I have been having some issues where my cuts were oversized (for profile cuts) and undersized (for pocket). This is on an Avid 4896 PRO with a 8.5 hp spindle. Material is 3/4" ply. Bit is a 1/4" compression. Other than the size, the cuts looks perfect.
investigated calibrating the axis motors and made some minor adjustments on step units and backlash, but nothing major. After I had both X and Y dialed in perfectly, I ran tests. I cut two 3x6 in. squares from the same 3.4" ply with the same compression 1/4" endmill I was using before. The pocket test was almost dead on, but the profile result was 3.0325" x 6.0325.
The only thing I can imagine is that I am doing something wrong in the software. I have tried cuts with both V-carve and Fusion 360 with similar results.
Any ideas as to next steps to troubleshoot?