Hello,

I have a home built machine that has run perfect for about 6-8 months with no issues. Within the past week, the z-axis will cut as told to do so in Mach3 or sometimes it will cut 1-3mm deeper than told to by the Gcode in Mach3.

Why would a machine cut perfect files as the gcode is wrote half the time? the other half of the time if the gcode says 2mm, it dives in at 5.6mm and cuts the file?

Facts of the problem.
1. If I write a file in Aspire, it will save as a Mach2/3 ATC Arcs txt file - no problem.
2. Mach 3 can open the file and run the file.
3. Lets say I want the file to cut at 2mm - it's 50/50 if it will.
4. If the CNC starts cutting the file it may start cutting at 4-5mm. If this happens I can shut down the cnc on Mach3, close the file and reload the file, restart the mill and It will cut 2mm.
5. If the cut goes deeper than what the Gcode says too Mach3 will see it and display the true depth.

Hardware
NVUM V2 5 axis controler
DM542 Microstepper drivers
Stepperline 23HS45-4204S stepper motors

Software
Vetric Aspire
Mach3

Things that have been accomplished, checked, and rechecked during troubleshooting.

1. The machine is grounded 7 ways from sunday - Good grounding!
2. The machine is calibrated- Perfectly
3. All units are in metric.
4. Z-axis stepper driver DM542 has been replaced.
5. All mechanical things on the Z axis are clean, tight and lubed.
6. Homing limits checked.
7. I slowed down my Z-axis in motor tuning.
8. I deleted Mach3 and reloaded the software and licence.

If anyone can help me out, it would be appreciated.

The American stuck in Germany,
Jeffrey