On 12/11/2015 2:03 PM, J. wrote:
> First hunch:
> Sloppyness in the z movement or in the spindle bearings. With lost steps as a 
> result.
>
> Because when you increase the 'load' the sloppyness is taken up by the back 
> pressure from the cutter.
>
> This problem has been the downfall of many stepper motor artists. A stepper 
> might lag as much as 2 steps from the driver output in certain conditions, 
> and yet recover again if running conditions are normal. But any mechanical 
> upset in that phase will result in lost steps.
>
> Happy hunting.

What's the precision rating of the stepper motors?

The smaller setting could be less than the motors+mechanicals of the Z 
axis can handle, and gravity is conspiring with the system to ensure the 
error is always downward.

Can you incorporate a Z height probe/setter and have it automatically 
recalibrate Z height before each pass?


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