IHSS60-36-30 motor tuning/issues

Look at actual tool diameter and compare it to tool diameter in CAM program.
Spindle run out will also cause a size problem.

So here is image with all important settingsTool I'm using is 5mm flat mill 3 flute (and is brand new, few cuts so wear is out of questions)I didn't see compensation at all in settings and Gcode there is no G41/42 so that is off also 
Attached milled part 

I know this sounds a bit wild/ like a longshot, but having measured ALL the dimensions at 1.12mm off, I would questions my metrology (if cutter comp, stock to leave and tooldiameter are ruled out).
Any scaling or ballscrew error in an axis should not result in the same absolute error over different distances. You mentioned that the square is off, are both of by 1.12mm? Some questions for the circles: Are they off the same way across both main axis (xy)?
The attached part looks ok, albeit the spindle trim may be off a bit and the cut shows some vibration.
Do you have a known 10mm reference (and be it an endmill) - does that truly measure around 10.00 with the same caliper? It got tricked by an offset caliper before, hence my question...

Share the settings for the 2d contour.
2d pocket is for roughing out the pocket. Finishing to size should be done with a 2d contour toolpath.
Since the difference is the same everywhere I expect a CAM issue.

Oher question, depth of the pocket, what was the difference there?.

tommylight wrote:

Screenshot of the path in LinuxCNC? What dimensions does it show there?

I have find fix and now is much much better (still have a room for improvements)
But is anyone struggling with this JMC IHSS60 motors please use next settings:


DIRSETUP   = 500
DIRHOLD    = 500
STEPLEN    = 5000
STEPSPACE  = 1000


Here is fresh milled image with kaliper measure
 

Left bottom circle(Fusion: 10mm): 9.91 milled
Big circles(Fusion: 20mm): 19.95
Center square(Fusion: 30mm): 29.95 milled
Depth (Fusion: 3mm): 3.01 milled

I'm very satisfied with result, took me a while to figure it out but works now....
Still need to learn how to do better finishing surface and speeds/feeds
Thanks everyone for looking into and giving me ideas image missing /media/kunena/emoticons/wink.png

P.S.
Github with all my changes:  github.com/ddB0515/CNCMakina
Still WIP so will be changes with time