I'm scratching my head here with a situation I'm currently having. Ill start from the top. I have a benchtop grizzly mill which is converted to a cnc with double nut ball screws, nema 34 stepper motors, microstep driver (ebay). This machine ran great for the past year but recently I've been having problems with motors stalling. I quickly jumped to the conclusion thinking it was just my motors were out of wack and stupid me started changing everything around with the motor tuning and mach 3 setting to get it up and running again. Needless to say it was my ways that needed the adjustment not the electronics. I believe I changed all electronic settings back to the way I had it and continued on making parts.
Heres my issue. I make and sell small aluminum covers to a local company. The covers are made from aluminum and measure .250 thick x 2.43 x 1.73 . I drill all the blanks first then they got bolted to a jig so I can do the outer profile to that size. My sizes are coming out around 2.46x 1.75. I though maybe its just the motor tuning but using a dial indicator I'm within .001 with no backlash, I then changed my steps per on the microdriver from 1600 to 800. Same exact results. It can't be the program since I've used it hundreds of times. I use the exact same cutter every time. Would the Kernel speed affect this in any way? I'm currently at 45000hz and I believe previously I was at 25000hz