Just wanted to thank everybody for all the excellent feedback. At the  
moment I'm leaning towards this being a cable shielding or grounding  
issue with my driver board (as suggested first by, I believe James  
Reed). I have had suspicions that I had some sort of grounding problem  
for a while, and his explanation of how a bad ground can cause a  
signal to be misinterpreted and reverse the feed direction made a  
light bulb go on. I'm still figuring out exactly what I'm going to do  
to resolve it, but I think that's the direction I am headed in.

A brief note about the 40 ipm feedrate I have been trying to test this  
at: I should have noted that there was almost no load on the cutter  
during these tests. I have been cutting about .04 inches into a wooden  
board for these tests, just to try and isolate what it will take to  
the motors to work smoothly and reliably. I would definitely slow it  
down if I was making more realistic cuts. Also, my X + Y screws are  
each 5 tpi, so the setup is sort of geared for zippiness as long as I  
don't try to cut anything at all substantial. :-)

Thanks for the notes on the HAL stepper settings and possible stepper  
resonance issues. Hadn't heard of ether of those before but will keep  
them in mind as I proceed.

Thanks again for the overall level of response on this issue. I have  
been impressed. I'll let you know if I come up with a resolution (or  
more questions :-) )...

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