I have noticed that there is a change in working diameter during the
return stroke of G76, and also that the return strokes are at
different radii.

Shouldn't all return strokes be along the notional "drive line" as
suggested in this forum thread?
http://www.linuxcnc.org/component/option,com_kunena/Itemid,20/func,view/catid,20/id,5023/limit,6/limitstart,6/lang,english/#13450

As he points out, it isn't important in the case of external
threading, but can be troublesome if you are internal threading with
limited clearance at the back of the tool.

The behaviour seems to be encoded in interp_convert.cc, lines
4365-4366 and 4399-4400.
If safe_x is safe, why add/subtract anything from it, why not just
move back to it, and retract?

I think this might also explain the rather worrying little "wiggle" at
the beginning of a threading cycle.

-- 
atp
"Torque wrenches are for the obedience of fools and the guidance of wise men"

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