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Hi Don,
We also used to experience such problems.. looks like the are inherent of Profile Sequences... so I avoid using them in toolpaths where the problem may arise...
What I do to get rid of this problem is to use Trajectory Milling Sequences with the option CONNECTION_TYPE set as Z_LAST, as you can see in the attached screenshot. Works like a charm!
HTH
Regards,
Daniel Santos - Sr. NC Programmer / CAM Support
Liebherr Aerospace Brasil
Regards,
Daniel Santos - Sr. NC Programmer / CAM Support
Liebherr Aerospace Brasil