Stepper to G540 to a pc running Mach3 doesn’t have a way to add a feedback signal. It’s open loop. Closed loop steppers have an encoder which feeds back to the driver and sometimes a dedicated motion board(not using Mach).
You either need more power (assuming the steppers are stalling) or need to lower the cutting loads. Btw G540 on a large nema 23 stepper generates a decent amount of torque. I use this combination but my steppers are 4” long. You can only put so much power into that size machine
Since you already have the drive system, I would try to lower the cutting forces: Different cutter, higher spindle speeds and or less stock. Are you sure the spindle didn’t stall? Cutter load up with aluminum?
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