You are DWO, are your rotary axis actually an ISO A/B?  All Haas machines using DWO/TCPC have to be defined correctly with the ISO rotary nomenclature. Older Haas trunnions were labeled A/B. This has been corrected with the NGC. 

Are you using G5.1? Have you tried filtering the code in Mastercam? 

The issue with this post is pretty well documented on this forum. 

https://www.emastercam.com/forums/topic/71325-posting-1-deg-inc-b-axis-move/

How tall is the wall. If its short, should not be too bad. What is the tolerance?

It can chip if your tools are not sharp. Make sure to face below the gel coat by .02 or so, so it does not delaminate. Making a chip with it will make the tools last...longer. I always cut it with coolant and run additional filters to collect the bulk of the crap. If you run coolant, run it on a machine with a small sump, because no matter how well you filter the coolant, overtime it will build up in the tank. 

If you do it properly it will not chip when facing over existing holes. 

People who don't have a 3rd party simulation software. Which is the majority of people with UMC-750s. 

Postablity wins hands down in my book...IHS and Mastercam's fall short in the machine simulation realm. 

Are you sure pre-staging is not causing your issue? Seems to me that you are prestaging, then with the large tool going back into the carousel, it then rotates back to the large tool pocket and continues with the double tool change.  

You will always have the double tool change on a machine without an intermediate station, as it always puts the large tool back into the pocket with the adjacent pockets blocked out. 

This trunnion is standalone so it can be mounted on machines where the "A" rotates around the X or Y depending on how it is physically bolted to the table. Smaller Trunnions, where it maybe switched back and forth I usually don't sweat it. 

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^^^ unless it's a Haas.

They fixed the A/B assignment issue in 2015 on their standalone trunnions. Now you have to have it defined correctly when using TCPC/DWO. 

Feel free to shoot me any questions you might have. 

https://diy.haascnc.com/reference-docs/mrzp-and-dwo#gsc.tab=0

Haas' stance.

You can achieve much better results on a UMC by running Renishaw's Axiset to more accurately find the center point of rotation. I run a 5 sided test program and achieve +/- .0007 on all wall thicknesses without breaking a sweat, using DWO. Machine warm up is also key. 

If you are not using TCPC or DWO than the Generic Haas Trunnion post is pretty good, about 5 or so minor changes have to be made. 

If you are using TCPC/DWO with the newer control. Taking Colin's class would be the most economic way to get a good post. 

You could write out the Macro call and associated commands as a manual entry, so it posts out correctly. 

I would make sure to change your 4th/5th axis feed-rates to inverse, unless your machine is too old to have inverse (1994ish).  

frc_cinit    : no$   #Force C axis reset at toolchange

changed this after looking at your 2nd file

sorry that was the original file, I did not see your post

I used the generic 4 axis machine definition and renamed it. The original vertical machine def was still thinking it was a vertical, it was just changing the axis letter designation based on what was defined for the rotary, but angles were still relative to a vertical.  The Front view was coming out at 90, which is what it should be on a vertical. And the right view was alarming out because it was still thinking it was a vertical 4th axis.

Things that I changed

-Used standard 4ax horizontal machine def

-turned on inverse time feeds in control def, and set max inverse to 45000.

-Turned on lock and unlock commands in the post. Haas does not require them for positional work, but requires the unlock for simultaneous. So to get it to work with the logic in place, you have unnecessary unlock and lock commands for positional work. It slows things down a bit on the machine, but its a post that is provided with Mastercam so....

-Relabeled the "B" axis to an A axis in the post because of older Haas rotary axis designation... 

liner-civicegg.ZIP

Looks like the post no longer handles the switch from vertical to horizontal, now the machine definition does. 

Max inverse time feedrate is 45000. If you have rotary feed moves on an older Haas you should be using G93. Sure you can set the diameter in the control and use g94. But it is half arsed.

Post your updated z2g file. 

This might be a deal breaker....it requires DPRNT. I have been able to DPRNT to USB on the last few machines  and I forgot because of how easy it is. DPRNT through RS232 is such a pain. 

If it has a probe, and macros it should not matter what control it is. But if you purchase it, they should take care of the leg work, you would just need to provide the macro variable locations.

I have solely used it on trunnion machines, but it is not limited to 5 axis mills. 

AxiSet will give you the centerline of rotation deviation for XYZ to adjust the parameters. It gives you a plot just like a ballbar, you adjust and rerun until you have achieved acceptable error. AxiSet has to be purchased, it has its own set of specific set of macros, has the excel sheet to analyze, and also uses the typical Renishaw measurement cycles in addition to the specific ones. 

I don't know if AxiSet can be used to check angles, I have only used it to check centerline of rotation. 

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One of the really great things about Blaser is that they won't just sell you something. They will test your water first to determine the best coolant type and concentration for your machines and parts.

I can not express how I hate Blaser. I worked in a shop that used more than a 55 gallon drum in a month, zero support for the ongoing issues we had. Switched to Chemetall and never looked back.  I go in roughly 10 shops a month now, I can tell who runs Blaser, just by walking in. So apparently it is not just my old job. We had skimmers and aerators on each machine, checked the concentration and pH, Blaser still smelled like vomit.

The first 8 years we ran Blaser, it was flawless, the last 2 years were horrendous. It makes me believe they changed their formula. As nothing changed on our end.

Techcool from Chemetall. Cut a lot of different types of plastics, and fiberglass blends. No adverse issues with any material I ran it on. 

Also, if your coolant rep isn't willing to address your issues, it is time to move on.