Hi Dan:
Vacation was great, thx.
Um, for the over travel ,override the FaceWidth settings. By default,
the program will use the actual gear width, and adds enough that the entire
saw blade emerges, overkill for most, so override the face width to the actual width of the gear for no wasted motion. It was recently recoded to make sure the blade is out during any angular motion..so check that is you modify the facewidth for more efficient cutting.
Nothing you can do about the pulley root depth. The 4th axis is actually not
computing its toolpaths form the numerical data, its a collision detection engine, it looks at the actual gear or pulley and computes how close it can move the tool to the 3d stl object's tooth shape. This makes it impossible
to do depth modification other than to modify the object. OK for gears, but the pulleys are defined shapes, there was no other possibility as the pulley
specs often simply dictate curve centers and radii as part of the spec. No actual dedendum information is provided for some types..
Art