubleshoot a gaining/losing step problem, I developed a test block code, hoping to help identify the problem... to be subject of another thread.
The current issue is the actual run produces odd curved ends on what should be rectangular ended slots. I thought it was a result of Constant Velocity, so changed to Exact Stops, and the problem got worse.
The cutter is a 4FL 1/4" carbide ball mill held in an ER11 on-size fractional collet, running at 19000 rpm, 175 ipm, 0.3125" depth per pass,in soft fir... so deflection shouldn't be a factor.
The attached pics show the run result, TurboCAD/CAM path and simulation, and CutViewer simulation. I also checked the code, and it defines rectangular paths.
Dial indicator check shows no backlash. Mach3 ver .066.
Any suggestions?