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Helical plunge boring can be done with no guess work at all. I have been doing it for years with excellent results. there are a few things that are very important to make it work properly.

This...

The reason you are getting so many lines of code to machine the arc,
is because you or not actually machining the arc in a Z-Level cutting operation.

You are actually machining the surface...

If your punch has a heel on it, your wire guy can program the wire path to leave the tab in that area. Then while cutting it off he can program it to step into the side of the heel a small distance...

If you have the books on the controller look in them. There is a parameter that controls how long the controller will wait to receive the program once the com port is opened. My controller is set for...

Thanks ToyMaker94566,

I believe problem is with the post. It outputs proper angle but not proper letter for axis rotation. Also leaves out the clamp & unclamp command.

I tried all 4 axis post...

Most Cam systems will work fine with an IGES file or if you only need a flat profile view on scale you can use a DXF file.

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Is anybody using Velocity 5.1 for 4 axis indexng on a horizontal with a B-axis?
Surfcam says that a seat of 3 axis plus will do 4-axis indexing.

I have read and done everything in the help files...