Drive Surface Distortions on 4-axis machine

[outlier]

Hi all, I am writing to try and get a better handle on some unexpected (and unwanted) aspects of using DriveSurfaces on 5Xtra. Is there a way to limit the toolpath generation to just 4 axis? The posts come out fine, but are always a bit smushed in the X (trunnion) direction if the drive surface has an slope in this direction and these deformations show up on the workpiece. It seems that the toolpaths are being calculated as if they were being cut with a 5 axis machine where the tooltip would be normal to the surface. This is illustrated in the view from the Top Cplane where the surface being cut is the drive surface, but the tool path does not reach either end due to the surface's convex shape in the direction of the A axis.

Any direction, suggestion, insight, or better yet solution to this problem would be extremely helpful. Many thanks, O


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[williamsmotower]

Have you tried 5x revolution toolpaths? They are simultaneous 5 axis, but the 4th axis does most of the work, the 5th only moves a few degrees.
In 5x mode, I draw a "spindle line" and a "revolution line" for reference, then I use these lines to click on in the 5X revolution box.

[williamsmotower]

I forgot to mention if you strategically place/angle these reference lines... it limits rotation.