@jay_s_uk Oh man, you're right. I updated DWC but for some reason the actual RRF didn't update. I fixed it. Will try again.

@OwenD This is the very definition of a helpful answer. Amazing when it is explained properly how you think to yourself "that was so easy, why couldn't I figure it out?"

@Phaedrux I'm part of the Millennium Mills design team. I'd be happy to show you how our Milo CNC mill works and how this specific problem is affecting efficient toolpath generation. I think you're also in Canada so I could show you live if that works. I've been avoiding further macro generation because I don't want to recommend these methods to our users if this can't be fixed.

@AndyE3D OK, I think I found out the cause of the problem- at least I have a theory... In my macro I had the z probe macro and xy probe macro making three samples and then averaging them to come up with the final WCS figures. The averaged figures have more decimal places and this seems to mess with the ability of the board to process a longer multi-machining-process file. When I remove the averaging procedures from the probing macros everything seems to run fine.

@AndyE3D OK, I think I found out the cause of the problem- at least I have a theory... In my macro I had the z probe macro and xy probe macro making three samples and then averaging them to come up with the final WCS figures. The averaged figures have more decimal places and this seems to mess with the ability of the board to process a longer multi-machining-process file. When I remove the averaging procedures from the probing macros everything seems to run fine.

@AndyE3D Thanks for looking at everything. I did try with M0 removed and had the same trouble. I haven't used any triggers or daemon.g or anything fancy. I will try inserting an M400 in the macros.

In my most recent attempt at a multi toolchange file I removed the M0. Early in the job the z axis decided it wanted to dive at top speed into the workpiece. It was alarming.

As before when I take exactly the same job and break it up into individual jobs everything runs fine.

@AndyE3D So the order of macros is:

1. Centre Workpiece.g is run so that the WCS knows where the top centre of the workpiece is.
2. The Tall Axle Insert Whole Job.gc file is run and before milling starts and with each tool change it calls:
   a)ManualToolChange.g which then calls
   i)ToolZProbe.g

There are two sensors used.
1. a sexbolt sensor which is used to determine xyz probe length as well as tool length
2. an xyz probe mounted in the spindle for the duration of the Centre Workpiece.g process

There is also a global variable defined in config.g which is used to exchange z offset information between the Centre Workpiece.g macro and the ToolZProbe.g macro. You can see it in this file

config.g

@AndyE3D And before the job is run a macro is run to set the WCS to the centre top of the workpiece:

Centre Workpiece.g

@AndyE3D That macro also calls a macro that determines the tool length:

ToolZProbe.g

@AndyE3D Really appreciate your time on this. I have attached the manual toolchange file. My macros are admittedly not the prettiest code since they are a work in progress. We will develop final macros when the concepts are proven.

ManualToolChange.g

@dc42 I've been wanting to do a video for the group to show "how to" do a job with tool changes but I keep delaying because nobody wants to watch me freeze up my mill. It used to work fine. I have a nagging feeling that it has to do with the extra precision now that I do multi-sampled averaged probing to set the WCS. Perhaps the extra decimal places are confusing the machine.

@dc42 Indeed, it started as me trying to troubleshoot the problem myself and I wasn't able to rename it when I couldn't solve it. Please rename the thread if that's possible.

@Phaedrux I'm part of the Millennium Mills design team. I'd be happy to show you how our Milo CNC mill works and how this specific problem is affecting efficient toolpath generation. I think you're also in Canada so I could show you live if that works. I've been avoiding further macro generation because I don't want to recommend these methods to our users if this can't be fixed.

@dc42 I uploaded the file as you requested. Still hoping you can look at it.