Hi Aaron,

I've recently been messing about with microstepping drivers trying to 
get precise rotation and some speed out of a little lathe head. I found 
that microstepping gave me all sorts of problems and that, at 1/8 steps 
- the limit of the drive I had, the highest possible speed was much 
reduced and lost steps were common. Also, set ups in the .ini file 
became more critical so that I was having to use velocity settings to 
the second decimal place and that an increase of 0.01 would make a 
noticeable change in velocity. I decided eventually that microstepping 
was too risky and so I have settled on 1/2 steps and different pulley 
ratio..
Your problems are undoubtedly with the values set in MAX_VELOCITY and  
STEPGEN_MAXVEL in the [AXIS_x] section of the .ini file which are the 
values that adjust the rapid speeds of each axis. The values in the 
similar settings in the [TRAJ] section limit the velocity for the whole 
machine and so should be just a little higher then the highest values in 
any of the [AXIS_x] sections. The same applies to acceleration values...
My set up was in metric with the latest release of EMC2 on Dapper Drake 
on a 1.7GHz processor PC with 1Gb ram and using a NEMA 23 stepper 
driving a watchmakers' lathe headstock through toothed belt drive.

Best wishes,
Ian
-----------------------
Ian W. Wright
Sheffield  UK

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