Why do I get these nasty corners?

I’ve seen corners like that before when the feed or acceleration settings were just a bit too high. Even if the pinions are tight, the machine can still flex a little under load, especially at 3/4” depth. You might try a shallower pass or drop the feed rate 10–15% and see if it smooths out.

Where do you change accel settings?

I dropped the speed 25% and still had the problem.

You’re on a Mach machine right? There’s a good thread about that here: Mach 4 Acceleration/ Deceleration

Before you even reach for a software solution make sure your machine is mechanically sorted out.

Pinions are tight as a drum, but I think I found the culprit. The Z-axis carriage mounting screws have worked themselves loose and the whole thing had a bit of pivot slop. I put some thread locking compound on them and re-tightened them. (I suggest other owners do the same). Fingers crossed this fixes it.

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