Strangely losing Steps in X axis. Help pls!

[rodw]

Review your decision on micro stepping. I have read opinions, possibly true, that micro stepping decreases torque. If you do not get a benefit from it then try not doing it. I think that in a setup like yours you won't see any benefit in the end product.

It may have been true once but its a load of crap today with decent drivers. I've attached a screen dump from my LAM Driver showing the difference between 800 steps/rev and 25600 steps per rev. But it does point out you need to be able to step at 32000 kHz to use the smoothed operation. Fortunately my hardware can run step pulses at 10 MHz.
I've run 20x microstepping on DM542 drivers for years and never observed any reduction in torque.

[cncuser1]

rodw: I'm happy to defer to those with more knowledge