Radius to end of arc error

Hi everyone, I've come across an error that I have not been able to figure out.

The error reads
"Radius to end of arc differs from radius to start: start=(X7.5183,Y5.6580) center=(X7.6296,Y5.6219)r1=0.1171 r2=0.0753 abs err=0.04179 rel_err=35.6966%"

I have adjusted the amount of decimal places in the post processor from 4 to 9. This ended up fixing this error on a previous file but did not work for this file. I have also tried adjusting the CENTER_ARC_RADIUS_TOLERANCE_INCH variable in the INI file. I have also made sure the tool table offsets are correct.

Any suggestions to help fix this issue would be appreciated! Thanks!

I encountered this in Fusion360 (in some cases) when using helical moves. In my case, believe it's something in the way F360 constructs the compound moves of a tool path with a continuously varying radius combined with a smooth ramp-down. The two ways I've worked around it are:

1. Turn off Allow Helical Moves in the F360 post processor options
2. Turn of Lead In and Lead Out in the CAM>Operation>Linking options.

If you're not using F360, I'm not sure if this helps. I know this isn't the ideal solution to the problem, but it can get you back to work. I haven't broken any tools with this approach...yet. I have been distracted by other priorities, so I haven't had time to dig into a more appropriate fix. It could be a bug, but I don't know enough to make that claim.

Hi Dan! I am not using Fusion for this project, but I will keep that in mind for future projects. I am currently using vectric aspire. I have been able to get two lines further by changing G90 to G90.1 at the beginning of the file, but am still getting the error.

That happens when you try to run a arc that is a segment of a radius, or if you have tool compensation and the selected tool is thicker than the smallest radius in the gcode.

An update: I ended up editing the post processor file in aspire. I changed the arc parameters from I J to R. This seemed to fix the issue.

Nice.