diff --git a/src/Mod/CAM/PathSimulator/AppGL/MillPathSegment.cpp b/src/Mod/CAM/PathSimulator/AppGL/MillPathSegment.cpp
index cfe4153fa0..793d69bdc7 100644
--- a/src/Mod/CAM/PathSimulator/AppGL/MillPathSegment.cpp
+++ b/src/Mod/CAM/PathSimulator/AppGL/MillPathSegment.cpp
@@ -39,6 +39,11 @@ constexpr auto pi = std::numbers::pi_v<float>;
 #define PY 1
 #define PZ 2
 
+// Maximum ratio of radius to chord length for treating arc as curved
+// Ratios above this indicate the arc is essentially a straight line
+// and should be treated as linear to avoid numerical precision issues
+constexpr float ARC_LINEARIZATION_THRESHOLD = 100000.0f;
+
 
 namespace MillSim
 {
@@ -71,9 +76,21 @@ MillPathSegment::MillPathSegment(EndMill* _endmill, MillMotion* from, MillMotion
     mXYAngle = atan2f(mDiff[PY], mDiff[PX]);
     endmill = _endmill;
     mStartAngRad = mStepAngRad = 0;
-    if (IsArcMotion(to)) {
-        mMotionType = MTCurved;
+
+    // Check if this is an arc motion and whether it should be treated as curved
+    bool isArc = IsArcMotion(to);
+    bool treatAsCurved = false;
+
+    if (isArc) {
         mRadius = sqrtf(to->j * to->j + to->i * to->i);
+
+        // Check if arc is essentially a straight line by comparing radius to chord length
+        // When radius >> chord length, floating-point precision issues occur in angle calculations
+        treatAsCurved = (mRadius <= mXYDistance * ARC_LINEARIZATION_THRESHOLD);
+    }
+
+    if (treatAsCurved) {
+        mMotionType = MTCurved;
         mSmallRad = mRadius <= endmill->radius;
 
         if (mSmallRad) {