Need help with stepper settings

andypugh wrote:
For Imperial gears the equation is reversed (it's just like TPI and mm pitch...)

PCD = teeth / DP.
So, a 20-tooth 10 DP gear will have a PCD of 2 inches and will roll 2 x pi inches for each revolution.

so 20/15 * pi = about 2.356275 inches per revolution
Say 10x microstepping (but get it as high as you can) == 2000 steps per rev => 848.797 steps per inch
That will be your step_scale in your ini file

Thanks to everyone for their help! Turns out my problem was 3 fold. First I was way off on my stepper scale and driver settings. Things started moving the right speed with those fixed then I had the acceleration way too high stalling the steppers and lastly on my x axis bad butt connectors were causing all sorts of problems so I soldered all wire connections. Now everything seems to be working as planned so I can move ahead with setting up all my limit switches and connecting my hypertherm.

I for sure would have never gotten these issues worked out without the help so thank you again!

Great work! Just experiment a bit with the microstepping. You will need to get this as high as you can with direct drive steppers to get smooth motion (which may still elude you). There is a bit in the primer about the desirable distance per rev and you are about double. I get away with about 30mm/rev but you are up around double that! Let us know how it goes.