[ger21]

I looked at the g-code viewer. When I run it it stops at this line
N23930G2X20.6098Y23.0182I0.0625J0.4519
and says "G Code Error Radius to end of arc differs from radius to start"

I have attached the g-code file from this. Any help would be greatly appreciated guys.

Change your IJ mode in General Config.

[JayCop]

Change your IJ mode in General Config.

I did have the same problem in mach3 before but I did change the IJ mode and do not get this error in mach anymore just in the Kmotioncnc viewer. I haven't been able to track down if there is a IJ mode setting n the Kmotioncnc software.

[PaulRowntree]

I looked at the g-code viewer. When I run it it stops at this line
N23930G2X20.6098Y23.0182I0.0625J0.4519
and says "G Code Error Radius to end of arc differs from radius to start"

I have attached the g-code file from this. Any help would be greatly appreciated guys.

@JayCop : is this the code from your CAM or from WarpDriver? I don't think my program should produce G2 or G3 codes at all, since they should be changed into short G1's. Warped arcs aren't arcs anymore.

EDIT : It IS from WarpDriver, but I see that Z=0.000. WarpDriver normally requires the tool to be zero'ed at the top of the work, and it uses -ve Z values to flag cuts. I will look at the code tonight to see if anything else is amiss. Can you post the original g-code as well?

@ger21 : thanks for the tip on IJ mode ... I never would have thought of that, and you saved me hours of looking for a bug in the code that wasn't there (hopefully).
Cheers!

[JayCop]

Thanks for looking at it for me Paul. Attached is the original gcode.

Also Paul is it possible to use the table surface as z-zero since the nominal thickness of my material changes a little each time so I prefer to zero off the table if not I will change to zeroing from the material?

[PaulRowntree]

@JayCop;
1) I have run your g-code produced by one of the Vectric programs through WarpDriver, and it ALWAYS generates the correct series of G1 codes from a G2 or G3, as long as the Z value is at or below the WarpThreshold. As far as I can see, you have Threshold set to 0.000, so this shouldn't be the problem, BUT since you are using Z=0 to be the bottom of the work, you should set WarpThreshold to be above the top of the material (see below).

2) The g-code from your Vectric program seems to missing a line [N190 I believe]. Your code is numbered
N180G00G20G17G90G40G49G80
N200T1M06
N210 (End Mill {0.125 inch})
Similarly, it looks like a line has been removed from the Warped Code you sent,
N12G0G20G17G90G40G49G80
( Passed along with only skew+renumbering )
***** Was something here removed ? ***
( Passed along with only skew+renumbering )
N16T1M06
( *** New Segment Start ********* )
( Warping code written by Paul Rowntree )
( Passed along with only skew+renumbering )
N18 (End Mill {0.125 inch})

3) The Z=0 only matters when using the roughing option of WarpDriver. If set to the bottom of the work, WarpDriver will do bad things to your material, things that don't even look like roughing. If you are not roughing (ie Passes=1.0) it shouldn't matter anywhere.

4) Setting the Accuracy to 0.0010 may be excessively small. It just makes the files bigger and the steps smaller; it should affect the G2 -> g1 conversions. I use 0.010"

I would like you to try setting the WarpThreshold to be about 0.020 above the top of your material, set the 'Verbose' flag on, and run this again. Please send the exact input and output files from this test and I will look again. So far, I see nothing wrong, and I am wondering if some round off error is at play.
Cheers!

[Khalid]

Seems your Z-axis is not stiff/rigid enough.. Also check the squareness of your Gantry...

[JayCop]

Seems your Z-axis is not stiff/rigid enough.. Also check the squareness of your Gantry...

Thanks for the sugestions Khalid. I went and checked on the stiffness. While the Z axis was very rigid (CNCrouterparts High Z plate on a R&P driven Y axis) I noticed while pressing on the z axis while it lowered the x axis was actually moving with only little force applied. I had loosened the R&P on both sides of the X axis when I was trying to figure out why I was loosing/overshooting steps. I did not tighten them back down enough especially the motors to the rubber drive pulley belt. Now that they are tight it takes quite a bit of force to move the x axis a few thousandths now. Every thing does move without binding still too. I will be able to test this out tomorrow or the next day to see if that helps any.

[ger21]

It probably doesn't like G91.1, which is incremental IJ mode in Mach3.

[PaulRowntree]

Yes, I mention that in the WarpDriver manual, I just comment it out in the source window before warping. By memory removing this line affects the mm/inch interpretations too, so make sure it is back in place for any files that you are sending to the machine and Mach3.

[PaulRowntree]

Looks good to me JayCop! Good luck with it.
Cheers!