It seems odd to me that Mach3 doesn't account for this, and it ought to be classified as a bug. This latest job making a tapping arm reminded me in short order that something needed tending to. I lowered the X axis accel to match the Z and forgot about it. I wouldn't have noticed it had it not been for easing back the accel on the X axis because it was faulting too much when I run with two 6" vises on the table. In any event, as I discovered early in my machining of the axis arms, it isn't a good idea to have different accelerations on two axes. I had heard on one individual having an issue with wildly different motor tuning on a knee versus his X and Y axis. Due to the high rate of feed (50 IPM) and some abrupt changes of direction to follow the profile, I hadn't really encountered the problem before. I discovered this was a problem while making my tapping arms. Mach3 Users: Make all of your Accelerations the Same on your Axes! If you didn't think you had much noise in your system, maybe its because you didn't have a way to check? Ground the cables at the electronics cabinet end (not the machine end, that can create ground loops). The noise went away immediately and life has been good since. No worries, I did what I should have done to start and grounded the foil inside my cables to the CNC electronics cabinet via their connector. I was getting a gratuitous limit fault from noise about every 2 to 3 minutes. That's when I became aware of just how much noise there was on the lines. I recently got my Home Switches going and decided to go ahead and enable them to act as limit switches too. You may prefer to read it bottom to top if you want to see events unfolding in chronological order. It's written blog style, with the newest entries at the top. Conversion of my Industrial Hobbies RF-45 milling
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