4th axis post SOMETIMES omits the "A" rotary coordinate

[myk]

I have posted here a few times about issues with my post processor and I have attached the post processor I am using below.

I have a long program with more than 50 operations and my post processor SOMTIMES neglects to put in an "A" axis rotation. Meaning the machine will put a feature on the wrong side of the part, or at least it will try before human intervention. It appears to be random because sometimes it will omit the A on an operation and other times it will put it in. If I post just the operation (not the full program) with the missing "A"rotaion the post will include the "A" axis rotation. But if I post the entire program it will omit the "A" rotaion on some of the operations. Because the A axis always returns to 0 at then end of each operation when the rotation coordinate is omitted the machine will go to the part and try to machine on the top when it should be at some other rotation other than zero.

An example of code is below, there are seven rotations prior to this piece of code and they all work fine:

N3719 G01 Y-1.001

N3720 G19 G02 Y-1.201 Z0.354 K0.2 F50

N3721 G00 Z1.5624

N3722 G17

N3723 G30 P1

N3725 M09

N3726 M01

N3727 G116 T4 Q3

(A180-BACKSIDE POCKET)

N3728 S12000 M03

A180 (<MANUALLY ADDED A ROTATION)

N3729 M08

N3730 G00 X-3.1425 Y-0.059

N3731 G56 Z1.4776 H04

N3732 Z1.0776

N3733 Z-0.1058

N3734 G01 Z-0.1558 F80

I have had to manually go through the program and check each tool and each operation. With over 50 operations this is a nightmare and very time consuming. To make a change to the program and repost is an awful thought but because this is a prototype part there are many changes.

Any thoughts on this? I have no idea why it would sometimes omit the "A" rotation in a full program but include it when posted individually.

Thanks in advance

[boopathi.sivakumar]

@myk 

Could you share the project which is having the issue!!