Dimensions Slightly Off

Hello,I recently retrofit an axiom router to use LinuxCNC. Everything works pretty decently. I am running into a problem where the dimensions of parts will be every-so-slightly off, but enough to know it's not just a tolerance problem. I think I've whittled down the problem to movement between cutting operations - when cutting a pocket (for example), the pocket is just the right size. But when it travels to the next operation (drilling a hole for example), the position of the hole will be slightly off from where it should be. Especially on longer parts when the travel is significant, the error is relatively larger. I've tested my stepper settings while setting up, and it jogs the correct distance.

I tried to lower the max velocity and acceleration, thinking that it could be overshooting at the higher travel speeds. This did not change anything (compared to the same part at a higher travel speed). Could it be a latency problem? I do get a latency warning every once in a while. Any other ideas?.hal and .ini files attached.

Let me know if this post should be moved to another category - first time posting here.

Thoroughly check the mechanical side, like every single component. More often than not that is where the problem is.

It was running very accurately with the old controller (RichAuto B18) - and I did not touch any mechanical components when switching to LinuxCNC. That's why I ruled any bad mechanical components or connections out.

I changed the orientation of the part I was using to test error by 90 deg and got worse error. I may just run through a new setup of LinuxCNC and see if that will fix anything.

There's something off with your ini & hal files. Both exactly the same size and seem to binary files.

Here is an example of what I am experiencing   . Each run is a different pocket run with the steppers at different microstepping values. Each time the bit goes down to start pocketing a new layer, the edge of the X axis of each is off from where it was from the layer above. What's weird is that each layer is lined up with itself in the X axis.

I'm not getting latency problems. I did input random high values (I think 20000 ns for each field) for the driver setup page because there is literally no information online about that (yes, I did contact the manufacturer - Troy).

I'm about ready to throw in the towel and buy new stepper drivers, but the things is, the drivers worked just fine not one week ago with the old controller.

Like I said your hal and ini files are not readable. Please repost them.
What drivers are being used ?

Losing steps should be quite easy to hear
if you run your program cutting air and with the
spindle off.

To verify that its not a mechanical issue that has crept in,
can you still run the old controller?

Sorry about the .hal and .ini. Try these:    

Drivers being used are old Troy (chinese) drivers (that worked fine with the old RichAuto controller): 

User manual here (drive file because it's too large for forum limits): drive.google.com/file/d/1BSWBPFRsO2LLnaD...kK4/view?usp=sharing

I did switch the X and Y axis steppers and the issue still happened on the same axis.

I can hear steps being lost while it is running, just not sure why they are being lost. I've tried each microstepping value I can, and I get the same problem.

I could try the old controller, but I'd like to do that as a last resort because that would take quite a bit of time to set back up.

I did tighten all mechanical connections.