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My dad machines little resistive elements for a customer of his. These
are generally under 1" dia and we run multiples of up to 8 at a time on
a custom pallet setup. We've tried using G92 to set offsets for each
nest, no subroutines; G92 with subroutines; G91 with and without
subroutines; and if a particular job is going to show lost steps, it
doesn't seem to matter how we approach it. Some parts do not lose steps.
Each part will show a different pattern of lost steps. The pallet base
has a .500 dia hole that we indicate from to establish datum, all
pallets and all programming is referenced from this hole. It's real easy
to drop an indicator in and check for lost steps.
For example, one particular part run in multiples of 8 parts per pallet
might show .0013 lost in X and .0003 lost in Y every for every pallet
load. With the tolerances on this job, Dad can let this accumulate over
two pallets before having to rezero. This is so consistent that he
stopped checking after every two pallets and simply would jog X.0026
Y.0006 and rezero. After running several hundred parts, he'd check with
the indicator after the last two pallet loads and be off exactly
.0026/.0006. (I don't recall exactly the sign (+/-) of the error or
corrections, but the numbers are real close to what he runs into)
This is with a program that does not use G92, it's done with geometry in
a subroutine, we move to a set entry point, enter the subroutine, enter
G91 and machine features, then back to G90 and exit the subroutine.
We lose NO steps in the Z axis.