I've had this ABS for a while now,

I’ve had this ABS for a while now, and have gotten success prints from it in the past. Now my extruder chews through the plastic. I have tried this on two machines with the same result, with different tensions on the idler to lessen the grip but nothing helps. Lower temperatures also doesn’t help.

I felt I stored the plastic rather well it a paint buckets with silica but is this common with humidified plastic (as its been getting warmer)? All my other plastics do not do this though.

In my experience, ABS with moisture in it usually just gets little bubbles in the print.

Decreasing idler force just makes a shallower bite for the drive gear, and therefore less grip. Changing grip force may influence bite depth enough to affect calibration, so check that.

Lowering the temperature raises the viscosity of the plastic, making the filament harder to push through the nozzle. A higher temperature might help.

Normally I’d say to check the nozzle for contamination too, but the adds are low that a 2nd machine also developed a clog at the same time. Not impossible, I suppose.

Try lower speeds

I have had major problems with PLA gathering moisture during long storage, but not ABS.

Whenever I had this issue it was a result of the hot end nozzle being too close to the print bed which caused bad stragglers over the printed parts causing a clog in the nozzle. If I’m seeing correctly you are getting quite a bit of squish is it possible you need to re-level the print bed?

Thanks for everyone’s responses, got more theories to try out now. Good to know ABS and PLA react differently to moisture contamination.

+Michael Spano Jr This print is a bit squished yes, but I get the same result when printing lifted as well.

Have you checked the diameter? Out-of-spec filament is the most common cause of grinding for me.