Using the express tool "modify, flatten objects" is there a setting for the accuracy to which the resultant arcs match the source spline? I am handling drawings for the creation of tool paths for a Flow waterjet machine and I have seen the resultant arcs differ from the original spline curves by a substantial amount (up to .15in) and often have to hand overtrace the splines. Also can I set it to substitute lines for arcs if they are too flat. I am working with a CAM software that doesn't always convert splines well and has a bad time creating workable tool paths if the arcs are more than about 1000in radius.
Have you tried SPLINEDIT command and convert to Pline with precision?
or using autolisp from CADALYST 12/03 AutoLISP Solutions SPLINE-TO-PLINE.LSP ?