Need help with stepper settings

Aaron, thanks for reporting in. I don't think you should rebuild your config until you let the guys have a look at your config. There are some timing settings for the steppers in the ini file that may need revising. From this point we'll probably be asking you to edit the files directly in a text editor. I prefer geany which you can install by typing sudo apt-get install geany.

I'm sorry, I'm not up with imperial gears but linuxcnc needs to know how many step pulses per inch of travel. Someone else will know the formula.
So start by calculating the distance travelled per revolution . From what you've said that will be 15 teeth. (measure it along your rack if need be) So multiply that distance by 200 x microsteps, then the scaling is that number divided by inches of travel per rev.

As far as microstepping goes, start with at least 10 x but becasue you have direct drive, this needs to be as high as possible (which changes your pules per inch)

rodw wrote: I'm sorry, I'm not up with imperial gears but linuxcnc needs to know how many step pulses per inch of travel. Someone else will know the formula.

For metric gears the PCD = teeth x module
So, a 20-tooth 2mod gear will have a PCD of 40mm. So it will roll 40 x pi mm down the rack for each revolution.

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.

i have attached my hal and ini files, thank you all for the help it is very much appreciated. this is my first attempt at anything like this and i am in over my head to say the least.

My first guess would be that you have the acceleration too high (~1/3G)

Your acceleration of 136 IPS/S and maximum velocity of 1.66 IPS
means only 0.0123 seconds to full speed. This is likely to stall your step motors

A good starting point for acceleration is about 10X the maximum velocity

Hi
the DM556t are non Digital there is maybe only a improved H-brige 542 inside
so the timing is 3500 3500 10000 8000 in the settings
DIRSETUP = 10000
DIRHOLD = 8000
STEPLEN = 3500
STEPSPACE = 3500

what microstepping do you got
you shoudt use on the T modell not more then 800steps per stepper Revolution
What Voltige is on the stepper for High speed you need 48V or even 72V
and what is the Driving system BELT ,Rack-pinion, Spindel

we run 8 Plasmas (2onDM556D) mutch faster then the DM542T

Attached is the manual 556t
I use it with nema 23, 10000 10000 5000 5000 and 800step 4xmicrostepping.
They are working OK.
Problems I had only when latency was to high on my laptop. But tweaking a little bit solved that problem.