Powermill Full 2015-0

8/18/2019 Powermill Full 2015-0

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PowerMILL 2015 Contents

Copyright © Delcam Ltd 1

PowerMILL 2015 ContentsChapters Page Number

Day 1 1. Getting Started 1.1 - 1.26

2. Machining Set Up in Detail 2.1 - 2.22

3. Area Clearance Strategies 3.1 - 3.54

Day 2 4. Finish Machining Strategies 4.1 - 4.54

5. Leads and Links 5.1 - 5.14

6. Boundaries 6.1 - 6.32

Day 3 7. Levels and Sets 7.1 - 7.10

8. Editing Toolpaths 8.1 - 8.22

9. Collision Checking 9.1 - 9.14

10. Patterns 10.1 - 10.18

Day 4 11. Curve Editor 11.1 - 11.1212. 2D Machining 12.1 - 12.48

13. NC Programs 13.1 - 13.10

14. Setup Sheets 14.1 - 14.8

Day 5 15. Specialist Finishing 15.1 - 15.38

16. Component Thickness 16.1 - 16.2217. Stock Models 17.1 - 17.18

18. Macros & User Menus 18.1 - 18.10

19. Tutorials 19.1 - 19.22



Contents PowerMILL 2015

2 Copyright © Delcam Ltd



PowerMILL 2015 1. Getting Started

Copyright © Delcam Ltd 1 - 1

This course covers the 3-Axis functionality available in PowerMILL . Additional FiveAxis license options are covered on a separate course.

PowerMILL can quickly create gouge-free cutter paths on imported componentdata. It supports Wireframe Triangle !urface and !olid models created by other"elcam products or from neutral formats such as I#$!. If the relevant DelcamExchange translators are purchased PowerMILL %ill also directly import datacreated by other proprietary &A" packages.

Start PowerMILL

1 "ouble-click the PowerMILL shortcut on the desktop'

On the training PC, the icon will be displayed as PowerMILL .

The PowerMILL screen is displayed'

The screen is divided into the follo%ing main areas'

a Main menu

1. Getting Started



1. Getting Started PowerMILL 2015

1 - 2 Copyright © Delcam Ltd

&lick one of the menu names on this bar (for example File ) to open a pull-do%nmenu list of associated commands and sub-menus. A sub-menu is indicated by asmall arro% to the right of the text (for example File - Recent Projects > ).*ighlighting this arro% generates a list of commands+names specific to that sub-menu (for example File - Recent Projects displays a list of recently openedpro,ects that opens directly %hen selected).

b Main Toolbar (sho%n un-docked)

This provides quick access to the most commonly used commands inPowerMILL .

c Explorer

The PowerMILL explorer provides control options and storage of PowerMILL entities created during the session.

d Graphics Win ow

This is the large visual display area to the right of the Explorer ( ook at theillustration on previous page).

e !iew Toolbar (sho%n as hori ontal)

/rovides quick access to standard vie% and shading options in PowerMILL .

f In"orma#ion Toolbar

This area provides a reminder of some of the active setup options.

g Tool Toolbar

0acilitates the rapid creation of tools in PowerMILL .

The other toolbars are not factory defaults and are therefore not sho%n at initialstart up. To display any of these select them under !iew > Toolbar .





0or example select !iew > Toolbar > Toolpa#h to display the Toolpa#hToolbar .

To change the background colour of the graphics area select Tools > $us#omise$olours and select !iew %ac&groun . The Top and+or 1ottom colours can bechanged independently and 2eset using 'es#ore De"aul#s to restore to the originalsettings'





PowerMILL remembers Toolbar and colour selections from one session to thenext. 0or example if a Toolbar is open %hen the session is closed it %ill appearthe next time PowerMILL is opened.





Mouse buttons$ach of the three mouse buttons performs a different dynamic operation inPowerMILL .

Mouse button 1: Pick and Select

This button is used for selecting items on menus options on dialogs and entities inthe graphics area.

The method of selection is controlled by options accessed from the !iewing toolbar the default being !elect using a %ox .

Select using a box

If the cursor is positioned on an entity such as part of a surface model and if themouse is clicked then the item turns yello% indicating that it is selected.

If you select another surface, all currently selected items are de-selected.

If you %ant to select more surfaces to add to the currently selected surfacethen %hile making selections hold do%n the Shift key on your keyboard.

If you %ant to remove a surface from your current selections hold do%n the Ctrl key on your keyboard and click on the surface that you %ant to remove.

Select by dragging the cursor

4se this option to select multiple entities by dragging the cursor across the requireditems. This is ideal for quickly selecting multiple surfaces on a model. To deselectentities press the Ctrl key %hen dragging across an entity.

Mouse button 2: Dynamics

(ooming in an ou# ' *old do%n the $#rl key and mouse button . 5ove themouse up and do%n to oom in and out.





Pan around the model' *old do%n the )hi"# key %ith mouse button . 5ove themouse in the required direction.

(oom %ox ' *old do%n the $#rl and )hi"# key drag a box around the area tooom into using the middle mouse button.

'o#a#e mo e ' *old do%n mouse button and move the mouse and therotation is centred about the tracker ball.

!iew )pinning ' "ynamically rotate the vie% and quickly release the mouse.The faster the mouse movement the faster it %ill spin. This feature is s%itchedoff by default. !elect Tools > *p#ions > !iew > +D Graphics and select the)pin !iew option to enable it.

Mouse button 3: Special Menus & PowerMILL ExplorerOptions

When this button is pressed it brings up a local menu relating to %hatever themouse is over such as a named item in the PowerMILL explorer or a physicalentity in the graphics area. If nothing specific is selected the 6ie% menu appears.





HELP!PowerMILL provides you %ith help in a number of %ays'

Tool#ips ' /lace the mouse cursor over a menu button. A description is of %hatthe button does is displayed.

*nline ,elp ' !elect *elp 7 &ontents from the 5ain Toolbar to access the onlinehelp documents. There is a full index and search facility provided.

To see a summary of all ne% functionality available in the current version ofPowerMILL select *elp 7 What8s 9e%.

$on#ex# )ensi#ive ,elp ' /ress the F- key to display the help page for the

currently active dialog. &lick the button in the top right hand corner of thedialog follo%ed by a left click in any of the input fields to focus on the help topicfor that part of the dialog.

PowerMILL .ser Forum ' :n the Main toolbar select ,elp 7 !isi# #he .serForum to participate in %eb-based user discussions on PowerMILL issues.

The link to access the forum from any other internet connection is'http://forum.delcam.com/

Telephone an Email )uppor# ' 4; customers %ith up-to-date soft%aremaintenance can call <= =>?3=<=< or mail [email protected] to get help oradvice on specific application problems.





Simplified PowerMILL ExampleThis example provides a quick overvie% of the machining process. It sho%s ho% tocreate and output a couple of simple toolpaths on a model of a valve chamber usingdefault settings %herever possible.

The basic procedure is'

a !tart up PowerMILL .b Import a Mo el .

c "efine the %loc& that defines the material si e (or 3" machining limits).

d "efine the cutting Tools to be used.

e "efine set up options ( 'api Move ,eigh#s / )#ar# an En Poin# ).

f &reate a 'oughing !trategy.

g &reate a Finishing !trategy.

h )imula#e the toolpaths.

i &reate an 0$ Program and output as a post-processed 9& data file.

j )ave the PowerMILL Pro1ec# to an external directory.

Import a Model2 0rom the Main menu select File > Impor# Mo el and bro%se for the model

file'

.....\PowerMILL_Data\Models\PmillGettingStarted.dgk

3 !elect an I)* - vie%.





Blanking model entities4se the %lan& )elec#e ( $#rl 2 3 ) option available on the Mo el context menu totemporarily hide the selected model components.

In the illustrations belo% the light blue surfaces are selected.

4se the %lan& Excep# ( $#rl 4 ) option available on the Mo el context menu totemporarily hide all model components except the selected ones.

The selected items are light blue.

To re-display all model components right-click in the graphics area and select.nblan& 5$#rl L6 . The blanked model components are displayed and selected (backto the left hand image above).

@ou can also toggle bet%een the blanked and unblanked status of modelcomponents. !elect the %lan& Toggle ( $#rl 7 ) option to s%itch bet%een theBlanked and Unblanked components of the model.





Defining a BlockThe %loc& dialog is used to define the 3" %orking limits. This could be the actualra% material si e or a user-defined volume localised to a particular part of thecomponent.

The settings on the %loc& dialog are set by default to De"ine b8 / %ox . Individual

values in the dialog can be edited or locked (greyed out) as required. $nter a valuein the Expansion field to include an offset in the block calculation.

&lick the $alcula#e button to define a block around the model dimensions.

1 &lick the %loc& button on the Main toolbar to display the %loc& dialog.

2 &lick the $alcula#e button.

3 &lick Accep# .





Defining a Cutting ToolThe Tool dialogs are accessed using the various tool buttons on the Tool toolbar.This is located to the bottom left corner of the graphics area.

0or this example tools %ill be created A Tip 'a iuse tool for roughing out anda %all 0ose tool for finishing.

1 &lick the do%n arro% to display all the Tool options .

2 /lace the cursor over a tool to vie% the description of the tool type (Tool tips).

3 !elect the &reate a Tip 'a iuse tool button .

The Tip 'a iuse Tool dialog is displayed.

4 In the Tip 'a iuse Tool dialog enter'





a 0ame D-9T'- It is recommended that the tool is renamed %ith a morerelevant identification.

b Diame#er -9 When you enter a value for the Diame#er the tool engthautomatically defaults to five times this value. @ou can edit this value ifneeded.

c Tip 'a i us -

d Tool 0umber - A Tool 0umber can be output to the 0$ Program . Ifthe machine has a tool changer this number %ill represent the location inthe carousel.

e &lick $lose on the Tip 'a iuse Tool dialog.

5 "efine another tool this time select the $rea#e a %all 0ose #ool button andin the %all 0ose Tool dialog enter'

a 0ame %0-9

b Diame#er -9

c Tool 0umber 9

d &lick $lose on the %all 0ose Tool dialog.

6 In the PowerMILL explorer panel on the left of the screen open Tools andright mouse click D-9T'- tool to raise the local menu and select Ac#iva#e .

Only one tool can be active at any one time and the word Activate in the

tool context menu is prefixed with a tick . he active tool is

automatically included in a strategy dialog when the strategy is created.In the PowerMILL explorer , the Active tool is displayed in bold text and prefixed with ! > !.

Rapid Move Heights

The 'api move heigh#s options provide safe control rapid tool movementsacross the component.

)a"e ( is the height above the ,ob at %hich the tool can move at a rapidfeedrate clear of any obstructions such as the %ork piece or clamps.

)#ar# ( is the height to %hich the tool %ill descend at rapid feed rate prior toapplying the plunge feed rate.

PowerMILL displays rapid moves as dotted red lines plunge moves as pale blueand cutting moves as green.





Setting up Rapid Move Heights

1 :n the Main toolbar click the 'api Move ,eigh#s button to open the'api Move ,eigh#s dialog.

2 &lick $alcula#e .

3 &lick Accep# .This automatically sets the absolute )a"e ( and )#ar# ( values to be above theblock by the distance in the incremental height fields sho%n at the bottom of thedialog.

An Absolu#e setting %ill al%ays cause the tool to feed do%n from the sameheight.





Tool Start and End PointThe )#ar# an En Poin# dialog allo%s you to define a position %here the tooltravels to before and after a machining strategy.

&lick the tool )#ar# an En Poin# button on the Main toolbar to displaythe )#ar# an En Poin# dialog.

1y default the tool )#ar# Poin# is set to %loc& $en#re )a"e and the En Poin# isset to Las# Poin# )a"e .

:ther )#ar# an En Poin# settings are configured by selecting the differentoptions in the Me#ho area on the dialog.

These include %loc& $en#re )a"e Firs#:Las# Poin# )a"e Firs#:Las# Poin# andAbsolu#e .

0or no% click Accep# to use %ith the default settings.

The D-9T'- tool is placed at the %loc& $en#re )a"e position ready for you tocreate the first toolpath.





Creating a Roughing Strategy1 0rom the Main toolbar select the Toolpa#h )#ra#egies button.

2 0rom the left hand list select +D Area $learance

3 0rom the right hand list select the Mo el Area $learance strategy. Thisdisplays the Mo el Area $learance strategy dialog.

4 In the Mo el Area $learance strategy dialog'





a In the Toolpa#h name field enter D-9T'-;Mo elArea$lear .

b !elect Style 'as#er %ith Pro ile ; $limb and Area ; An8 .

c $dit the Thic&ness value to be <= (This is the amount of material that %illbe left on the ,ob).

d $dit the )#epover value to be ? (This is the distance bet%een each rasterpass (the %idth of cut)).

e The )#ep own value (depth of cut) is left at the default value of .f &lick $alcula#e to process the machining strategy.

Simulating the toolpath5 0rom the PowerMILL explorer right mouse click on the Toolpa#h

D-9T'-;Mo elArea$lear and from the local menu select )imula#e "rom)#ar# .

The )imula#ion toolbar %ill appear ,ust above the graphics area.

6 0rom the )imula#ion toolbar click the Pla8 button to run the )imula#ion .

he other buttons in the Si!ulation toolbar allow you to perform otheractions such as Pause , Step , Search , "oto .





Creating a Finishing Strategy7 In the PowerMILL explorer right click the %0-9 tool and select Ac#iva#e (or

double left click on the tool8s PowerMILL explorer icon).

8 0rom the Main toolbar select the Toolpa#h )#ra#egies button.

9 0rom the left hand list select Finishing .

10 0rom the right hand list select the 'as#er Finishing strategy and click *4 .





11 In the 'as#er Finishing strategy dialog'

a 0or the Toolpa#h 0ame enter %0-9;'as#erFinish .

b $dit the )#epover value to <=+

c &lick $alcula#e to process the machining strategy.

The 'as#er Finishing pattern is pro,ected do%n B onto the component takinginto account tool geometry and machining settings.

he toolpath link moves, clear of the "ob, are not displayed in this illustrationfor clarity.

Toolpath Simulation and ViewMILL

PowerMILL provides t%o levels of options for simulating toolpaths' The first level )imula#es the cutting tool movement along the toolpath.

The second level ( !iewMILL ) includes a shaded image of the stock materialbeing progressively reduced as the tool moves along the toolpath.

Toolpath Simulation12 In the PowerMILL explorer right-click on the toolpath

D-9T'-;Mo elArea$lear and from the local menu select Ac#iva#e .

The Ac#ive toolpath is displayed in bold text and prefixed %ith a > symbol.

13 In the PowerMILL explorer right-click on the roughing toolpathD-9T'-;Mo elArea$lear and select )imula#e "rom )#ar# .





14 The Toolpa#h )imula#ion toolbar is displayed at the top of the screen. This

displays the name of the toolpath and tool together %ith buttons to control thesimulation.

4sing the simulation control buttons you can'

Play ; start the simulation and play it in continuous mode.

Pause ; pause the simulation.

Step Back ; step the simulation back by tool moves. &lick the Play button

to resume continuous mode.

Step Forward / step the simulation by tool moves. The faster the speed

(defined using Speed Control ) the bigger the step. &lick the StepForward button again to see the next move or click the Play button to resumecontinuous mode.

Search Backward ; step the simulation back to the previous toolpathsegment.

Search Forward ; step the simulation to the next toolpath segment. &lick

the Search Forward button again to see the next component or click the Play button to resume continuous mode.

Go to Beginning ; moves to the start of the toolpath.

Go to End ; moves to the end of the toolpath.

Speed Control ; controls the speed of the simulation. The fastestsetting is by having the slider at the right the slo%est at the left.

!elect Poin# #o Poin# (toolpath points per second) or Fee ra#e (a

multiple of the stored federate) as the basis for the simula#ion

feedrate.

15 &lick the Pla8 button and )imula#e the #oolpa#h .

16 Ac#iva#e the finishing toolpath %0-9;'as#erFinish and repeat the simulationprocess.





ViewMILL1 Ac#iva#e the roughing toolpath D-9T'-;Mo elArea$lear and select it in the

)imula#ion Toolbar.

2 0rom the Main pull do%n menus select !iew > Toolbars > !iewMILL to raisethe !iewMILL Toolbar.

The !iewMILL toolbar is displayed. Initially all the buttons are greyed out.

3 &lick the button to toggle the graphics %indo% into the !iewMILL mode(The !iewMILL toolbar buttons are no% active).

4 &lick the button to select a Plain )ha e Image .





5 &lick the Tool button to display the tool.

6 &lick the Pla8 button to start the !iewMILL simulation.

7 After the si!ulation has finished select the toolpath %0-9;'as#erFinish on

the )imula#ion toolbar follo%ed by the #ool button .

8 &lick the Pla8 button again to vie% the continued simulation of materialremoval by the finishing toolpath.

9 In the )imula#ion toolbar select the $lose button to delete the!iewMILL session.





NC Programs (Post-Processing and NC data Output)1 0rom the Main menu select Tools > $us#omise Pa#hs to open the

PowerMILL Pa#hs dialog.

This displays the PowerMILL Pa#hs dialog.

2 In the PowerMILL Pa#hs dialog select the option 0$ Programs *u#pu# .

This controls %here the post-processed 9& data files are output ready todo%nload to a machine tool controller.

3 &lick the Add path to top of list button.

4 In the )elec# Pa#h dialog %hich appears bro%se to the required location$@ Temp 0$Programs and click *4 .

5 In the PowerMILL explorer right-click 0$ Programs and select Pre"erences to display the 0$ Pre"erences dialog.





0$ Pre"erences enables you to control the content of output files to do%nload

to a machine tool.

The *u#pu# Fol er defaults to the location already defined in Tools >$us#omise Pa#hs .

6 In the 0$ Pre"erences dialog click Machine *p#ion File button. This displaysthe )elec# Machine *p#ion Filename dialog.





7 !elect hei B<<=op# and click *pen . This selects the hei B<<=op# file andreturns you back to the 0$ Pre"erences dialog.

8 $lose the 0$ Pre"erences dialog.

9 In the PowerMILL explorer right-click 0$ Programs and select $rea#e 0$Program .

An empty 0$ Program appears in the PowerMILL explorer and the 0$Program dialog is displayed.

10 Within the PowerMILL explorer use the left mouse to select and drag thetoolpath D-9T'-; Mo elArea$lear onto the 0$ Program - .

#lternatively, right-click on the toolpath D12TR1-ModelAreaClear and selectAdd to > NC Program .

A copy of the toolpath na!e %ill appear in the 0$ Program indicating that ithas been assigned as part of the output file.





11 In the PowerMILL explorer click and drag the toolpath %0-9;'as#erFinish onto 0$ Program 1.

&lick the small + box to expand and vie% the contents of the 0$ Program .

The toolpath names are listed in the NC Program ready to be post-processed.

12 In the 0$ Program dialog displayed in the graphics area click the Wri#e buttonto start the post processing operation. An Information dialog is displayed %ith aprogress and confirmation summary.

13 $lose both the 0$ Program and In"orma#ion dialogs.

14 @ou can find the created 9& data file -=#ap under $@ #emp 0$Programs onyour computer.

Saving the Project15 :n the Main toolbar click the )ave button.

As this is the first time that this Pro1ec# is saved the )ave Pro1ec# As dialog%ill open.





If the Pro1ec# has been )ave before then it %ill simply be updated.

16 0rom the Main menu select File 7 )ave Pro1ec# As '-

......\COURSEWORK\PowerMILL-Projects\PmillGettingStarted

17 0rom the pulldown menus select File 7 Dele#e All follo%ed by Tools 7'ese# Forms .

The content of PowerMILL explorer is deleted and all dialogs are reset to theirdefault settings.

The externally stored copy of the Pro1ec# ( P!ill"ettingStarted ) can bereopened as required.

Additional Exercise1 Impor# the Mo el '-

......\PowerMILL_Data\Models\facia.dgk

2 )ave #he Pro1ec# as '

......\COURSEWORK\PowerMILL_Projects\Facia-1

3 4se the same Tools and machining s#ra#egies to those in the previousPro1ec# (/mill#etting!tarted).

4 :nce this exercise is completed (and saved as a Pro1ec#6 locate the pulldown menus and select File 7 Dele#e All follo%ed by Tools 7 'ese# Forms .



PowerMILL 2015 2. Machining Setup in Detail


In the previous section, the toolpaths were created using the default valueswherever possible.

We will now look at the machining Setup options in more detail.

In particular:

Setting up direct access to regularly used files using Customise Paths . Setting Feed rates .

Workplanes (Positional datums to create appropriate machining set ups .

Tool with Shank and Holder definition.

PowerMILL Panes!he PowerMILL panes are located above the PowerMILL explorer area.

!he first pane displays the PowerMILL explorer (as shown above .

!he second pane displays the HTML browser used for viewing Help files.

!he third pane opens the PowerMILL Recycle Bin .

2. Machining Setup



2. Machining Setup in Detail PowerMILL 2015


Setting up direct access to regularly used folders1 !o Import a "odel via the Main pull down menus, select File # Import

Model .

!he Import Model dialog is displayed.

$ changes the directory to the current Pro%ect directory.

$ changes the directory to the Examples directory.

!his folder contains a selection of sample model files which are installedwithin PowerMILL in a directory called Examples .

$ changes the directory to the first user$defined directory.

$ changes the directory to the second user$defined directory.

!o customise the paths for user$defined directory folders:





2 &rom the Main menu select Tools # Customise Paths . !he PowerMILLPaths dialog is displayed.

3 Select the File Dialog Button 1 option from the drop$down list.

4 'lick the dd path to top o! list button and browse to:

......\PowerMILL_Data\Models

5 'lick OK .

6 epeat steps ) and *, but this time select the File Dialog Button " optionto link directly to:

....\PowerMILL_Data

Outside the training environment, the location of the PowerMILL_Data directory will depend on where you have installed it!





Loading a model into PowerMILL1 &rom the Main menu, select File # Import Model .

2 +se #hort$ut Button 1 or browse to:

....\PowerMILL_Data\Models

A variety of Model formats can be imported into PowerMILL . Use the Filesof type filter to widen or narrow your choice.

Please note: direct transfer - file formats (eg: A "A, Pro#$%"$##&, etc'are only available as a cost option.

3 ack in the main form, select the file Workplanes%xample1&dgk and thenclick 'pen .

4 &rom the (iewing toolbar ( ight of graphics area select (iew !rom top

)*+ followed by ,esi-e to !it .

!he model is displayed in the PowerMILL graphics as viewed down the -$a iswith / aligned from left to right, and 0 from bottom to top.





Viewing the Model1lthough the model is displayed, it is a good idea to look at it from all angles tofully understand its si2e and features.

1bove is the (iews toolbar (shown aligned hori2ontally .

y default, the (iewing toolbar is aligned to the right hand side of the graphicsarea. !hese options mainly include basic visual orientations along with severalshading modes, many of which provide specialist analysis of the model.

5 &rom the (iew toolbar, select an isometric I#' 1 view.

In most cases, the / dimension of a machine tool table will be greater than 03 inwhich case, the longer side of the component may e ceed of the travel limits in 0.

If this is the case, it will be re4uired to align the component with the longest sidealong / to ensure that it can be positioned within the travel limits.

Saving the ProjectIt is good practice to create a Pro.e$t as soon as possible and then to #a/e it atregular intervals during the session.

6 5n the Main menu, select File # #a/e Pro.e$t s :

....\COURSEWORK\PowerMILL-Projects\WorkplaneExample1-EX1





Setting Feed rates!he current Feed rate values are applied directly to a newly created toolpath . !heFeed rate values can be stored in a Tool definition to update the Feed rate dialogaccordingly on Tool activation. 1t this stage we will look at manually setting the

feed rate individually. 'lick the Feeds and #peeds button on the main toolbar to display the Feeds and #peeds dialog.

!he default values (as shown above can be modified as re4uired and $$eptselected for them to be the default for future toolpaths. ppl0 is used to updatethe Feeds and #peeds of an active toolpath . 6ote ppl0 is 7greyed out8 (asabove if there is currently no active toolpath .

Creation and Application of Workplanes.When a model is imported into PowerMILL it is more than likely that the originalglobal datum ( Trans!orm will not provide a suitable position9orientation for toolsetting or applying machining strategies.

Workplanes provide the ideal method of creating suitable machining datums andalignments without having to physically move the component model .

Workplanes are additional datums that can be moved and9or orientated within theglobal environment. 5nly one workplane can be active at any one time. If noworkplane is active, then the original global Trans!orm is the datum.

y deactivating a workplane , the original coordinate set$up can easily be re$activated for tasks such as checking original dimensions or for importing a 7newissue8 updated model.





Workplane (1) - At Top of Selection7 With the left mouse button depressed, drag a bo over the entire mode l to

select it.

8 In PowerMILL explorer , right$click Workplanes and select Create and'rientate Workplane # Workplane at top o! #ele$tion .

1 Workplane is created and appears at the top$centre of the selected model.!he new Workplane 1 is also registered in PowerMILL explorer .

9 ight$click the newly renamed Workplane 1 and select $ti/ate .

!he ne t step will be to rotate the new $ti/e $ Workplane $ 1 to re$orientatethe model such that the longer side is aligned to the 2 xis .

10 &rom the same local menu, select Workplane %ditor to display theWorkplane editing toolbar.

11 ouble click the Twist a3out * button. !his displays the Twist dialog.

12 ;nter ngle "45 and click $$ept .

13 'lick the 6reen Ti$k located to the right of the Workplane toolbarto accept the changes.





14 Select a (iew !rom top )*+ to see the effect of the rotated, Active Workplane providing a more suitable machining position for the model.

!he Workplane is shown positioned on the top of the model, which has thelonger edge aligned to /.

Workplane (2) - Positioned using the Block1nother method of creating a Workplane is from ey points on the definedBlo$k .

15 &rom the main menu, select the Blo$k Icon the following form willappear select $ti/e Workplane press Cal$ulate followed by $$ept .





16 In the PowerMILL explorer , ight mouse click on Workplanes to accessthe following menus.

17 Select Workplane Positioned using Blo$k from the above menu.

18 'lick the new Workplane on to the orange sphere located at the centre ofthe bottom face of the Blo$k .

he new workplane will inherit the default name .

19 ight click on the workplane and from the local menu, select $ti/ate .





$ote that Block definition moves relative to the active dat!" .

20 $ti/ate the new Workplane and from the local menu select theWorkplane %ditor .

21 ouble click on the Twist and enter 175 degrees so that the newworkplane is normal to the underside of the model.

22 Select $$ept for the new workplane " to be updated.

!he Blo$k returns to the correct position relative to the model which in this case isdimensionally the same for both Workplanes 1 and " when either is $ti/e .

23 e$activate Workplane " .





!he Blo$k is now dimensionally positioned relative to the global Trans!orm .

24 Select File $ #a/e Pro.e$t :$

!he contents of the Pro.e$t saved earlier will be updated.

Block Coordinate System!he above type of Blo$k 'o$ordinate, definition ( $ti/e Workplane is ideal for *1 is applications. !he physical re$positioning of the Blo$k will provide a usefulvisual warning if the machining datum, Workplane is de$activated.

5ther Coordinate #0stem options become essential for advanced applications suchas multi$a is, #Pl!s set ups. In this case the Blo$k definition can be fi ed toeither the 6lo3al Trans!orm or a 8amed Workplane .





Workplane Aligned to Geometry!his option enables the user to create a Workplane perpendicular to a face usingWorkplane aligned to 6eometr0 . !he ne t e ample shows this in detail. (Seeoriginal model orientation .

1 Select File 2 Delete all followed by Tools 2 ,eset !orms .

2 Import the Model :$

......\PowerMILL_Data\Models\InteriorTrim.dgk

3 While the centre mouse wheel is depressed, move the mouse to rotate the

view of the Model so that the base of the pocket is fully visible.

4 ight click on Workplanes and select Create and 'rientate Workplane followed by Workplane aligned to 6eometr0 .





5 <eft mouse click on the base of the pocket (as shown below to locate anew Workplane (with its -$a is normal to the surface .

6 In the PowerMILL explorer , right click on the new workplane and select$ti/ate .

7 +se the left mouse and click on the bottom face of the pocket to make itselected (shaded light blue below right .

8 !hen right click on Workplanes to open the local menus below.

9 &rom Create and 'rientate Workplane , select Workplane at Top o!#ele$tion .

10 !he new Workplane will be centrally located at the base of the pocket.

11 ,ename the new Workplane as Datum and make it $ti/e .

12 Delete the original Workplane .





!he new Workplane is created central to the pocket base as shown below.

13 #a/e the Pro.e$t as:$

......\COURSEWORK\PowerMILL_Projects\Workplane-Example2

14 Select File = Delete all followed by Tools = ,eset !orms .

Other local Workplane menu, creation options

a Create Workplane produces a single Workplane on the current activedatum and opens the Workplane %ditor conte t toolbar.

b Create and 'rientate Workplane opens the following form, that providesa selection of specialised Workplane creation options.





Speaker Core Example - Set Up1 Import the Model :$

......\PowerMILL_Data\Models\speaker_core.dgk

Use B!tton $ in the I"port Model dialog for )uic access!

&or this e ample it is re4uired for the long side of the component to be aligned tothe direction and not 9 as shown above.

2 epress the left mouse key and drag a bo across the whole model toselect all #ur!a$es .

3 &rom the PowerMILL explorer , select Workplanes $ Create and'rientate Workplane = Workplane at Top o! #ele$tion .

4 In the PowerMILL explorer right mouse click on the new Workplane andfrom the local menu select Workplane %ditor .

5 In the above toolbar, click on the *2Twist option and enter :5 in the formfor the Workplane rotation angle.

6 $$ept the %wist form and then click on the 6reen tick on the toolbar toe it the Workplane %ditor (and finally accept the changes .

7 $ti/ate the new Workplane 1 .





8 Select an I#' 1 view.

!he long side of the component is now running along the direction.

6ow that the component model is suitably aligned, the ne t stage is to createsome suitable cutting Tools ready to carry out the machining process.

Tool and Holder Definition&or the cutting Tools in this e ample the #hank and Holder will be included aspart of the overall definition.

6ote it is also possible to store specific !eeds and speed values in a !ooldefinition. 6ot a default setting, but PowerMILL can be set to recognise theseand automatically update the Feeds and #peed dialog on activation of theTool .

9 &rom the PowerMILL explorer select Tools $ Create Tool $ Tip,adiused .





10 In the Tip ,adiused Tool dialog, input a &a"e D;5T,< $ 'ia"eter ;5 2%ip Radi!s < $ Len(th 1<5 $ %ool &!")e r 1 .

11 In the #hank dialog, click dd a shank $omponent and enter:=pper>Lower 'ia"eter ;5 and Len(th 155 .

12 In the Holder dialog, click dd holder $omponent and input:

=pper Diameter = 1"5

Lower Diameter = :5

Length = ;5

'/erhang $ "55





he *verhan( is the vertical distance from the bottom of the Holder tothe bottom of the tool %ip .

13 In the Holder dialog, click the dd holder $omponent button . ;nter:

=pper Diameter = 1"5

Lower Diameter = 1"5

Length = ;5

14 In the Holder dialog, click the dd holder $omponent button ;nter:

=pper Diameter = 1;5

Lower Diameter = 1;5

Length = ";





15 Close the dialog.

*ou can control the style in which the tool is displayed in the graphicswindow. "n the PowerMILL explorer , right+clic on the %ool $ '+,%R and from the local menu, select Shaded .

A %ool can be saved outside PowerMILL as a permanently storedtemplate (.ptf'.





Block Definition!he default option for Blo$k is Box (1 rectangular volume . 5ther optionsinclude C0linder (a cylindrical volume , a Triangle model (eg 'asting , andPi$ture 9Boundar0 (; truded ) wireframe contours .

!he dimensions of the Blo$k can be entered manually or calculated directly tothe !ype of entity: Model , Boundar0 , Pattern , or Feature .

!he 'pa$it0 slider controls the degree of shading (from the left, initiallywireframe and then graduating from clear to dense .

16 Cal$ulate a Blo$k using De!ined 30 $ Box and T0pe $ Model .

17 "ove the 'pa$it0 slider fully to the left for a wireframe Blo$k .





Rapid Move Heights!he ,apid Mo/e Heights options enable safe rapid moves between tool tracksclear of the top of the Model or Blo$k (whichever is the higher .

18 In the ,apid Mo/e Heights dialog, click the Cal$ulate tab to set #a!e * and #tart * to the default values of 15 and ; respectively above the Model or Blo$k .

he Rapid Move Hei(hts are calculated relative to the highest point on

the Block or Model .

"f parts of the "odel are selected, then the de+selected parts will beignored when the Rapid Move Hei(hts are calculated!

y default the Tool will traverse across #a!e * and then drop to #tart * using a,apid move (eg 65 . It will then continue downwards at the Plunging Feed,ate (eg 61 .





Start and End Point!he #tart Point and %nd Point define the first and last points on a toolpath. !hesecan be controlled using > different positional options.

19 In the #tart and %nd Point dialog, $$ept the default settings :

c #tart Point $ Blo$k Centre #a!e

d %nd Point $ Last Point #a!e

Save Project20 It is essential to regularly #a/e your work outside the PowerMILL session.

y saving to a Pro.e$t the contents of the PowerMILL explorer are savedinto an e ternal folder.

21 Select File $ #a/e Pro.e$t s :$....\COURSEWORK\PowerMILL-Projects\Spkr-Core

o $ot lose the Pro.ect as it will be continued in the following chapter.



PowerMILL 2015 3. 3D Area Clearance


The main strategies for roughing a 3D component model are called 3D AreaClearance . These provide a choice of 2D material removal methods, whichprogressively machine the area ( Slice ), up to the component contour, down asequence of user-defined Z Heights .

Thickness and Tolerance (Applied to 3D Area Clearance)uita!le values are required to control the accuracy and amount of e"cess material

to !e left on a component !y a toolpath. The parameters used for this purpose arepreset and are called Thickness and Tolerance .

Thickness is the amount of e"tra material specified to remain on the wor#-pieceafter machining. This can !e applied generally (as shown), or independently asseparate Radial and Axial values within the machining options.

3. 3D Area Clearance



3. 3D Area Clearance PowerMILL 2015


Raster – Model Area Clearance exampleThe Raster ( Model Area Clearance ) strategy follows a series of l inear movesacross the Block limiting to the component form at the active Z height . $t then, (!ydefault) performs a Profile pass around the component to leave a constantthickness around the Slice .

1 %nsure that the recently saved Project (Spkr-Core ) is still active.

2 Activate !oth the Workplane and the tool D !"R# .

3 &rom the $ain tool!ar select Block and using, Defined by Bo% ' TypeModel select Calc&late followed !y accept .

4 &rom the $ain tool!ar select Rapid Move Heights and in the form selectCalc&late followed !y Accept .

5 &rom the Main tool!ar select "oolpath Strategies and from 3D AreaClearance open a Model Area Clearance strategy.

6 elect '( to open the Model Area Clearance strategy form.





As soon as the Model Area Clearance dialog is opened, the unprocessedToolpath appears in the PowerMILL explorer .

7 $n the Model Area Clearance strategy dialog

a %nter the "oolpath na$e as D !"R#)A*

b elect St+le as Raster .c &or C&t direction - Area select An+

d et "hickness to !,

e et Stepover to -!

f et Stepdo.n to *!

g eeping all other values as default, Calc&late the strategy.

h *fter the "oolpath has !een created, close the dialog.

Double left mouse click on the individual toolpath symbols to activate orde-activate them.

+lic# the small + !o" to e"pand and view data used to create the toolpath.





Rapid Move Heights combined with Leads and Linksou can modify the !asic Safe Z and Start Z from the Rapid Move Heights dialog.

+lic# the Calc&late !utton to set the Safe Z and Start Z to !e at safe distancesa!ove the top of the Model (whole or selected) or Block (whichever is the highest).

Safe Z is always above Start Z .

Safe Z specifies a fi"ed height at which rapid moves across the wor# piece cansafely occur.

Start Z specifies a fi"ed height at which the slower, plunge feed rate is applied!efore the tool cuts into the wor# piece.

Rapid Move Heights wor#s in con unction with the /eads and /inks dialog ,providing a more comprehensive choice of "oolpath lin# options.





Safe ' *pplies the plunge feed rate from a fi"ed height a!ove the o!. This ismore predicta!le and reassuring, !ut the non-cutting (air) moves ta#es moretime and is inefficient, especially in the case of large, deep components.

Ski$ - ena!les the downward, rapid feed rate to continue to a specifiedincremental Start Z a!ove the full plunge depth !efore the slow plunge feedrate cuts in/. Ski$ then applies a rapid retract to an incremental Safe Z a!ovethe highest point on the component in l ine/ with a linear lin# move to the ne"t

plunge position. To cater for all types of machine tools, this move is a Ski$0eed Rate (01) (solid purple line), instead of a Rapid (0 ) (dashed red line).

1ncre$ental - applies the rapid feed rate all the way down to an incremental Start Z measured from the full plunge depth, at which point, the slow Pl&nge0eed Rate cuts in/. The Pl&nge option differs from Ski$ in that all rapid lin#moves occur at the Ab ol!te Safe Z .

The default Link move settings in the Model Area Clearance strategytemplate are Short"Lon# = Skim and Defa!lt = Incremental .





Feed RatesThe 0eeds and Speeds dialog uses the St+le and Colo&r of elements along atoolpath to register the correct apid 4ove or &eed ate values.

&i"ed 2 !4 Rapid moves 5 ed Dashed, "oolpath elements

6aria!le 2 *4 0eed Rate moves 5 0reen78range, "oolpath elements.

9lunge 2 *4 0eed Rate moves 5 9ale :lue, "oolpath elements

#im 2 *4 0eed Rate moves 5 9urple, "oolpath elements.

1 &rom the Main tool!ar, select the 0eeds and Speeds !utton and enter thevalues (shown !elow) in the C&tting Conditions area of the dialog.

2 +lic# Appl+ to assign these values to the active "oolpath ( D !"R#)A* ) and thenselect Accept to close the dialog.

3 $n the Po.erM1// explorer , right-clic# on the toolpath and select Settings5 .

The toolpath can also be activated or deactivated using the Activate option inthe context menu.

4 This reopens the Model Area Clearance dialog.

5 elect the ma#e a copy of the Toolpath !utton.

6 8n the left of the Model Area Clearance dialog is a local explorer window.





;hen a local explorer option is selected the individual page is displayed in themain dialog. This ma#es it easier to navigate specifically through the pages forthe required strategy.

7 &rom the local explorer , select the to the left of /eads and links to access thefurther options /ead in , /ead o&t , and /inks .

8 $n the /inks page change the Short , /ong , and Defa&lt lin# moves to Safe .

9 +lic# Calc&late to create a new "oolpath with the modified settings. 8nceprocessing is complete, close the dialog.

The "ool now performs rapid moves (dashed red) at a fi"ed height ( Safe Z ) a!ove the part (Default height is *! ).

*ll Pl&nge feedrate (pale !lue) moves start from a height !etween the Safe Z and the top of the part (default height is )





Statistics9rovides you with essential information a!out the active toolpath and associatedparameters.

1 $n the Po.erM1// explorer , right-clic# the latest "oolpath D !"R#)A*6* andfrom the local menu select Statistics .

The dialog with information a!out the toolpath and its associated settings is

displayed.

$n this case, the total machining time is around 7hrs * $ins

2 ight mouse clic# on the original "oolpath D !"R#)A* and from the local menuselect and view the Statistics .

$n this case, the total machining time is around 3hrs 3-$ins .

This large saving is achieved simply !y using Ski$ in the /inks dialog. $n theoriginal toolpath, Safe was used, resulting in an e"cessive amount of the /ink moves !eing in fresh air.

Simulating the toolpath3 ight mouse clic# on the "oolpath D !"R#)A* and from the local menu select

Si$&late fro$ Start .

f not already displayed the above Sim!lation toolbar will appearautomatically.

4 <se the Pla+ !utton to run the simulation and control the seed with the slider!ar.

5 $f the 8ie.M1// tool!ar is not already open, from the $ain pulldown menusselect 8ie. ' "ool9ar ' 8ie.M1// .





6 $n the 8ie.M1// tool!ar, select the Red sphere to connect 8ie.M1// to thesimulation controls (The sphere will now !e reen and the current Block will !eloaded into 8ie.M1// ).

7 elect the Plain Shaded 1$age option and run the si$&lation again

8 witch the 8ie.M1// to :o 1$age to return to the Po.erM1// session

and then disconnect 8ie.M1// from the si$&lation process.

;hen you toggle !ac# to Po.erM1// , the 8ie.M1// session still e"ists in the!ac#ground, ready to include further toolpaths as required.

$f the 8ie.M1// session is still connected, then, even though it is set to :o1$age , 8ie.M1// will continue to update it in parallel with any further toolpathsimulations.

Saving the Project9 &rom the Main menu, select 0ile = Save Project .

The Project (....\COURSEWORK\PowerMILL-Projects\Spkr-Core ! is now

updated.

;e will now delete the contents of the Po.erM1// explorer and return thePo.erM1// session !ac# to the original default settings.

10 &rom the Main menu, select 0ile = Delete All .

11 &rom the Main menu, select "ools = Reset 0or$s .





Other Model Area Clearance - Style examplesThere are > different Style options in the Model Area Clearance strategy.

;e have already used Style ' Raster in the previous e"ample. o for the ne"tsection we will simply show the !asics of other 3 options ( 'ffset Model , 'ffset All ,and 8orte% ) on a single ? level.

Offset Model – Basic exampleThis variant of the 'ffset Area Clearance is primarily designed for $i#h Speed Machinin# . $t provides very consistent tool loading at the e"pense of increasednum!er of rapid air moves across the component. This strategy, if applied correctly,can go a long way to minimise wear to !oth tooling and machine.

The strategy is !ased on the profile around the component at each ? @eight, !eingcontinually offset outwards, to !e trimmed to the limits of the material Block .

1 1$port the Model

......\PowerMILL_Data\models\Handle.dgk

2 Save Project As

......\COURSEWORK\PowerMILL_Projects\Handle

3 +reate a Dia *# , Tiprad 3 , "ool named D*#"R3 .

4 Calc&late a Block to the full model dimensions. /ock the Z $a% and Z $in values, enter an ;%pansion value of *! and Calc&late .

5 $n the Rapid Move Heights dialog, select Calc&late .





6 elect "oolpath Strategies , and from 3D Area Clearance open a ModelArea Clearance strategy.

7 $nput data into the pages of the form e"actly as shown !elow.

8 elect the 'ffset page and tic# the Spiral option.

9 elect the 0lat $achining page and select Machine flat - 'ff .

10 *t the !ottom of the dialog, clic# Calc&late to create the "oolpath .

11 Close the dialog and select an 1S' * view.





The toolpath is displayed above with the Lead and Link undrawn.

12 $n Po.erM1// explorer , right-clic# the "oolpath and select Si$&late fro$Start to display the Si$&lation tool!ar.

13 8n the Si$&lation tool!ar, select Pla+ to view the toolpath simulation.

To stop the simulation, press the Esc key on your keyboard.

The tool continuously, clim! mills, starting each tool trac# at a distance from thematerial Block to allow the tool to reach optimum 0eed Rate !efore contact.The material removal rate in this type of strategy is generally very consistent.The strategy can !e further improved using advanced settings to progressivelysmooth away sharp corners and straighten the toolpath geometry as it offsetsfurther away from the component form.

14 $n the Po.erM1// explorer , right-clic# the active D*#"R3)'ffsetModel toolpath and select Settings to reopen the Model Area Clearance dialog.

15 +lic# to create an active copy of the toolpath .

16 $n the Model Area Clearance dialog, select the High speed page.





a elect Profile s$oothing and set Radi&s ( "D< ) to the ma"imum slidervalue of !,-

b elect Raceline moothing and set the slider value to - (A).

c +lic# Calc&late to create a new toolpath D*#"R36'ffsetModel6HSM withthe improved smoothing characteristics.

+ompare the Model Area Clearance toolpaths. Bote the progressivestraightening of tool trac#s on the second strategy with - = Racelines$oothing applied.





Offset All – Basic exampleThis variant of the 'ffset Area Clearance is !etter suited to softer materials suchas modelling foam, resins etc. $t will remove material with a larger tepo%er andthe minimum amount of lifts, !ut this is more than li#ely to result in the tooltrac#scontaining sharp changes of direction and an inconsistent removal rate.

1 $n the Po.erM1// explorer , right-clic# the active D*#"R3)'ffsetModel "oolpath and select Settings to reopen the Model Area Clearance dialog.

2 +lic# to create a copy of the "oolpath .

3 Rena$e the new toolpath as D*#"R3)'ffsetAll .

4 $n the Model Area Clearance dialog, main page select Style ' 'ffset All andthen input data as shown !elow.

5 $n the Model Area Clearance dialog, select the High speed page and update thedata as shown in the following illustration.






7 Close the dialog and select an 1S' * view.

8 9erform a toolpath Si$&lation to o!serve the tool movement in this strategy.

$n the a!ove 'ffset)All style toolpath, the tool plunges into the individual areasand profiles it/s way outwards following !oth the component $odel and Block forms.





Vortex - Basic exampleThis specialist, variant of Model Area Clearance is primarily designed for use withsolid car!ide tools on hard materials. ;herever necessary the 8orte% strategyapplies comple", optimised trochoidal, movement to achieve the ultimate controlover the loading on a cutting tool.

1 $n the Po.erM1// explorer , right-clic# the active D*#"R3)hs$6* "oolpath and select Settings to reopen the Model Area Clearance dialog.

2 +lic# and create a copy of the "oolpath .

3 $n the Model Area Clearance dialog, main page select Style ' 8orte% .

a $nput "hickness !,

b $nput Stepover *

c $nput Stepdo.n -! 4 elect the 0lat $achining page and set Machine flat to 'ff .





5 elect the 8orte% 9age and set Mini$&$ Radi&s 2r4 to 3.0

$ncreasing the Mini$&$ Radi&s value will enlarge the inherent Trochoidal moves which should in turn ena!le a higher 0eedrate to !e used with the8orte% strategy.

6 elect the <nsafe segment removal page, tic# emove segments smaller thanthreshold and input a Threshold " TD<) value of .C


8 +lose the dialog and select an 1S' * view.





9 elect 0ile - Save Project to update the contents of -

......\COURSEWORK\PowerMILL_Projects\Handle

10 &rom the Main pull down menus, select 0ile = Delete All .

11 &rom the Main pull down menus, select "ools = Reset 0or$s .









17 Calc&late the Model Area Clearance toolpath and once processing is complete,close the dialog.

The internal, sharp corners around the toolpath outer profile are now smoothed.

18 &rom the Main pull down menus, select 0ile = Save Project to update the storeddata (......\COURSEWORK\PowerMILL-Projects\MountingBlock ).

19 &rom the Main pull down menus select 0ile = Delete All .

20 &rom the Main pull down menus select "ools = Reset 0or$s .





Model Rest Area Clearance example$t is generally good practice to use as larger diameter tool as possi!le for the initialArea Clearance operation. This ensures that the ma"imum amount of material isremoved as quic#ly as possi!le. @owever, the large diameter tool may not have fullaccess to certain internal corners or poc#ets within the component. *s a result,these areas will require further roughing out with one or more, smaller diameter

tools !efore running the 0inishing strategies.$n the Model Rest Area Clearance options, a smaller "ool is referenced either toan e"isting "oolpath or a Stock Model , such that tool trac#s will only !e producedlocally within the remaining material (stoc#).

1 1$port the $odel

......\PowerMILL_Data\models\WingMirrorDie.dgk

2 Save Project as

......\COURSEWORK\PowerMILL-Projects\WingMirrorDie-Ex13 +reate a "ip Radi&sed tool of Dia >! tiprad # and Bame D>!"R# .

4 &rom the Main tool!ar open the Block dialog and Calc&late using the defaultsettings, Defined by - Bo% to and Type - Model .

5 <sing the default settings, select Calc&late in the Rapid Move Heights .







a %nter "oolpath na$e - D>!"R#)D*

b elect St+le - 'ffset Model

c $nput "hickness !,

d $nput Stepover -

e $nput Stepdo.n *!

8 $n the local explorer , select the /i$its page, and set the Block ) /i$it to /i$ittool centre to 9lock edge .

9 $n the local explorer , e"pand the /eads and /inks options, and then select /ead1n .





10 $n the /ead in window, select *st Choice - Ra$p -

11 $nput the following Ra$p 'ptions

12 +lic# Calc&late to process the Model Area Clearance toolpath.

13 elect an 1S' - view.

The 'ffset Model - Area Clearance strategy follows the model contours whilegradually offsetting into the remaining material at each ? @eight.

14 ight-clic# the toolpath and select Si$&late fro$ Start to display theSi$&lation tool!ar.





15 %nsure that the 8ie.M1// tool!ar is also active.

16 witch the 8ie.M1// 'n?S&spend setting to a green sphere , and then

select the hiny shaded image icon .

17 9ress the Pla+ !utton to start the simulation.

#ndrawing the tool will speed up the s imulation. $ou can control the displayof the tool by left clicking on the tool entity, light bulb in explorer.

The finished result indicates that in some areas of the model there is still too muchmaterial for the finishing strategies to cope with.

*s a result, a further area clearance strategy is required using a smaller tool tocontinue locally into the remaining areas. This technique is #nown as Rest machining.

18 +lic# to suspend 8ie.M1// .

19 +lic# to return to the Po.erM1// window.





Rest Roughing using a Reference Toolpath1 +reate a "ip Radi&sed tool of Diameter *# , Tip adius 3 and name it as D*#"R3 .

2 elect "oolpath Strategies , and from 3D Area Clearance open a ModelRest Area Clearance strategy.

:y directly selecting Model Rest Area Clearance , the Rest $achining optionsand the most suita!le style, 'ffset Model will already !e active in dialog.

a %nter a new Toolpath name D*#"R3)D*

b eep the "hickness as !,

c %nter Stepover as *

d %nter Stepdo.n as

e S elect the Rest page in the strategy dialog.





f elect the Rest $achining type as "oolpath , enter D>!"R#)D* as thereference toolpath, and input Detect material thicker than as !,

g $n the local explorer , select <nsafe seg$ent re$oval page and if set, !n-tick the Re$ove seg$ents s$aller than threshold option.

h Activate the D*#"R3 tool to !e used in the new toolpath.

3 +lic# Calc&late to process and create the additional 'ffset Model ) AreaClearance toolpath and then Close the dialog.

4 &rom the Main pull down menus select 0ile ) Save Project to update

......\COURSEWORK\PowerMILL-Projects\Wing_Mirror_Die





5 witch the 8ie.M1// 'n?S&spend !utton to a green sphere .

6 elect the Rain9o. Shaded 1$age .

7 ight mouse clic# on the toolpath D*#"R3)D* and select Si$&late fro$ Start .

8 9ress the Pla+ !utton to start the simulation.

The 8ie.M1// simulation shows this toolpath shaded in a different colour whereit has machined in areas the previous toolpath did not cover.

The &eference toolpath has successfully accessed material closer to thecomponent form.

This will reduce the ris# of e"cessive wear or damage to tools used for thesu!sequent finishing operations.

9 +lic# the 8ie.M1// 'n 7S&spend !utton to a red sphere and then clic#to return to the Po.erM1// window.

Rest Machining using a Stock Model*n alternative method for rest roughing is the use of a Stock Model instead of a&eference toolpath .

The !enefits of using a Stock Model compared to a reference toolpath are

The remaining surplus material can !e visualised and registered along with theassociated toolpaths.

* rest machining strategy referenced to a Stock Model will include the effect ofall previous toolpaths currently registered to that Stock Model .

* toolpath that was created to a different .orkplane (for e"ample, multi-a"is)can !e referenced to a Stock Model .

t is not possible to apply a re t machining strategy referenced to atoolpath that was created to a different workplane .





$n this e"ample a Stock Model is created to initially include the D>!"R#)D* toolpath. Then, a copy of the toolpath, D*#"R3)D* is created using the StockModel for the re t machinin# reference.

1 $n the Po.erM1// explorer , Activate the toolpath D>!"R#)D* .

2 $n the Po.erM1// explorer , right-clic# Stock Models and select Create StockModel .

3 Accept the a!ove default values for the trian#le me h creation.

4 $n the Po.erM1// explorer , right-clic# the newly created Stock Model * andselect Appl+ = Active "oolpath 0irst .

:oth the currently active Block and toolpath are added to Stock Model .

5 &rom the same menu, select Calc&late to physically update the Stock Model .





* triangular mesh will appear representing the state of the material after the effectof the first machining strategy, D>!"R#)D* .

$n the ne"t two actions, The Stock Model will !e changed to -

a 6isually remove the component form ( Sho. Rest Material ).

b 6isually change the style from triangle mesh to a shaded form ( Shaded ).

6 &rom the same menu, select Dra.ing 'ptions = Sho. Rest Material .

7 &rom the same menu, select Dra.ing 'ptions = Shaded to display the shadedview of the Stock Model .





8 $n the Po.erM1// explorer , Activate the toolpath D*#"R36D* .

9 ight-clic# on the toolpath D*#"R36D* and select Settings to open the ModelRest Area Clearance strategy dialog.

10 +lic# to create a copy of the toolpath.

11 elect the Rest page and modify the settings as !elow using Stock $odel * .

12 +lic# Calc&late to create an alternative and more efficient Rest Machining toolpath named D*#"R3)D*6* .

13 Close the machining strategy dialog.





*lthough the toolpath D*#"R)D*6* appears (coloured purple) as a referencedentity in the Stock Model list, the resultant machining effect is notautomatically added.

14 $n the Po.erM1// explorer , right-clic# the toolpath, D*#"R3)D*6* and select

Add to = Stock Model .

At this stage, the Stock Model will disappear from the screen.





15 ight-clic# the active Stock Model and select Calc&late to update it.

16 &rom the Main pull down menus, select 0ile = Save Project to update

......\COURSEWORK\PowerMILL-Projects\WingMirrorDie



Exercise

Area clearance with both unsafe segment removal andrest roughing

1 1$port the Model

......\PowerMILL_Data\Models\Cowling.dgk

2 elect an 1S' * view.





Machining setup3 +reate the following tools

"ip Radi&sed tool ' *ame D*#"R3 , Diameter *# Tip adius 3

"ip Radi&sed tool ' *ame D*-"R* , Diameter *- Tip adius *

4 +reate a Workplane and centrally position it to the top centre of the Model , andthen Activate it.

5 Calc&late a Block using Defined by ' Bo% and "+pe ' Model , then change theMin Z value to )@! and loc# it !y selecting the ad acent padlock .

6 Calc&late the Rapid Move Heights using the default settings.

Area Clearance Strategies1 +reate a Model Area Clearance strategy named D*#"R3)R H* using

a The D*#"R3 tool.

b The Style as 'ffset All .

c Stepo%er @ and Stepdown *-

d * Thickne of !,

e $n the 0lat Machining page use /evel .

f elect <nsafe seg$ent re$oval (use the default settings) to prevent theD*#"R3 tool from attempting to machine into the central poc#et.





2 +reate another Model Area Clearance strategy named D*-"R*)R H* using

a The D*-"R* tool.

b The Style as 'ffset Model .

c tepover 2 and tepdown 3

d $n the 0lat Machining page use Area .

e %na!le the Rest $achining page and reference to the previous toolpath.

f Disa!le the <nsafe seg$ent re$oval option.

3 Save Project As

......\COURSEWORK\PowerMILL_Projects\ModelAreaClear-Exercise





ViewMILL Simulation

4 9erform a 8ie.M1// simulation with the Rain9o. Shaded 1$age optionactive on !oth of the Model Area Clearance toolpaths.

5 elect ;%it 8ie.M1// to close the current session.

Do not close the Pro+ect as it will be continued in the following section.

Area Clearance using the Step option$f a large stepdown is used in the Area Clearance strategies then the !ul# of thewaste material will !e removed as quic#ly as possi!le. This will inevita!ly leave largesteps on the remaining stoc# that would normally !e reduced using a separate rest roughing operation. @owever, if it is accepta!le to use the same "ool then the Step option will provide rest machining within the same Area Clearance strategy. $n thiscase additional passes are applied (where required) that step upwards !etween theoriginal Z Heights .





1 Activate the e"isting toolpath D*#"R3)R H* to restore the settings used.

2 un a new 8ie.M1// simulation (as shown a!ove) on the toolpath D*#"R3)R H* .

3 elect ;%it 8ie.M1// to close the current session.

4 ight mouse clic# on the active toolpath D*#"R3)R H* and from the local menu

select Settings .

5 elect the 4a#e a +opy/ of the toolpath option .

6 Rena$e the new toolpath as D*#"R36Step)R H*

7 $n the main page of the dialog change the Style to 'ffset $odel .

8 $n the Model Area Clearance , local explorer , select Step c&tting .

9 Tick the Step c&tting !o" and enter values e"actly as shown !elow.

10 elect Calc&late to create the toolpath D*#"R36Step)R H* .

11 un a new 8ie.M1// simulation on the toolpath D*#"R36Step)R H* .





The a!ove image shows the effect of the Step c&tting option trac#ing upwardsfrom the first slice to get closer to the model form.

The +omponent has !een oughed 8ut/ with ma"imum efficiency, close to thefinal shape within the same strategy.

12 Save the Project .







Model Area Clearance – Vortex example

8orte% machining is an area clearance strategy which rapidly removes materialfrom a 3D part while controlling tool load. 8orte% is !est suited to solid car!idetools and is frequently used in com!ination with step cutting.

The engagement angle never e"ceeds that produced !y a straight line cut with a

given tepo%er . This eliminates e"cessive tool load and all full-width cuts. Thisena!les you to increase feed rates. *s the tool approaches the ma"imumengagement angle, the strategy automatically changes to use a trochoidal path toavoid tool overload.

1 'pen the (read-only) Project -

……\PowerMILL_Data\Projects\Vortex2-Start

2 Save Project As -

……\COURSEWORK\PowerMILL_Projects\Vortex2

3 Activate the .orkplane , "opCentre)dat&$ .

4 &rom the $ain tool!ar select Block and using, Defined by Bo% ' TypeModel select Calc&late followed !y accept .

5 &rom the $ain tool!ar select Rapid Move Heights and in the form selectCalc&late followed !y Accept .






7 $n the Model area clearance page of the strategy dialog

a %nter "oolpath na$e ' D*#"R3)8orte%)R H*

b elect St+le ' 8orte%

c et C!t direction ' :oth Profile and Area - Cli$9

d $nput "hickness !,

e $nput Stepover 3,!

f $nput Stepdo.n *-,!

8 8pen the 8orte% page of the strategy dialog

a $nput Mini$&$ radi&s 2r4 as 3,!





9 8pen the Step c&tting page of the strategy dialog

a Tick the Step c&tting !o" and then input a Step&p value of *,!

10 8pen the 0lat $achining page of the strategy dialog

a et Machine flats to /evel .

11 8pen the Approach page of the strategy dialog

12 $n the Helical ra$p options window, select Max ,i# an#le > with a Circlediameter !,# and $ei#ht .

13 *t the !ottom of the dialogue select Calc&late to process the 8orte% - ModelArea Clearance toolpath.





14 9erform a 8ie.M1// si$&lation on the toolpath to o!serve the 8orte% strategy.

15 Save the Project .








a %nter the *ame as ;M*-)0lats'00 .

b et "hickness to !,

c et Stepover to

d et Stepdo.n to *-

e elect the 0lat machining page and set Machine flats to 'ff .

10 +lic# Calc&late to process the toolpath and then Close the dialog.





;hen the Machine flats option is set to 'ff , the toolpath totally ignores the flatsurfaces of the model. $t maintains the defined Stepdo.n value and performs areaclearance across the material Block at each Z Height .

1 ight-clic# the active toolpath, ;M*-)0lats'00 and select Settings .


3 +hange the new toolpath name to ;M*-)0lats/;8;/ .

4 8n the 0lat $achining page, change Machine flat to /evel .

5 Calc&late to process the toolpath and then Close the dialog.

6 ight-clic# the active toolpath and select Settings .


8 +hange the toolpath name to ;M*-)0latsAR;A .





9 8n the 0lat $achining page, change Machine flat to Area .

10 Calc&late to process the toolpath and then Close the dialog.

The Model Area Clearance toolpath now removes material locally across each&lat face leaving a total of . mm stoc# (The "hickness plus the "olerance ).

11 elect 0ile - Save Project to update -

......\COURSEWORK\PowerMILL-Projects\AreaClearFlats

Machining Flats separately using Slice Area Clearance$n Po.erM1// Pro it is possi!le to use Slice Area Clearance to separatelymachine the flat areas of a model to their e"act height. This could !e used

a *s a finishing strategy, applied to the flat areas after a Model AreaClearance roughing strategy where Machine flat was set to /evel orArea .

b *s a secondary roughing strategy, applied to the flat areas only, that followson from a Model Area Clearance where Machine flat was set to 'ff .

There are several types of 2D entity that are supported in the Slices options -





12 ight-clic# on the ;M*- -0latsArea toolpath and select Activate to reinstate allsettings and parameters used.

13 elect "oolpath Strategies , and from 3D Area Clearance open a SliceArea Clearance strategy.

a %nter *ame as ;M*-)SliceAC .

b et Slice as 0lat .

c et Style as 'ffset all .

d et Tolerance !,!- e et Thickne !

f et Stepo%er

14 elect the 0lat $achining page (*vaila!le when Slice 0lat is active) and

a +hec# that the Allo. tool o&tside flat !o" is ticked .

15 elect Calc&late to process the toolpath and then Close the dialog.





This Slice Area Clearance strategy is confined to the 0lat areas only.

*t the moment, the cutter profiles around the edge of the holes located within aflat area. $f preferred, the strategy can !e changed to 1gnore Holes (!elow aspecified Diameter) causing the tool to pass straight across them.

16 ight-clic# on the Active toolpath and select Settings to re-open the Slice AreaClearance dialog.

17 +lic# on to create a copy of the toolpath.

18 ename the toolpath as ;M*-)SliceAC)1gnoreHoles and then select the 0lat $achining page.

19 elect a Tick in the 1gnore holes !o".

The "hreshold (tool diameter units) defines the ma"imum siEe of holes toignore. ;ith the tool ;M*- selected and the "hreshold set to - , holes that aregreater than Dia 2>mm will not !e ignored.

20 elect Calc&late to process the toolpath and then Cancel the dialog.





The cutter now passes across the top of the holes without lifting, producing asmoother, more efficient, toolpath.

I#nore $ole refers to the area defined by the slice definition at the top ofthe holes. The flat base of any hole will still be machined.

21 ight-clic# the Active toolpath and select Settings to re-open the Slice AreaClearance dialog.

22 +lic# on to create a copy of the toolpath.

23 ename the toolpath as ;M*-)SliceAC)M&ltipleC&ts and then select the 0latmachining page.

a elect the M&ltiple c&ts option and set the Bum!er of cuts as 3.

b $nput the Stepdo.n as -,!

c elect the 0inal stepdo.n option and input *,!

24 elect Calc&late to process the toolpath and then Close the dialog.





$f there is a large amount of material remaining a!ove the flat areas, then theM&ltiple C&ts option is applied to reduce the tool loading during AreaClearance .

The %D& shaped lat area at the very top level does not use 'ultiple (uts asthe top of the )lock is the overall * limit for the strategy.

+elect ile - Sa%e Pro+ect to update -

(......\COURSEWORK\PowerMILL-Projects\AreaClearFlats)





Further information on Area ClearanceMachining

The following is reference information for the many different options contained inthe Area Clearance dialogs. This can also !e found !y using Help .

Restrict Tool Overload – Trochoidal movesThis option is availa!le to Area Clearance strategies in which St+le - 'ffset$odel is set. The dialog for activating and entering the Ma%i$&$ overload value(A) is located on the High speed options page.

$f the tool reaches a specified overload situation, Po.erM1// automatically inputs atrochoidal path to eliminate full width cuts. This will occur in corners, narrowchannels, slots, etc. The degree of movement is controlled with the slider as apercentage value in the form.

Thickness+lic# the "hickness !utton in strategy dialogs to enter separate Radial

and A%ial thic#nesses.

- adial Thic#ness

- *"ial Thic#ness







Cut DirectionThe C&t Direction settings control the direction of the tool along the toolpath

An+ ' This instructs the cutter to machine in !oth directions.

Cli$9 ' This instructs the cutter to profile such that the material is to the rightof the direction of travel (+lim! milling).

Conventional ' This instructs the cutter to profile such that the material is tothe left of the direction of travel (+onventional milling).

Wall FinishingThe Wall 0inishing page in the Model Area Clearance strategy dialog allows youto ma#e an additional, final profiling pass to further reduce tool wear.

Allow tool outside blockThe Allo. tool o&tside 9lock setting is availa!le on the /i$it page of the ModelArea Clearance dialog.

This ena!les the strategy to e"ist outside the Block !y the tool radi! value.

This option limits the strategy with the tool centre flush with the Block .

Flat MachiningThe 0lat Machining page of the Model Area Clearance dialog contains options tocontrol if and how the flat areas of a component are machined. These include 'ff ,Area , and /evel .

/evel - 0lat Machining occurs across the whole area defined !y the Block .

The nominal tepdown value is locally reduced as required to accommodateeach lat area as part of an equally spaced group.

Area - 0lat Machining is confined to the individual lat areas.

The nominal Stepdo.n value remains constant (independent of the lat areas).

RampingThe Ra$p option is availa!le on the /eads and /inks dialog to use where it isimpossi!le to approach from outside the Block at the full machining depth (fore"ample, within a poc#et).

There are 3 different options for the type of Ra$p move - "oolpath , Circle ,and /ine . These can !e used to lead on to the start of a tool trac#.

The Zig angle is the angle of descent along the machining direction as the toolramps into the material. $f the length of the Zig angle is limited to a finitedistance, a ramp move in the opposite direction ( Zag angle) can also !e applied.





The Ra$p /ength is defined as "ool Dia$eter <nits ( "D< ). &or e"ample, *amp Gength of - "D< would equal 2 mm for a Dia 1 mm tool.

$f Add approaches fro$ o&tside is set, it will ta#e priority over Ra$ping .

$f the defined geometry for a Ra$p move is such that it would cause a gouge,then the tool approaches using a default Pl&nge move.



PowerMILL 2015 4. Finishing Strategies


Finishing strategies machine the actual component form, and where applicable,follow on from the Area Clearance operation. Suitable values are required tocontrol the accuracy and amount of excess material to be left on a component by atoolpath. The parameters used for this purpose are called Thickness andTolerance .

Thickness is the amount of extra material specified to remain on the work-pieceafter machining. This can be applied generally as an offset from the model (as

shown , or independently as separate Radial and Axial values within the machiningoptions.

It is also possible to assign additional Thickness values to selectedsurfaces on the model (Component Thickness).

Tolerance controls the accuracy to which the cutter path follows the shape of thework-piece. !or roughing, use a coarse tolerance, and for finishing use a finetolerance.

A positive Thickness value should always be greater than the Tolerance value.

4. Finishing Strategies



4. Finishing Strategies PowerMILL 2015


Raster Finishing and Pattern FinishingRaster Finishing works by pro"ecting a wireframe, #attern down the $-axis ontothe model. The standard pattern applied in Raster Finishing is obtained byentering values directly into the Finishing dialog. Two other types of s tandardpattern strategy (not covered in this course include Radial and Spiral .

The Pattern Finishing strategy uses an existing, pre-defined Pattern orToolpath , which is either pro"ected down $ onto the model or used in situ as aDrive Curve to generate the toolpath.

Typical previews of all % available pattern strategies are shown below as vieweddown $.

The Raster finishing strategy is used as an example in the next section.

Raster Finishing1 !rom the Main pull down menus select File - Delete All and Tools - Reset

Forms .

2 Then select File & pen Pro!ect '

…...\PowerMILL_Data\Projects\Handset_Start





3 !rom the Main menu , select File & Save Pro!ect As '

......\COURSEWORK\PowerMILL-Projects\Handset_PatternMC

4 Activate the existing toolpath D"#TR$-R%&' to restore all the set-up settings.

5 Activate the tool ()'" .

6 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Raster Finishing strategy.

7 lick * to display the Raster Finishing strategy dialog and enter the followingsettings and values.





a )ame the toolpath ()'" -Raster-S+M' .

b *nter the Tolerance as , ' and Thickness as , .

c Select rdering - St/le as T0o 1a/ .

d *nter a Stepover of "

e lick the Previe0 tab to display the pattern (as shown below .





Several options exist to add lead and link moves at the start and end of eachindividual tooltrack. The aim is to provide a smoother transition for the tool toapproach tangentially onto the component form instead of simply plunging directlydown the $-axis.

8 +n the Raster Finishing dialog open the 2eads and 2inks options (left click onthe small box containing .

9 Select the 2ead in page and select 1st choice as 3ertical arc , input Angle 4, ,Radius 5 , , and un-tick the option Add leads to short links .

10 Select 2ead out the same as lead in .

11 Select the 2inks page and input the value and options exactly as shown in thefollowing image.

12 lick Calculate to process the toolpath and then Close the dialog.





The above toolpath contains sharp corners along the vertical plane. These can bearc fitted within the Raster Finishing dialog.

+n the Raster Finishing , &igh speed page the Arc fit corners option inserts aradius in the vertical plane (maximum , " Tool iameter nits .

13 +n Po0erM622 explorer , right-click the ()'" -Raster-S+M' toolpath andselect Settings .

14 lick to enable the toolpath ()'" -Raster-S+M' to be edited.

15 /n the strategy dialog'

a /pen the &igh speed page.

b Select the Arc Fit option and edit the Arc Radius to the maximum value , "

c lick Calculate to process the toolpath and then Close the dialog.

16 $oom into the toolpath to view the arc fitted tooltracks'





The value , " ( TD7 , multiplied by the tool diameter ( '" produces a radius of " .

17 +n Po0erM622 explorer , right-click the ()'" -Raster-S+M' toolpath andselect Settings .

18 lick to create a copy of the toolpath named ()'" -Raster-S+M'8'

19 0ename the new toolpath as ()'" -Raster-F6)' and input suitable finishingvalues as shown in the following image.






+f the raster pattern is pro"ected downwards parallel to a steep wall then theactual distance between the tooltracks is likely to become unexceptably large.

!or this reason the raster pattern in ()'"-Raster-F6)' has been created at a'$# Angle to minimise where the tooltracks run parallel to steep walls.

21 0un a full 3ie0M622 simulation on all 1 existing toolpaths.

22 isconnect 3ie0M622 from the simulation process ( hange the sphere from

green to red and then select )o 6mage to return to the Po0erM622 view.







27 lick pen .

The imported Pattern is made up of 3 geometry and is positioned relative tothe Transform (4orld co-ordinates .

)ext this 3 geometry will be pro"ected along $ onto the 1 model to create asingle Pattern Finishing toolpath with a negative Thickness value.

28 Activate the tool ()' .

29 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Pattern Finishing strategy.





a *nter the Toolpath name ()'-+ngrave

b +nput Pattern ' .

c +n 1-2xis applications the Base position can be set to either Automatic or3ertical , for the Pattern form to be pro"ected down 9 onto the model .

d *nter a Tolerance , ," and Thickness -, .

30 Select the 2ead in page and select 1st choice as )one .

31 Select the option 2ead out the same as lead in .

32 Select the 2inks page and input the value and options exactly as shown in thefollowing image.





33 Select Calculate to process the toolpath then Close the dialog.

The Pattern is machined to an offset depth of -, . into the finished modelform.

It is not possible to use a –ve thickness value that is greater than the ToolTip adius. There is! however! an alternative way to achieve this ( Chapter10 Patterns ! page 20 " Deep Pattern achining ).

34 Simulate the engraving toolpath in 3ie0M622 .

35 Select File - Save Pro!ect to update the contents of'

......\COURSEWORK\PowerMILL-Projects\Handset_PatternMC





3D Offset and Constant Z Finishing+n this section, $D ffset and Constant 9 finishing strategies are applied to amodel that consists of a combination of flat and steep areas plus a pocket withvertical walls. +n this example a (oundar/ will be created and used to limit the twostrategies to where they are most effective.

1 Select File - Delete All and File - Reset Forms .2 Select File - pen Pro!ect and in the dialog browse to'

…...\PowerMILL_Data\Projects\camera_start

The Pro!ect is locked and subsequent changes cannot be saved unless theincluded lock file is deleted.

3 Select * to continue loading the Pro!ect into the Po0erM622 session.

4 !rom the Main pull down menus, select File & Save Pro!ect As '

......\COURSEWORK\PowerMILL_Projects\Camera_Example

The Pro!ect already contains a Tip Radiused tool and a Model Area Clearance

toolpath along with the associated settings.





Creation of a Shallow Boundary to define specificmachining areas

2 Shallo0 (oundar/ creates segments around areas of the model that aredefined by an !pper and "o#er threshold angle. +t is therefore specifically suitedto steep walled and shallow surface machining techniques.

There are several other types of Boundar$ options available to suitvarious applications and these are covered later in Chapter % .

+n the below example, a Shallo0 (oundar/ is used to discriminate areas mostsuited to the individual machining strategies. This type of (oundar/ is calculated,taking the Acti&e Tool , Thickness , and Tolerance into consideration.

1 efine a (all )ose tool of Diameter ', called ()', .

2 +n the Po0erM622 explorer , right-click (oundaries and select Create(oundar/ & Shallo0 .

3 +n the displayed Shallo0 (oundar/ dialog'





a *nter the )ame as Shallo0()',

b *nter !pper Angle $, and "o#er Angle ,

c *nter Tolerance as , ,"

d *nter Thickness as ,

e *nsure the correct tool ()', is Active .

f 7n-tick the box, Allo# boundar$ to be pri&ate .

g Appl/ and Accept the dialog.

4ith the model , Tool , and toolpaths undrawn, the (oundar/ can be viewedas shown'

This :oundar/ is made up of numerous segments5 each one dividing the model intosteep and shallo0 areas. 2ny of these segments can be selected and individuallydeleted at any time, except when it is assigned to a toolpath and locked.





Constant Z FinishingConstant 9 Finishing pro"ects each tool track hori6ontally onto the component atfixed heights defined by the Stepdo0n .

2s the component surface becomes shallow, the actual tool stepover increases untilit becomes non-existent on flat areas.

1 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Constant 9 Finishing strategy.

2 +n the Constant 9 Finishing dialog'

a *nter a Toolpath name 7 ()',-Constant9

b Tick the Spiral option.

c *nter a Tolerance of , ,"

d Set the Cut Direction to Clim: .

e *nter a Stepdo0n of , #





3 /n Constant 9 finishing dialog, select the 2imit page and with the Boundar$ Shallo0()', active, set Trimming to *eep outside .


8y using the (oundar/ - Trimming option as *eep outside , the toolpath islimited to the steep areas of the model .





Introduction to Leads and LinksThe above toolpath has inherited circular Ramp lead moves (pale blue from thepreviously activated toolpath Rough p' . !rom the main toolbar we will open the2eads and 2inks dialogue and apply &ori;ontal Arcs to both the start and end ofthe 2ong link moves and n Surface to the Shor t link moves ( < . .

1 lick the 2eads and 2inks button on the Main toolbar.

2 Select the 2ead 6n tab and'

a +n 2ead in , change the 'st Choice to &ori;ontal Arc , Angle 4, andRadius #

b Tick the Add leads to short links box.

c lick the 2ead ut the same as lead in button.

3 Appl/ and Accept the dialog.

The tool now leads in and out of the toolpath with a &ori;ontal arc .

+f the tool lifts, it will only lift by the skim distance taken from the first page ofthe 2eads and 2inks dialog ( 9 &eights tab .

The rapid feed moves at skim height are purple in colour while the plungefeed moves are light blue.





3D Offset Finishing$D ffset !inishing creates the toolpath stepover relative to the 'D odel providing consistency over both flat and steep areas. To produce an improved toolmovement over the model a Shallo0 (oundar/ will be used to limit this strategyto where it is most effective.

1 !rom the main toolbar, select Toolpath Strategies and from Finishing open a $D ffset Finishing strategy.

2 +n the $D ffset !inishing strategy dialog'a *nter Toolpath name as ()',-$Doffset

b Tick the Spiral option

c Set the Cut Direction to Clim:

d *nter a Tolerance of , ,"

e *nter a Thickness of ,

f *nter a (tepo&er of , #





3 /n the $D ffset finishing dialog, select the 2imit page

4 Select the (oundar/ - Shallo0()', .

5 Select Calculate to create the toolpath and then Close the dialog.

The Toolpath follows the contours of the (oundar/ segments and is producedonly within the shallo# areas of the model ( )nside the (oundar/ .

This toolpath has inherited the current settings in the 2eads and 2inks dialog,as applied to the previous toolpath ()',-Constant9 . 2 more suitable optionfor bot 2ead in and 2ead out would be 3ertical arc .

6 lick the 2eads and 2inks button from the top of the screen.7 Select the 2ead in tab and'

a n-tick Add leads to short links , change the 'st Choice to 3ertical Arc ,Angle 4, and Radius # .

b lick the 2ead ut the same as lead in button.






The toolpath now is more efficient with the rapid moves at skim height , the longlinks using 3ertical Arc 9eads, and the short links being linked along the surface.

To further improve this 'D *ffset strategy! you can tick the (moothing option. This results in sharp corners being replaced with a smooth blendwherever possible.

9 Simulate all of the toolpaths in 3ie0M622 .

10 Select File 7 Save Pro!ect to update (but do not close '-

To update'- ......\COURSEWORK\PowerMILL-Projects\Camera_Example





Optimised Constant Z FinishingThis strategy is a mixture of Constant 9 and $D ffset machining5 Constant 9 isapplied to steep areas and, $D ffset is applied to other areas.

11 e-activate the (oundar/ , (hallo#B+10 in the Po0erM622 explorer .

12 !rom the main toolbar, select Toolpath Strategies and from Finishing open an ptimised constant 9 Finishing strategy.

a *nter Toolpath name as ()',- ptC9

b Tick the Spiral , Closed ffsets , and Smoothing options.

c *nter the Tolerance as , ,"

d Set the Cut direction to Clim: .

e *nter a Stepover value of '

f /n the 2imit page, make sure that the (oundar/ is not selected.

13 Select Calculate and when the toolpath is created, Close the dialog.

)ote the consistent 1 Stepover across the whole component.





14 !rom the Main menu, click the 2eads and 2inks button to display the 2eadsand 2inks dialog and then, select the 2inks tab.

a hange the Short=2ong Threshold to 2.

b hange the Short links to n Surface .c hange the 2ong and Default links to Skim .


16 Select File - Save Pro!ect to update (but do not close '-

......\COURSEWORK\PowerMILL-Projects\Camera_Example





Steep and Shallow FinishingThis strategy includes the following additional options'-

The option to input a Threshold Angle to control the extent of the Constant 9 and$D ffset areas of the toolpath.

The option to input a steep shallo0 overlap value between the Constant 9 and$D ffset areas.

1 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Steep and Shallo0 Finishing strategy.

2 *nter the values exactly as shown'

a *nter Toolpath name as ()',-SteepAndShallo0 .

b !or the *rder select Steep first .c !or the Threshold angle input $, .

d Tick both of the Spiral boxes.

e !or both the Stepdo0n and Stepover input ' .

f !or T/pe (shallow select $D offset .

g Tick the Smoothing box.

3 Select Calculate to process the toolpath and then Close the dialog.





4 Select File - Save Pro!ect to update'-

......\COURSEWORK\PowerMILL-Projects\Camera_Example

Steep and Shallow finishing with separate ShallowStepover

8oth ptimised Constant 9 and Steep and Shallo0 strategies have an option toapply a separate, larger Stepover across shallow areas. This option is designed toenable a more efficient machining of shallow areas with a Tip Radiused tool.

The main advantage with the Steep and Shallo0 strategy is that the ThresholdAngle is user defined. This can be set to , making the large stepover apply overflat areas only.

1 Delete All and Reset Forms .2 Select File - pen Pro!ect and in the dialog browse to'

......\PowerMILL_Data\Projects\ADV-SteepShallow-Start

3 lick OK to load the read-only Pro!ect into Po0erM622 .

4 Save Pro!ect As '

......\COURSEWORK\PowerMILL_Projects\ADV-SteepShallow-EX1

5 +n the Po0erM622 explorer , right-click on the existing toolpathD'5t$-SteepShallo0-F6) and select Settings .





The component form includes 3 flat areas which are currently finished with thesame small stepover as the angled walls. !or more efficiency, an option isavailable for a larger stepover to be independently applied to the shallow flatareas.

6 lick Rec$cle to enable edits to the existing toolpath.

7 pdate the main page of the dialog exactly as shown below.

a Select *rder as Steep first .

b +nput the Threshold angle as ,

c Tick the Calculate using cusp box and input .

d +nput a Stepdo0n of , ,' and a aximum stepdo#n of , $

e !or the shallow regions, enter a Stepover of 5






The flat areas are machined more efficiently using a large stepover while the steep areas use a small, variable stepdo0n based on the cusp height . Thisprovides an efficiently produced, consistent finish over the whole form.

9 0un a 3ie0M622 simulation on both the Roughing and ,inishing toolpaths.

10 Select File - Save Pro!ect , to update'-

......\COURSEWORK\PowerMILL_Projects\ADV-SteepShallow-EX1





Corner FinishingCorner Finishing strategies identify and remove material in corners that areinaccessible to previously used, larger tools. There are 1 independent types ofstrategy' Along , Stitch , and Automatic .

2ll Corner Finishing strategies include a Threshold Angle option. This is theangle down from the hori6ontal, where the steep and shallo# portions meet.

The Threshold Angle can be defined to prevent the tool running up or down steepslopes. !or example, you could apply a Stitch strategy to track across the steep areas, while using the Along strategy in shallo# areas.

If the Threshold Angle is -0 then the (teep area will not e#ist.

The Corner Finishing and Multi-Pencil strategies machine the areas that areinaccessible to the 0eference tool (3 but are accessible to the active tool, as in thediagram.

+n the following example, the Corner Finishing strategy uses a ia :; 8all )osefor the reference tool, and a diameter ia < 8all-nose to perform the restmachining.

1 Select File - Delete All and Tools - Reset Forms .

2 !rom the Main menu, Select File - pen Pro!ect and select'

......\PowerMILL_Data\Projects\CornerFinish_Start

3 !rom the Main menu, select File - Save Pro!ect As '

......\COURSEWORK\PowerMILL-Projects\CornerFinish





Corner Along Finishing4 Select an 6S " view.

5 Activate the toolpath , D'5T$-rghA' to restore the settings.

6 reate a ia < ball nose tool named ()# .

7 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Corner Finishing strategy.

a *nter Toolpath name as CornerAlong8Shallo0 .

b hange utput to Shallo0 and Strateg/ to Along .

c Set Cusp to , ,$

d Set Cut direction to Clim: .

e /n the Tool page, check that the ()# tool is Acti&e .

f Select the Corner detection page and select the Reference tool as ()', .





8 Select the 2ead in page and set the "ead in to )one .

9 Calculate to process the toolpath and then Close the dialog.

10 Simulate the toolpath and observe the order of the machining'

)ote' 4ith utput set to Shallo0 , the toolpath has stayed within the shallowareas of the model (between hori6ontal and a downward angle of 1; egrees .

If a Threshold angle of -0 is used! the (hallo# option will apply to allvalid rest areas. In this case the (teep option is non"e#istent.





Corner Stitch Finishing


a *nter Toolpath name as CornerStitch8Steep .

b hange *utput to Steep and (trateg$ to Stitch .

c heck that the ()# tool is active on the Tool page.

d heck that the Reference tool is ()', on the Corner detection page.


This time, only the steep areas are machined.

3 !rom the Main menu select File > Save Pro!ect to update'-

......\COURSEWORK\Projects\CornerFinish





Corner Automatic Finishing


a se Strateg/ - Automatic .

b hange utput to (oth .

c hange the Threshold angle back to $, ,


This strategy automatically uses Along for the Shallo0 areas and Stitch for theSteep areas.





Corner Pencil FinishingCorner Pencil creates a single toolpath along the actual intersection between non-tangential faces on the model.

1 !rom the main toolbar, select Toolpath Strategies and from Finishing

open a Corner Pencil Finishing strategy.

a hange utput to Shallo0 .

b hange the Threshold Angle to 90

$ote% &ith a Threshold Angle of -0 the (teep angle will not e#ist! so only*utput with (hallo# or Both selected will enable a toolpath to be created.

c /n the Tool page, make the ()# tool active.

2 Select Calculate to process the toolpath, and then Close the dialog.





Corner Multi-pencil FinishingCorner Multi-Pencil Finishing creates a multi-track, rest finishing, toolpath basedon the Pencil Finishing strategy. /n creation it visually looks similar to a CornerFinishing toolpath, but on closer inspection there are subtle differences to thetoolpath order and that it includes tool tracks along the model intersections.

1 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Multi-Pencil Finishing strategy.

d hange utput to (oth .

$ote% &ith a Threshold Angle of -0 the (teep angle will not e#ist! soonly *utput with (hallo# or Both selected will enable a toolpath to becreated.

e hange the Threshold Angle to 4,

f /n the Tool page, make the ()# tool active.

g +n the Corner detection page check that ()', is selected.



......\COURSEWORK\Projects\CornerFinish





Flat FinishingThese strategies apply to purely flat surfaces only. !lat areas within a variableheight surface are not recognised. The minor discrepancies in the flatness of asurface is controlled by a Flat Tolerance value.

1 Delete All and Reset Forms .2 !rom the Main menu, select File - pen Pro!ect '

......\PowerMILL_Data\Projects\FlatFinish_Start

3 Select File - Save Pro!ect As '

......\COURSEWORK\PowerMILL-Projects\FlatFinish-Example1

Offset Flat Finishing1 +n the Po0erM622 explorer , both Activate the ia := *nd >ill ( +M'5 Tool ,

and ensure that no (oundar/ is active.

2 !rom the main toolbar, select Toolpath Strategies and from Finishing open an ffset Flat Finishing strategy.

3 Select Calculate and when completed, Close the dialog.





The imported Pro!ect contains both an ffset Area Clear roughing strategy andan ptimised Constant 9 finishing strategy. +t is recommended that ffset Flats (+M'5Flats-a' is run directly after the $D Area Clearance ( D'5t$-a' . !or thisreason, it would make good sense to move it up the toolpath order in thePo0erM622 explorer .

1 +n the Po0erM622 explorer , hold the left mouse key down on the ffset Flats Finishing toolpath ( +M'5Flats-a' while dragging it to the new position.

2 #erform a 3ie0M622 simulation on all 1 toolpaths to check that the method andresult of removed material is acceptable.

The 3ie0M622 simulation after the ffset Flat Finishing strategy is shown above.





Raster Flat Finishing

1 !rom the main toolbar, select Toolpath Strategies and from Finishing open a Raster Flat Finishing strategy.

2 Select Calculate and when completed, Close the dialog.


......\COURSEWORK\PowerMILL-Projects\FlatFinish-Example1





Flat Machining example1 Select File - Delete All and Tools - Reset Forms .

2 Select File - 6mport Model '-

......\PowerMILL_Data\Models\Flats.dgk

3 Save the Pro!ect as'-

......\COURSEWORK\PowerMILL_Projects\FlatFinishing-Example2

4 reate a ",mm diameter +nd Mill tool named +M", .

5 Calculate the (default (lock and then reset the Rapid Move &eights .

6 /pen an ffset Flat Finishing strategy and'-

a )ame the toolpath +M",-FlatFin .

b lick the use Axial Thickness button and enter separate Thickness valuesfor Radial , # and Axial ,

c Calculate to process the toolpath and then Close the dialog.





>ost of the Flat areas are finish machined, apart from the gap between thepstands and inside the holes due to the ",mm diameter tool being too large. 4e

will now use a smaller tool to Rest machine these areas.

7 reate a Dia ', +nd Mill , named +M', .8 Activate the Toolpath , +M",-FlatFin and then select Settings .

1 lick to create a copy of the strategy.

2 +n the main ffset flat finishing page of the strategy dialog'

a *nter Toolpath name as +M',-FlatFinRest .

b *nter Stepover as $ ,

c Activate the +M', tool.

d Tick the Rest machining box and then select the Rest page.





e /n the Rest page, select the reference Toolpath as +M",-FlatFin .

3 Calculate the toolpath and when created, Close the dialog.

The final finishing passes at the base of the holes and the area behind the bossare now created'


......\COURSEWORK\FlatFinishing-Example2





Surface Finishing Example 1The Surface Finishing strategy creates tool tracks that follow the natural, surfacecur&es on a single, selected, Surface .

The tool tracks in a 'urface inishing strategy will not run parallel to theedges of a trimmed! surface.

1 !rom the Main menu, select File - Delete All and Tools - Reset Forms .2 pen the read-only Pro!ect '-

......\PowerMILL_Data\Projects\EditToolpaths_3

3 !rom the Main menu , select File - Save Pro!ect As '

......\COURSEWORK\PowerMILL-Projects\PunchForm_3

4 Activate the toolpath D',TR'-F6)' to reinstate all the original settings.2ll you need from the original settings is the original5 Active 1orkplane ,(lock , Rapid Move &eights? and the Tiprad tool named D',t' .

5 e-2ctivate both the Toolpath D',TR'-F6)' , and Boundar$ ' .

6 Select the upper surface on the punch model (as displayed above .

7 /pen a Surface Finishing strategy and enter values as shown below.





8 Select the Pattern page'

a Set Pattern direction 7 7

b n-tick Spiral , and then select *rdering - T0o 0a/

c Select (tart corner - Min 7 max 3

9 Select Calculate to create the toolpath and then Close the dialog.





10 !rom the Main toolbar, click the 2eads and 2inks button.

11 /n the 2inks page'

a *nter Short=2ong 7 Threshold $ ,

b Select Short - Circular Arc

c Select 2ong - Skim

d Select Default 7 6ncremental

12 Appl/ the dialog to update the acti&e toolpath .

4here the 2ink move from the end of a tool track to the start of the next iswithin 1 mm, an (orange arc move will be implemented.





+n the resultant toolpath, the natural order of the tool tracks and link moves

across the 3 narrow areas is not very efficient.This can be fixed by applying suitable toolpath +dit - Reorder options.

13 0ight-click on the toolpath and from the local menu, select +dit > Reorder .

14 +n the Toolpath 2isting dialog, click the Automatic reorder and reverse button.

The toolpath follows the curves of the selected surface.

The illustrated toolpath is created with a ' mm Stepover to help with visualisation.+t has also been edited using the Automatic Reorder and Reverse option toeliminate as many air moves as possible.

To further improve the efficiency of this strategy, several of the tool tracks on theupper flat area can be deleted to take advantage of using a bigger Stepover for theDia ', mm flat area of the tool used.





1 !rom the Main menu, select Dra0 > Cursor > Tool to help with thevisualisation for the next action.

2 Select groups of = tool tracks leaving the single tool track outside each set asshown below'

The Tool outline is displayed above to visualise suitable Stepover ( Dra0 >Cursor > Tool .

3 0ight-click the toolpath and select +dit > Delete Selected Components toremove the selected tool tracks.

4 +n the 2eads and 2inks dialog select the 2inks options and change theShort=2ong threshold to '# before selecting Appl/ .


......\COURSEWORK\PowerMILL-Projects\PunchForm_3





Toolpath Z-Limits

2ll Toolpath types, except drilling, can now be limited to applied maximum andminimum 9 values within the defined (lock .

1 !rom the main menus, select File 7 Delete All and Tools 7 Reset Forms .

2 pen the read-only Pro!ect '-

......\PowerMILL_Data\Projects\Zlimits-Start

3 Save Pro!ect As '-

......\COURSEWORK\Zlimits-EX1

The Pro!ect already contains ? Toolpaths , < of which have been put in asub-folder named P' . The 3 remaining Toolpaths require modification asthey are both duplicating areas already included in other strategies. This willbecome evident during a .ie# )"" simulation .





4 Activate the toolpath D",TR$-Constant9-F6)' to reinstate the original (lock and settings.

5 0un a .ie# )"" simulation on the existing +C Program P' .

6 /nce completed save the 3ie0M622 model at this stage.

The angled face and lo#er recesses have yet to be finish machined. The 3remaining toolpaths both operate over the full extent of the (lock .

D",TR$-Const9-F6)' needs to be localised to operate down the angled face to the top of the lower recesses.

()@- ptConst9-F6)' needs to be localised to operate inside the 3 lo0errecesses .

This will easily be achieved for both toolpaths within the strategy dialog usingthe 9-2imits option.





7 0eturn to the Po0erM622 ( +o )mage view and disconnect 3ie0M622

from the simulation (Switch the @reen Sphere to 0ed .

8 +n the Po0erM622 explorer ! right mouse click on the toolpath D",TR$-Const9-F6)' and from the local menu, select Activate followed by Settings to open the strategy dialog.

9 Select Rec$cle followed by the 2imit page and tick both the Maximum and Minimum boxes.

10 !or The Maximum select Pick the highest / .alue option.

11 Snap the ke$ point (shown above at the top corner of the angled face tocollect and insert the value -'' @"$4. .

12 !or The Minimum select Pick the lo#est / .alue option.





13 Snap the ke$ point (shown above on the top of the flat area to collect andinsert the value -., .

14 8ack in the dialog select Calculate to re-process the updated Constant 9 finishing strategy and then Close the dialog.

15 +n the Po0erM622 explorer 0ight mouse click on the toolpath ()@-ptConst9-F6)' and from the local menu, select Activate followed by

Settings to open the strategy dialog.

16 Select Rec$cle followed by the 2imit page and this time tick "ust theMaximum box.

17 +nput the value -., ," in the Maximum box.

18 8ack in the main form select Calculate to re-process the updated ptimisedConstant 9 finishing strategy and then Close the dialog.





19 0e-connect 3ie0M622 and continue the existing simulation with the 3 updatedtoolpaths5 D",tR$-Const9-F6)' followed by ()@- ptConst9-F6)' .

The omponent is now fully machined.

20 Select File 7 Save Pro!ect to update'-

......\COURSEWORK\PowerMILL_Projects\Zlimits-EX1





Toolpath Processing Options

Calculate4hen all the settings and values are input ready to create a toolpath, the Calculate button can be clicked to start the toolpath calculation process.

ou cannot use other Po#er )"" options while the toolpaths are beingcalculated.

Queue+f the ueue option is applied the user can continue working in Po0erM622 whilethe toolpath is processed in the background. Several strategies can be put in thequeue to be calculated in the background, in sequential order.

To ueue a toolpath for calculation, you can, either'

lick the ueue button in a strategy dialog, or,

0ight-click on a toolpath and select ueue from the local menu.

The * Calculator + symbol changes to the * ueue + symbol when thetoolpath is ,ueued.

Batch Process/nce all data has been entered into a strategy dialog, click the OK button to save

the settings and close as an un-processed toolpath.Aou can save one or more un-processed, machining strategies to be sequentiallycalculated at a later time.

To (atch Process toolpaths, right-click a toolpath and select Batch Process .





Toolpath Processing QueueThe Toolpath - ueue option allows you to continue working in Po0erM622 whilethe toolpath is being processed in the background. /ne or more strategies can beadded to the ueue and they are calculated in the background, in sequential order.

The following Bstart upC Pro!ect contains two unprocessed toolpaths. The dialog for

each one will be opened in turn, but ueue will be used instead of Calculate . Thisenables you to continue work on a new Corner finishing - Along strategy whilethe original toolpaths are processed in the background.

1 Select File - Delete All and Tools - Reset Forms .

2 Select File B pen Pro!ect '

......\PowerMILL_Data\Projects\ToolpathProcessing-start

3 Select File - Save Pro!ect As '

......\COURSEWORK\PowerMILL-Projects\ToolQueue-ex1

4 +n the Po0erM622 explorer , right-click the toolpath named D"#t$-rgh andselect ueue .

5 0epeat this on the Toolpath named ()'5-fin' .





6 4hile the original toolpaths are being processed in the background, Activate the tool ()5 .

7 /pen a Corner Finishing strategy and set the (trateg$ to Along . *nter theother values exactly as shown below.

8 Select the Corner detection page and select the Reference tool as ()'5


The latest Corner ,inishing strategy starts processing immediately andis likely to be completed before the (teep and (hallo# finishing strategycurrently pending in the ueue .





4hen a toolpath is added to the ueue , and is in an unprocessed status, theCalculator s$mbol on the Toolpath in the Po0erM622 explorer changes to

the ueue symbol .

10 Select File - Save Pro!ect to update'

......\COURSEWORK\PowerMILL-Projects\ToolQueue-ex1



PowerMILL 2015 5. Toolpath Leads and Links


If a tool is allowed to start machining directly at the start of a tool track, it firstplunges down into the remaining stock, and then suddenly changes direction to runalong the tool track. This is likely to result in machining marks, vibration, andexcess wear on both the tool and machinery.

To avoid sudden loading on the tool, appropriate Lead moves (at cutting feedrate)on and off tool tracks can be applied.

Air moves ( Link ) between individual tool tracks can add significant amount of extratime to a machining operation. This can be greatly reduced by applying alternative,Link move options.

lick on the Main toolbar to display the Leads and Links dialog and options.!ou can also access the Leads and Links dialog from within a strategy dialog. "otethat Leads and Links can be retrospectively applied to an existing toolpath.

Z HeightsSkim and Plunge distance # $rovides variable control of rapid move heights withina component. These operate in con%unction with &afe ' and &tart ' to minimise slowand unnecessary air moves while machining the component form.

Skim distance An incremental distance above the model where rapid feed movesoccur from the end of one tool track to the start of the next. The tool traverses at ahigh feed rate across the model, clearing the highest point along its route by the&kim value.

Plunge distance An incremental distance above the local, component surfacewhere a downward rapid movement of a tool changes to plunge feed move.

5. Toolpath Leads & Links



5. Toolpath Leads and Links PowerMILL 2015


Lead In/Lead out MovesLead In controls the tool movement onto the start of a tool track and Lead Out controls the movement away from the end of a tool track.

Available Lead In and Lead Out moves are

"one

&urface normal arc

*ertical Arc

+ori ontal Arc

+ori ontal Arc -eft

+ori ontal Arc ight

/xtended 0ove

1oxed

&traight

amp

$ocket centre

In the above illustration #

# Lead In 2 Vertical Arc

# Lead Out 2 Vertical Arc

# Link move 2 Skim

Toolpath colour codes

Purple # apid &kim 3eed ate 45

Pale Blue # $lunging 3eed ate 45

Green/Orange # utting 3eed ate 45

Dotted Red # 3ull apid 46

Leads and Links are effectively extensions to tool tracks and must be gougeprotected. Gouge c eck is set as default and any Lead that would result in agouge is not created.

7n tooltracks where the !st " oice cannot be applied, then the #nd " oice isused. If it is not possible to apply either then the Lead options are applied as $one .

The current Leads and Links settings are automatically applied when creating newmachining strategies.





ExampleThe following example illustrates the retrospective addition of suitable -eads and-inks to finishing toolpaths. The pro%ect contains one oughing toolpath and three3inishing toolpaths.

1 &elect %ile & Delete All and 'ools & Reset %orms .

2 &elect %ile & Open Pro(ect

... \PowerMILL_Data\Projects\LeadsLinks-Start

3 &elect %ile & Save Pro(ect As

......\COURSEWORK\PowerMILL-Projects\LeadsLinks-example

4 &elect an ISO# view.

5 Activate the toolpath, B$)&*in! .





Vertical Arc LeadsVertical Arc # Leads create a circular movement downward at the start andupward at the end of each individual tool track. 1y default, with the Gouge c eck option selected, the additional moves are not made if a gouge might occur.

# Toolpath segment

# adius

# Tangent angle

# -ead

6 7n the Main toolbar, click to open the Leads and Links dialog.

7 7n the Leads and Links dialog, select the Lead In tab and

a &elect Vertical Arc from the !st " oice list.

b /nter an Angle of +,-, and a Radius of )-,

c lick Appl. .

There is now a Vertical Arc leading onto most of the tool tracks.

The new (gouge protected) Vertical leads have not been created on the tooltracks that stop close to a raised area of the model.





8 lick the "op. to Lead Out button.

9 lick Appl. to update the active toolpath.

8here gouge free, a Lead Out move is applied at the end of each tool track.

10 &elect Vertical Arc from the #nd " oice list.

a /nter an Angle of +,-, and a reduced value Radius of -,

b As before, click the "op. to Lead Out button.

c lick Appl. .

8herever it is gouge free on the above toolpath a !st " oice of Lead In/Out with a Vertical Arc is applied.





If this is not possible without a gouge occurring, then the 9nd hoice of aRadius , Vertical Arc is attempted.

If neither the 5st or 9nd hoice is possible without a gouge occurring, then noLead In/Out is applied to that part of the toolpath.

LinksA Link move is the movement of the tool from the end of a tool track to the start ofthe next. 3or efficient tool moves across the model, you can reduce the height ofthe link moves to be closer to the local model form.

S ort/Long t res old # This defines the distance limit up to which the S ort &Links apply. Any move from the end of a tool track to the start of the next,which exceeds this distance is defined by the Long # Link move.

3or S ort links, the available options include Sa*e 0 , Incremental , Skim , OnSur*ace , Stepdo1n , Straig t , and "ircular Arc .

3or Long links, the available options include Sa*e 0 , Incremental , and Skim .

3or De*ault (first and last) links the available options include Sa*e 0 ,Incremental , and Skim .

Arc *it rapid moves can be applied, if compatible with a machine controlsystem.

1 3rom the Main menu, select 'ools # Reset %orms to reset the Leads and Links settings to the factory defaults.

2 Activate the toolpath B$)&*in! .

3 lick and open the Leads and Links dialog.

4 &elect the 0 2eig ts tab to access the Skim and Plunge distance options.

Skim Distance # is the incremental height at which the tool clears thehighest point on the model between tool tracks.

Plunge Distance # is the Incremental height above the model at which thetool rapids down to before using the Plunge %eed Rate .

5 &elect the Links tab.





a /nter the S ort/Long t res old as 3

b -ink move distances less than this value will use the S ort options and thosegreater will use the Long options.

c &elect Short as "ircular arc and Long and Default as Skim .

6 lick Appl. .

The distance between the ends of adjacent tool tracks is greater than theShort/Long threshold value in several areas of the toolpath (In theseinstances Skim moves apply).

7 Increase the value for S ort/Long t res old to 4 .

8 lick Appl. .

By increasing the value of the Short/Long threshold , the number ofoccurrences of Short Link - Circular Arcs has increased.

The remaining Link moves would benefit from Vertical Arc # Lead In/Out moves, but not on the existing "ircular Arc -inks.





9 Input the following a Lead In settings

10 &elect the following button to copy the lead in settings to the lead out settings.

The Vertical Arc - Leads are also added to the Circular Arc - Short linkmoves. This can be prevented by un ticking the Add leads to short links option.

11 :se lead out t e same as lead in to copy leads

12 :n#tick the Add leads to s ort links option.

13 lick Appl. .





The Lead moves exist on the Long links but not on the S ort links .

Applying Leads and Links locally to individual tool tracks14 :se the left mouse key to select one of the individual link moves where the

-ead is currently a Vertical Arc .

15 In the Leads and Links dialog, select the Lead In tab and select !st " oice as56tended Move with Distance !, .

16 &elect the "op. to Lead Out tab.

17 lick Appl. .

18 The selected Vertical Arc lead move is changed to an 56tended move.

19 &elect %ile # Save Pro(ect to update

......\COURSEWORK\PowerMILL-Projects\LeadsLinks-example





Horizontal Arc LeadsThis produces circular leads on the hori ontal plane. This type of lead is fre;uentlyused for toolpaths running at constant ', or with only small changes in ' height.

Toolpath segment

adius

-ead

Tangent angle

1 3rom the Main menu, select Tools - Reset Forms to return the Leads and Links settings to default.

2 In the Po1erMILL explorer , right#click the B$)&*in# toolpath and selectActivate .

3 &elect an ISO! *iew.

4 lick on the Main toolbar to open the Leads and Links dialog.

5 &elect the Lead In tab, and change !st " oice to 2ori7ontal Arc with anAngle of 8 and a Radius of 3-,

6 lick "op. to Lead Out and then Appl. .





There is no need to utilise the 2nd choice options as the st Choice of!ori"ontal Arc - Leads #n/$ut have appeared on all the tool tracks.

7 In the existing !st " oice # Lead In page input a value of 8 for the Distance and select Appl. .





Extensions56tensions are additional lead options that are applied outside the existing LeadIn/Out moves.

8 &elect an ISO view.

9 In the Leads and Links dialog, select the 56tensions tab and for both theIn1ard and Out1ard options, enter a Vertical Arc with Angle +,-, andRadius 8-,

10 lick Apply .

A Vertical Arc # 56tension is added to all of the Lead In/Out moves.

Additional Short Links optionsIn addition to Sa*e , Incremental , and Skim , the following options are alsoavailable in the S ort link section. These additions are not available in the Long link options.

On Sur*ace # This links the tool tracks with a gouge free, direct move that

follows the surface form. Stepdo1n # The link move remains at a constant height and performs a gouge#

checked move to the start of the next tool track, where it then feeds down ontothe surface.

Straig t # In this case, the link is a gouge#checked, direct linear move to thestart of the next tool track.

"ircular Arc # This links the tool tracks with a gouge#free circular move thatfollows the surface form.





Exercise1 Activate the B$)&*in3 toolpath and Appl. the Leads and Links as follows

a Links Long/Short/Default Skim .

b Lead In 5st hoice # Ramp # 7ptions # Ma6 0ig Angle , %ollo1'oolpat , and 2eig t !

c Lead Out 5st hoice # Vertical Arc Angle +, Radius 3

The Links have been visually removed to enable a better view of the Leads .

2 In the Leads and Links dialog select the Lead in page and input ,-8 in the boxnamed Overlap distance 9tool diameter units: .

3 Apply the Leads and Links dialog.

Overlap Distance causes the cutter to continue beyond the natural end point alongthe original toolpath by a specified distance based on the Tool <iameter ( 'D; ). Inthis case the distance is 3mm ( ,-8 'D; ).





Arc Fitting Rapid Moves

Leads and Links Arc %itting works on all &apid 'o(es including Skim moves. This option is idealfor applications where you want to avoid sharp changes in direction= for example,

+igh &peed 0achining.

!ot all machine tool controllers will support this option.

The Arc %it Rapid Moves option is located in the Links dialog.

The Arc *it rapid moves box must be ticked .

The Arc radius is defined as a proportion of the active, Tool <iameter ( 'D; ).



PowerMILL 2015 6. Boundaries


A Boundary consists of one or more closed wireframe segments. Boundaries aremainly used to limit machining strategies to specific areas of the component.

Earlier in the course, Boundaries were utilised to limit machining strategies, sothat they occur in more compatible areas of the component.

For example, Constant Z finishing is more effective on steep sidewalls and Raster finishing on shallow areas.

There are several options available for creating boundaries. Most involve interactionwith other PowerMILL entities eg Tools , Thickness , Stock Model , etc!, whileUser Defined will access a separate dialog for direct input of existing geometric,entities.

Switch off the Private Boundaries creation option1 From the ain pulldown menus select Tools " !"tions and in the dialog select

Boundaries " Pri#ate $oundaries .

2 Un%tick the box named &llow new $oundaries to $e "ri#ate .

3 #elect &cce"t to close the !"tions dialog '

6. Boundaries



6. Boundaries PowerMILL 2015


User Defined BoundaryTo access the User Defined " Boundary options, go to the PowerMILL explorer ,and select Boundaries $ Create Boundary $ User Defined .

This will access a separate sub%menu in which the range of options, generallyinvolve direct input of existing wireframe entities.

Insert (ile % &pens the browser to locate an externally stored geometry file.

The Boundary , Pattern , and Tool"ath buttons are disabled unless a compatibleentity is selected in the ad'acent input box.

Model % (nserts the edge of the selected odel .

Sketch % &pens the Cur#e )ditor toolbar.

Co "osite cur#e % &pens the Create Co "osite Cur#e toolbar.

*irefra e Modelling % )rovides access to the )ower#*A)E wireframemodule.

4 From the Main menu, select (ile % Delete &ll .

5 #elect (ile %Sa#e Pro+ect &s +

......\COURSEWORK\PowerMILL_Projects\BoundaryBasics

6 #elect (ile %I "ort Model'''

......\PowerMILL_Data\Models\cowling





7 #elect the surfaces defining the central poc et and fillet.

8 (n the PowerMILL explorer , right%clic Boundaries and select Create %UserDefined .

9 (n the User Defined Boundary dialog, clic the Model button.

A Boundary segment is created around the edge of the selected part of themodel.

10 #elect a View from top -! and switch off the shaded view but retain thewirefra e view.





11 (n the PowerMILL explorer , right%clic Boundaries and select CreateBoundary % User Defined .

12 (n the User Defined Boundary dialog, clic the Sketch buttonto open the Cur#e )ditor toolbar.

13 &n the Cur#e )ditor toolbar, clic the following button to open the!"tions dialog.

14 n%tic Intelligent Cursor %Sna""ing !"tions to switch off the

(ntelligent /ursor enabling 0free form1 s etching.

15 /lic &cce"t to eep the changes.

16 From the Cur#e )ditor toolbar, select Create a Be,ier cur#e .

17 sing the left mouse ey, clic points within the model to create a s etchedBoundary .





If required, use Undo to sequentially remove any invalid points.

While the Intelligent cursor is switched off do not attempt to close thesegment by trying to snap the ‘final span’ back on to the start point.

18 &n the Cur#e )ditor toolbar clic to open the !"tions dialog.

19 #elect Intelligent Cursor %Sna""ing !"tions and tic % Use IntelligentCursor .

20 Then snap the final span of the Be,ier Cur#e onto the original start point.

21 &n the Cur#e )ditor toolbar clic to accept the changes and close thesession.

22 (f the Boundary segment is not smooth enough, right mouse clic on it andfrom the local menu, select )dit % S"line Selected to open the S"line fittingtolerance dialog.

23 Enter the value 2 and clic to apply and close the dialog.

The Boundary segment is splined through the polyline points as a curvemaintaining the original form to within a maximum deviation of 2.

(n instances where the re3uired deviation would be greater than 2, a tangencywill remain either side of the affected points.





Selected Surface BoundaryA Selected Surface Boundary defines one or more segments around where theactive tool would fully machine the selected surfaces. The segments represent thetip position of the active tool .

1 /reate a Block %Defined by Bo- using Type % Model .

2 /reate a Ball .osed tool of Dia eter /0 with the Name B./0 .

3 #elect the surfaces defining the central poc et, including the fillet.

4 (n the PowerMILL explorer , right%clic Boundaries and select CreateBoundary % Selected Surface .

5 sing the above settings, clic &""ly to create a single segment, SelectedSurface Boundary .





Shallow BoundaryA Shallow Boundary defines one or more segments where the model dropsthrough a specified U""er &ngle downwards from the hori4ontal plane. (t isdesigned to differentiate steep and shallow areas where Constant Z and Patternstrategies are more effective. The $oundary is calculated relative to the active toolparameters.

1 (n the PowerMILL explorer , right%clic Boundaries and using the defaultsettings, Create Boundary % Shallow .

%Shallow area more suited to Raster (inishing above 56 degrees!.

%Steep area more suited to a Constant Z Finishing below 56 degrees!.

2 &""ly the form to create the above Boundary segments.

Silhouette BoundaryA Silhouette Boundary defines the outline around the maximum dimensionsselected model, offset by the tool radius .

1 #elect the following surfaces on the model+

Use the Shift key on your keyboard to select multiple surfaces.





2 7ight%clic the Model and select )dit % Delete Selected Co "onents .

3 8ith the selected areas now deleted, in the PowerMILL explorer , right%clicBoundaries and select Create Boundary %Silhouette .

Rest BoundaryA Rest Boundary defines the area inaccessible to a specified reference tool. (t alsore3uires a smaller active tool to be specified otherwise it will not generatesegments.

1 /reate a Ball .osed tool of Dia eter 1 with the .a e B.1 .

2 (n the PowerMILL explorer , right%clic Models and select Delete &ll toremove the incomplete component.

3 I "ort the original Model bac into the Pro+ect +......\PowerMILL_Data\Models\cowling





4 (n the PowerMILL explorer , right%clic Boundaries and select CreateBoundary % Rest to open the Rest Boundary dialog.

5 (nput xpand !rea 2 , select Tool B.1 , and "eference Tool B./0 .

6 #et with #imit tool centre to bloc$ edge .

7 /lic &""ly to create the following Rest Boundary .

8 /lic &cce"t to close the dialog.

9 Sa#e the Pro+ect to update+%


10 #elect a 3iew down the Z &-is and Un%draw the model.

The above Boundary identifies areas on the component that are inaccessible tothe B./0 tool geometry to be locally machined with the B.1 tool.

&n closer inspection, the central poc et area would be more effectivelymachined with a flat bottomed tool and a smoother, more continuous toolpath,can be created if the 2 spurs are removed from the outer segment to bemachined later as a separate toolpath!.





Editing Boundaries(t is often necessary to edit the original geometry defined by Boundary segments.The best way to achieve this in PowerMILL is via the dedicated Cur#e )ditor tool.As it is not exclusive to Boundaries , a more detailed range of Cur#e )ditor ,options and applications are covered in Cha"ter // .

1 (n the PowerMILL explorer , right%clic the Rest Boundary 0 ! entity and inthe local menu select )dit %Co"y Boundary to create a copy named 04/ !.

2 (n the PowerMILL explorer , right%clic the original Rest Boundary 0 ! and"ename it as Master .

3 "ename the new copy of the Rest Boundary 04/ ! as Rest .

4 (n the PowerMILL explorer , clic the light bulb ad'acent to Master to stop itfrom being displayed in the graphics area.

5 #elect the % inner segments on the Rest $oundary Rest ! by dragging a boxaround, and then press the Delete ey on your eyboard to delete them.

The next stage is to remove the two spurs, which will be carried out after anexplanation of the Boundary )ditor dialog.

Boundary – Access to the Curve Editor&nce created, you can modify a Boundary segment using the options available onthe Boundary Toolbar.

/lic on the Boundary toolbar to activate the Cur#e )ditor toolbar.

You can also double click a boundary segment to activate the &urveditor !oolbar.





Edit > Transform1 (n the PowerMILL explorer , right%clic on the boundary Rest and from the

local menu, select Cur#e )ditor .

2 (n the Cur#e )ditor toolbar select the !ffset option

3 (n the !ffset toolbar, select the 5D S ooth button, input a Distance of 1 andthen press the Return ey.

4 /lic in the Cur#e )ditor toolbar to accept the changes and exit.





Curve Point - editingThe Point editing options are located towards the right hand side of the /urve

Editor toolbar .

1 (n the PowerMILL e-"lorer , right%clic Boundaries and from the local menuselect Tool$ar .

2 &n the Boundary toolbar, clic the Cur#e )ditor button to display theCur#e )ditor toolbar.

3 #elect the outer $oundary seg ent in the graphics area.

The points are displayed on the selected boundary segment.

4 Zoo into the area of the selected segment and select all the points that definethe spur.

!o select multiple points, hold do"n the Shift key "hile selecting the points "ith the mouse.

5 &n the Cur#e )ditor toolbar, clic Delete "oints to remove the spurfrom the segment.

6 7epeat the procedure on the other spur.





7 /lic , to accept changes and exit the Cur#e )ditor .

Other boundary editing options7ight%clic on a Boundary in the graphics area or in the PowerMILL explorer andfrom the local menu, select )dit to view other boundary editing options.





Edit > Spline Selected1 (n the graphics window, select the outer segment of the boundary Rest .

2 (n the PowerMILL explorer , right%clic the Boundary "est and select )dit $S"line Selected .

3 (n the S"line fitting tolerance dialog, enter 0.1 and clic to apply.

4 7e%select the outer segment to view the effect of the #pline.

The selected segment is now #plined /urve fitted and the points re%distributedwithin the specified tolerance value! to produce a smoother form with unnecessarypoints removed. This improves the 3uality of subse3uent operations such asoffsetting of the boundary.

Review the modified Boundary5 (n the PowerMILL e-"lorer , clic the light bulb next to the copy of the original

boundary Master created earlier. The original $oundary is displayed alongsidethe edited $oundary , Rest illustrating the effect of the 9mm 5: &ffset.

Create a 3D Offset strategy limited to the modified Boundary

6 &cti#ate the B.1 tool and Boundary named Rest .

7 &n the Main toolbar, clic to display the Strategy Selector .

8 From the (inishing options, select the 5D !ffset (inishing strategy.





9 (n the 5D !ffset (inishing strategy dialog, enter data as below.

10 /lic Calculate to process the toolpath and then Close to exit the dialog.





Create a Boundary for the original side branches.

11 ndraw the B.1%Rest(in toolpath and boundary Rest by switching off therespective light bulb symbols in the PowerMILL explorer .

12 #witch on the respective light bulb to display the Boundary named Master .

13 (n the graphics area, select the outer segment of the displayed Boundary named Master .

14 (n the PowerMILL explorer , right%clic the boundary Master and select )dit %Co"y Boundary selected only ! to create a new boundary Master4/ consisting of the outer segment only.

15 Rena e the boundary Master4/ as S"ur/ .

16 #elect a view from top Z .

17 (n the PowerMILL explorer , turn off the light bulb ad'acent to the boundaryMaster to remove it from view.

18 (n the PowerMILL explorer , right%clic the boundary S"ur/ and select&cti#ate .

19 (n the graphics area, double%clic the boundary segment to activate the Cur#e)ditor toolbar.

20 #elect all "oints along the boundary segment except those which define therectangular part of the upper spur.

Use the Shift key on your keyboard to select multiple points on theboundary segment.

Use the CTRL key on your keyboard to deselect one or more of theselected points on the boundary segment.

If preferred it is okay to select and delete the points in stages.





21 &n the Cur#e )ditor toolbar+

a /lic the Delete Points button to delete all the selectedpoints.

b /lic the ;oin /lose button to close the open rectangular segment.

c )ress #hift on your eyboard and select the points at the base of therectangular segment.

d &n the status bar below the graphics area, clic the "elative 'ove button

and enter 2 %6 for the < and = move, values! in the data box and pressnter on your eyboard.

The selected points are moved by a distance of 7%6 .

22 /lic to exit the Cur#e )ditor toolbar.

23 /lic the light bulbs on to display both Boundaries Rest and S"ur/ , and then

Resi,e the 3iew .

24 (n the graphics area, double%clic the Boundary S"ur/ to activate the Cur#e)ditor toolbar.

25 Form the Cur#e editor toolbar, select Transfor ations %Mirror option .

26 &n the Mirror toolbar select (rigin at the active wor$plane .





27 Ensure that the 8ee" !riginal option is set.

28 From the Mirror toolbar, clic the 'irror in )* button .

29 /lic on the Mirror toolbar to accept and close.

30 &n the Boundary Transfor toolbar, clic to accept and exit the toolbar.

The Boundary named S"ur/ now contains 2 segments.

1 Ma e sure that the tool B.1 and boundary S"ur/ are both &cti#e .

2 From the Strategy Selector , (inishing options, select the Raster (inishing strategy and enter data as shown on the following page+

3 /lic Calculate to process the toolpath, and then Close the dialog.





The machining strategies are localised and the tool trac shape controlled withthe help of edited Boundaries originating from a single 7est Boundary.

4 Sa#e the Pro+ect to update+%






Creating Blanking Surfaces usingBoundaries

Blan ing surfaces are used to cap holes and poc ets in a model to prevent the toolfrom machining into those areas. =ou can create three types of planes in)owerM(>>.

Block " creates a plane, at a specific - *eight, after the material bloc isdefined.

Best (it " creates two planes, one touching the boundary at its highest point,and the other through its lowest point. The planes are parallel to the best fitplane the plane that has the smallest maximum distance from the boundary!.

Pro+ected " creates a plane parallel to the <= axis of the active wor plane. Theplane will have the - *eight of the highest point of the boundary.

Example1 #elect (ile % Delete &ll and Tools % Reset (or s .

2 I "ort the Model +

......\PowerMILL_Data\Models\pockets.dgk

3 Calculate the Block defined by Bo- to the Model Min?Max limits.

4 #elect the top surface of the odel shown shaded!.

5 (n the PowerMILL explorer , right mouse clic on Boundaries and from thelocal menu select Create Boundary 9 User Defined .





6 /lic the Model icon and then select &cce"t to close the dialog.

7 n%draw the odel to enable a clear view of the $oundary .

The Boundary produced has @ segments. For this example, only the twosmallest segments are re3uired.

8 #elect the two highlighted segments by dragging the cursor over them.

9 (n the PowerMILL explorer , right%clic Models and from the local menu selectCreate Plane % Pro+ected .

10 )laner Surfaces have been created inside the boundary segments .

#o need to $ave the %ro&ect this time'

11 #elect (ile % Delete &ll and Tools % Reset (or s .





ExerciseI "ort the Model …\PowerMILL_Data\Models\bucket.dgk and generate @surface planes to cover the foot recesses on the upper base surface.





Block defined by BoundaryAn existing Pro+ect will be opened that contains multiple components that will beroughed out using a complex Block arrangement defined by Boundary segments.

12 !"en the read%only! Pro+ect +%

…\PowerMILL_Data\Projects\MultiBlock_Start

13 #ave the Pro+ect as+%

.…\COURSEWORK\PowerMILL_Projects\MultiPart_Block

14 #elect all of the component models :rag a box over all surfaces !.

15 (n the PowerMILL explorer right mouse clic on Boundaries and from thelocal menu select Create Boundary %User Defined .

16 (n the User Defined Boundary dialog ensure that the !llow Boundary to be

private box is un+tic$ed and then clic on the Model icon .

17 #elect &cce"t to close the User Defined Boundary dialog.

18 &cti#ate the new Boundary .

19 From the main toolbar select the Block options .

20 (n the dialog select Defined by + Boundary and Type 9 Model followed byCalculate .





21 #elect &cce"t to close the Block dialog.

The complex Block is as shown above consisting of localised triangle modelsaround each individual component.

22 :e%activate the Boundary .





23 (n the PowerMILL explorer right mouse clic on the existing, un%processedtoolpath D/6TR/%R:;/ and from the local menu select )dit " Set .a edPara eter .

24 (nput Block and select the green tic$ to accept.

The current Block definition will now be active within the unprocessed Model&rea Clearance strategy.

25 (n the PowerMILL explorer right mouse clic on Tool"aths and from the localmenu select Batch Process .

Batch Process will se3uentially run down the toolpath list in this case 9! andCalculate all valid, un%processed strategies.

26 #elect (ile %Sa#e Pro+ect to update+%

…\COURSEWORK\PowerMILL_Projects\MultiPart_Block





Private BoundariesAll Boundary types will by default! be created as "ri#ate . This ma es theBoundary exclusively owned by an individual machining strategy. (f the

parameters or entities used in the strategy are modified, then the associated"ri#ate $oundary will automatically ad'ust on calculation.

Pri#ate Boundaries are of particular use in Te "lates as they will automaticallyregenerate when the host tool"ath is calculated on a new model.

A "ri#ate $oundary is not suitable in cases where the segments will need to bedeleted or geometrically edited once assigned to the host strategy . (t is howeverpossible to create a copy on which you can switch off the &llow $oundary to $e"ri#ate option within the dialog.

(t is also possible to prevent Boundaries from being created as private+%

From the ain pull down menus select Tools " (ptions " Boundaries %,rivateBoundaries , and un%tic &llow new $oundaries to $e "ri#ate .

Private Boundaries – Example:-1 #elect (ile % Delete &ll and Tools % Reset (or s .2 !"en the readonly! Pro+ect +%

......\PowerMILL_Data\Projects\PrivateBoundaries_Start

3 Sa#e Pro+ect &s +%

......\COURSEWORK\PowerMILL_Projects\PrivateBoundaries-EX1





The Pro+ect includes a Constant Z and a 5D!ffset finishing toolpaths both ofwhich currently apply over the whole of the Block area. To localise the 2 finishingtoolpaths to areas of the model where they are most effective both strategies will berecycled to include a Shallow " private boundary .

4 From the ain pulldown menus select Tools %!"tions %Boundaries %Pri#ate$oundaries +%

5 Tick the box named &llow new $oundaries to $e "ri#ate .

6 #elect &cce"t to close the !"tions dialog '

7 &cti#ate the toolpath , B./2%CZ%S)M/ .

8 From the toolpath , Bn/2%CZ%S)M/ local menu select Settings , followed bythe "ecycle option.

9 (n the Constant Z dialog select the Li it page.

10 From the Boundary pull down options select Create a shallow $oundary .





11 sing the default settings &""ly and &cce"t the Shallow Boundary dialog.

(nitially the new Boundary / will exist in the PowerMILL explorer until thetoolpath is calculated. At that point it will disappear become invisible! from theBoundary folder. *owever, the folder name, Boundary will still be displayed in

bold text to identify the existence of the hidden private Boundary /

!he private Boundary "ill be displayed in the ,ower'I## explorer ifthe above option is tic$ed in the local Boundaries menu.

12 #elect the Li it page and set Trimming to 8ee" outside .

13 Calculate but do not Close ! the Constant Z (inishing strategy.

The Constant Z strategy B./2%CZ%S)M/ is now limited to be outside thesegments of private Boundary /





14 #elect the 0create a copy1 option in the Constant Z (inishing dialog.

15 Modify the Toolpath Name to B./2%CZ%(I./ , input Tolerance 2'2/ ,Thic$ness 2 , and Minimum stepdown 2'5

16 Calculate the new toolpath and Close the dialog.

17 A new private Boundary will automatically, be created with the sameparameters Tolerance , Thickness , etc! as used in the main page of theConstant Z (inishing dialog.





18 (n the PowerMILL explorer , right mouse clic on Boundaries and from thelocal menu tick the option Dis"lay "ri#ate Boundaries .

19 8ith the 2 existing private Boundaries displayed, right mouse clic on eitherand from the local menu select )dit " Co"y Boundary .

20 7ight mouse clic on Boundaries and from the local menu untick the optionDis"lay "ri#ate Boundaries .

&nly the new private Boundary will be displayed in the PowerMILL explorer but will later become hidden once it has been applied in a new toolpathcalculation.

Exercise21 (n the PowerMILL explorer , &cti#ate the toolpath B./2%5Doff%S)M/ and

then select Settings to open the dialog.

22 "ecycle with the new private Boundary /4/4/ , &cti#e and with Trimmingset to 8ee" inside .





23 Calculate a &opy of the above toolpath with the new Name B./2%5Doff%(I./ and with Tolerance 2'2/ , Thickness 2 , and Ste"o#er 2'5

24 From the ain pulldown menus select Tools " !"tions and in the dialog selectBoundaries " Pri#ate $oundaries .

25 Tick the box named Display private $oundaries in the explorer .

!his demonstrates that if a toolpath containing a ,rivate Boundary is

copied then the ne" one "ill contain a separate ,rivate Boundary .







PowerMILL 2015 7. Levels and Sets


Levels and Sets allow you to control the selection and display of modelcomponents in the PowerMILL graphics area.

You can Acquire components from the currently imported Model to a Level or Set .Once acquired to a Level or Set , you can select, de-select, display, or hide Modelcomponents from the individual Level or Set context menus.

The subtle differences between Levels and ets are illustrated using the followingexamples.

Creating Levels1 !rom the Main menu, select File " Delete All and Tools " Reset Forms .

2 elect File " Import Model #

......\PowerMILL_Data\Models\CowlingWithClamps.dgk

The imported Model includes clamps, which#

$ust be avoided by all machining strategies created in the Project .

$ust not be included in the calculation of the Block .

To ma%e the model selection easier, a new Level named Clamps will be createdand all clamp surfaces assigned to it. &nother Level , named Splits will be createdand all ' split surfaces assigned to it.

(reate a )ia *+ all ose tool named BN ! .

n the PowerMILL explorer , right-clic% Levels and Sets and select CreateLevel .

7. Levels and Sets



7. Levels and Sets PowerMILL 2015


3 Rename the new Level as Clamps .

4 (reate another new Level and Rename it as Splits .

&ll model components are currently acquired to the default General Level .

f the original (&) model has components already assigned to different Levels ,then these will be recreated when the model is imported into the PowerMILLproject .

Acquiring model entities to a Level5 n the PowerMILL explorer , clic% the /light bulb0 off next to the Level named

Clamps .

&ny items acquired to this level will no longer be displayed.

6 n the graphics area, use the left mouse and Shift %eys to select all s"r#aces except the clamps.

7 On the %eyboard select Ctrl $ to blank the selected S"r#aces .





8 elect the Clamp surfaces 12old down the left hand mouse %ey while dragging abox over them3.

9 n the PowerMILL explorer , right-clic% on the level named Clamps and select Acquire Selected Model Geometry .

The clamps disappear from the view 1The Level is switched off3.

10 On the %eyboard select Ctrl L to unblank all eligible S"r#aces .

11 elect the ' S"r#aces defining the split face and Acquire them to the levelnamed Splits .

12 witch off the level named Splits to visually chec% that the correct s"r#aces have been acquired.

13 witch on all levels 1The clamps and split s"r#aces reappear3.





& Selected S"r#ace Bo"ndar% will now be created to limit the clamps from beingmachined.

1 n the PowerMILL explorer , right-clic% the Level , General and choose SelectS"r#aces . The main component s"r#aces excluding the split faces are selected.

2 4hile still in the PowerMILL explorer , right-clic% the Splits level and chooseSelect S"r#aces . The split face surfaces are added to the current selection.

3 Calc"late a Block using the default Bo& and Model options.

4 5se the default Rapid Move 'ei()ts and Start and *nd Point options.

The Block is created to the dimensions of the selected surfaces.

5 Left mouse clic% in the graphics area away from the model to deselect allentities.

6 n the PowerMILL explorer , clic% on the Level , +eneral , and with the Ctrl %ey held down, clic% on the Splits level .

oth the selected levels will be highlighted in the PowerMILL explorer .

7 6ight-clic% on one of the highlighted levels and choose Select S"r#aces . &lls"r#aces excluding the clamps are selected.

8 Appl% a Selected S"r#ace Bo"ndar% with Radial T)ickness ! , Limit set toBlock Edge , with Allow boundary to be pri ate un-tic%ed.





9 (hec% that both the Tool B!"# and Bo"ndar% " are Active so that they will beautomatically included when a new machining strategy is created.

10 !rom the main toolbar, select Toolpat) Strate(ies and from Finis)in(

open a Steep and S)allow Finis)in( strategy.11 n the Steep and S)allow Finis)in( dialog, enter data exactly as shown in the

following illustration.





12 (lic% Calc"late to process the toolpat) and then Close the dialog.

The Radial T)ickness of ! used in the outer Bo"ndar% segment provides asuitable clearance around the clamps.





Switching Off a Level1 n the PowerMILL explorer , switch off the light bulbs on both the +eneral and

Splits levels.

Only the Clamp S"r#aces are displayed in the graphics area.

2 6ight-clic% the toolpat) and select Settin(s to re-open the dialog.

3 elect create a Copy and clic% Calc"late to process a new toolpat) .

4 Close the Raster Finis)in( dialog.

Even if a le el is switched off, $owerM%&& will still create a toolpath overall (including un-displayed) parts of the model.





Sets& Model entity will always exist on a Level but not on more than one at the sametime. You cannot delete a Level while Model entities are acquired to it.

& Model entity can co-exist on more than one Set at the same time. You can deletea Set while Model entities are acquired to it.

1 !rom the Main menu, clic% File " Delete All and Tools Reset Forms .

2 !rom the Main pulldown menus File " Import Model and select#

......\PowerMILL_Data\Models\YogurtTray.dgk

3 (reate a Set and rename it as AllPkts,Set .

4 $anually select all s"r#aces defining the 7 poc%ets.

5 4ith the 7 poc%ets still selected, right-clic% AllPkts,Set and select Ac-"ireSelected Model +eometr% .

6 $anually select all s"r#aces defining the bottom left poc%et.





The selected s"r#aces will soon be acquired to two Sets simultaneously.

7 (reate a new Set and rename it as Pkt ,Set .

8 6ight-clic% Pkt ,Set and select Ac-"ire Selected Model +eometr% .

9 witch off both the level General and the Set $kt"'Set .

10 witch on AllPkts,Set .

&ll s"r#aces currently acquired to AllPkts,Set are displayed, including thosethat exist on the visually /switched off0 Set .

11 witch off the Set All$kts'Set and then switch on the Set $kt"'Set .

&ll s"r#aces acquired to Pkt ,Set are displayed. These are also displayed when theAllPkts,Set is switched on and Pkt ,Set is switched off. This illustrates that modelentities can be acquired to more than one Set at the same time.

1 witch off Pkt ,Set and then switch on AllPkts,Set .2 6ight-clic% AllPkts,Set and from the local menu clic% Select S"r#aces .

3 (reate a new Level and rename it as AllPkts,Lev .

4 n the PowerMILL explorer , right-clic% Level All$kts'&e and select Ac-"ireSelected Model +eometr% .

5 witch off all Levels and Sets except AllPkts,Lev .

&ll surfaces acquired to AllPkts,Lev are displayed.





6 (reate a new Level , rename it as Pkt ,Lev , and then switch it off.

7 $anually select all s"r#aces defining the bottom left poc%et.

8 n the PowerMILL explorer , right-clic% Pkt ,Lev and from the pop-up menuselect Ac-"ire Selected Model +eometr% .

&ll s"r#aces defining the bottom left poc%et disappear from the view on beingacquired to the 1switched off3 level $kt"'&e . This illustrates that unli%e Sets , it isnot possible for model entities to exist in more than one Level at any one time.

witch on the level $kt"'&e and the bottom left poc%et surfaces are displayedagain.

When using a combination of &e els and Sets it is good practice to keepthe Sets visually switched off. If you want to select items from a

particular Set , then, right-click on it and use one of the Select optionsfrom the conte t menu.

!his prevents confusion if you switch a &e el off only to find the includeditems are still visible due to a Set containing the same items being

switched on.



PowerMILL 2015 8. Editing Toolpaths


Edit > TransformThe Transform option allows you to Move , Rotate , and Mirror toolpaths relativeto the Transform (Global datum) or an active workplane .

To access the options right-click on a toolpath and select Edit > Transform .

Transform > Move - The Move function allows a selected toolpath to bemoved by a user-defined Distance along a selected a is.

Transform > Rotate - The Rotate function allows the rotation of a selectedtoolpath by a user-defined Angle around a selected X, Y, or Z a is.

Transform > Mirror - This provides ! options to Mirror a selected toolpathacross the XY, XZ , or YZ planes. "hen a toolpath is mirrored, #ower$%&&identifies the gouge status to be unknown, so it is advisable to check for gouges.

It is important to note that when a toolpath is mirrored, the cuttingdirection effectively becomes reversed.

%n the following e ample a single toolpath is created and then the Transform >Move option applied to copy toolpaths into the remaining cavities.

1 'elect File - Delete All and Tools - Reset Forms .

2 'elect File > Open ro!e"t -


8. Editing Toolpaths



8. Editing Toolpaths PowerMILL 2015


The ro!e"t contains a multi-cavity die and a Dia #$ %all &osed tool.

toolpath will be created in the lower left cavity that is limited to be inside a'ele"ted '(rfa"e *oundary.

3 'ave ro!e"t As

......\COURSEWORK\PowerMILL-Projects\Transform

4 +reate a %lo"k using Defined )* > %o+ and T*pe > Model .

5 ,al"(late the Rapid Move ei.hts using the default settings.

6 'elect all of the s(rfa"es (including the fillet) that define the bottom left pocket.

7 %n the owerM/00 explorer , right-click %o(ndaries and select ,reate%o(ndar* > 'ele"ted '(rfa"es .

8 %n the 'ele"ted '(rfa"e %o(ndar* dialog, tick Roll Over and enter aToleran"e $1$2 and un-tick , Allow )o(ndar* to )e private .





9 +lick Appl* and A""ept the dialog.

'ele"ted '(rfa"es %o(ndar* defines the limit where the active Tool andassociated parameters would fully machine the selected surfaces.

10 pen the Optimised ,onstant Z Finishin. strategy and enter the values andsettings e actly as shown in the dialog pages below

11 +lick ,al"(late to process the toolpath and then ,lose the dialog.





12 %n the owerM/00 explorer , right-click the toolpath %&#$- o"ket and select

'im(late from 'tart , and click la* in the 'im(lation toolbar.

Transforming toolpaths*efore transforming toolpaths, it is advisable to create a master copy of the original.

1 ight-click the %&#$- o"ket toolpath and select Edit > ,op* Toolpath andthen Rename the copy %&#$- o"ket3# as %&#$-Master .

2 %n the owerM/00 explorer select the toolpath %&#$-Master and with the leftmouse key depressed, drag it onto Toolpaths to move it to the top of the list.

3 %n the owerM/00 explorer , right-click on the toolpath %&#$- o"ket and

select Edit > Transform to display the Toolpath Transform toolbar.

4 'witch off the /append toolpaths0 option .

5 n the Toolpath Transform toolbar, click Move .

6 n the Move toolbar, click 4eep ori.inal with &o1 of ,opies as 2 .

7 %n the data entry bo located below the graphics area, enter the relativedistance along 1 as 5$ , and press Enter on your keyboard.

X Y Z values (separated by a space) are entered into this box as re uired.

8 %n the Transform toolbar, click to close and accept the changes.





Two new copies of the original toolpath named %&#$- o"ket3# and %&#$-o"ket32 are created and transformed along X by a relative distance of 5$ .

2ote %t is possible to directly append all of tool tracks into a new, single toolpath%&#$- o"ket3# .

This is achieved by selecting the A(tomati"all* append transformed toolpaths

option before applying the transform values.

Gouge checking a toolpath ne t to the toolpath indicates that it has not been gouge checked directly to

the model.

1 A"tivate the toolpath BN10-Pocket_1 .

2 ight-click on the toolpath BN10-Pocket_1 and from the local menu select6erif* > Toolpath .

3 %n,he"k select the 7o(.es option.

4 Appl* the Toolpath 6erifi"ation dialog.





owerM/00 information bo is displayed to inform of the gouge checkingstatus. %n this instance, No gouges were found .

%n the owerM/00 explorer , the style of the icon also updates indicating thatthe toolpath is gouge free.

5 epeat the 6erif* > Toolpath process on %&#$- o"ket32

Multiple Transform6 Delete both of the toolpaths %&#$- o"ket3# and %&#$- o"ket32 .

7 ight mouse click on toolpath %&#$- o"ket and from the local menu selectEdit > Transform .

8 'elect the option A(tomati"all* append transformed toolpaths .

9 'elect the option M(ltiple Transform to open the following dialog.

10 3nter 8 for number of copies and a pitch of 5$ for both in and ! beforeselecting A""ept .





11 %n the Transform toolbar, click to close and accept the changes.

! new toolpat" ( BN10-Pocket_1 ) is created that machines all " poc#ets.

12 A"tivate and 6erif* the new toolpath %&#$- o"ket3# to check for .o(.es .

13 'elect File - 'ave ro!e"t to update

......\COURSEWORK\PowerMILL-Projects\Transform

Edit > Limit…Edit > 0imit provides a series of options to retrospectively, trim a toolpath to a

lane , ol*.on , or %o(ndar* .

$hese types of retrospective limiting will be undone if the #trateg$ is re%calculated.

4or more permanent toolpath limiting use a %o(ndar* as part of the original'trate.* calculation.

typical application for retrospective Toolpath limiting would be the (one off) re-machining of a local area that has been welded.





Edit > Limit > To a PlaneEdit > 0imit to - Plane allows the user to select a plane at specified distance alongthe X, Y, or Z a is.

The Edit > 0imit to - Ar)itrar* option allows the user to specify an 1,5,6 Point and a user defined, Nor%al vector for the limiting plane.





Edit > Limit > to a Polygon7sing the mouse, you can sketch polygons with any number of sides.

This allows comple areas to be defined, with the option to save the %nside, utside,or *oth sides of the polygon.

&efore ma#ing a polygon ensure that the snap filter is set to pic# Anywhere .

Edit > Limit > to a BoundaryThis provides the option to retrospectively limit a toolpath to an e isting%o(ndar* . This is okay if a temporary, 8uick solution is acceptable, otherwise the%o(ndar* should ultimately be included within the strategy calculation for apermanent solution. typical application for this would be the /one off0 machining ofan area that has been welded due to a previous error.





If the Delete &riginal option is selected, it causes the deletion of theoriginal toolpath once the new toolpath is created.

If the toolpath is re%'alculated any retrospective limiting will not apply tothe new or edited strategy.





Changing the Order and Direction within Toolpaths – EX1

4or toolpaths containing internal link moves, the order and direction of the tooltracks can be changed. 4or e ample, if a machining se8uence starts at the bottomof the part, and progresses upwards, reversing the order will change the tool trackse8uence to start at the top of the part and make it progress downwards.


2 4rom File > Open ro!e"t select the read-only ro!e"t


3 'elect File > 'ave ro!e"t As

......\COURSEWORK\PowerMILL-Projects\EditToolpaths-EX14 %n the owerM/00 explorer , right mouse click on the toolpath )n#2-finish-

a# and then from the local menu select 'im(late from 'tart .

The tool 'li%( Mills across the form, stepping downwards to the base beforestepping up the other side.





5 &eft-click to select all tool tracks on )n#2-finish-a# beyond the centre of theform (5ellow in the illustration above).

6 %n the owerM/00 explorer , right-click the active toolpath , (n1)-finis"-a1 and from the local menu select Edit > Reorder to open the following dialog.

The selected segments are shown highlighted (blue) in the dialog.

3ach segment is listed in the order of e ecution. %f a toolpath segment isselected on the list, the corresponding segment is highlighted in the graphicsarea (and vice versa). 5ou can modify or move the selected toolpath toanother position in the pecking order.

5ou can use the buttons on the left hand side of the dialog for changing theorder and direction of selected segments. %f no segments are selected, thewhole of the toolpath will be edited.

The buttons to the lower left of the dialog are A(tomati" Reorder

and A(tomati" Reorder and Reverse . These can only be applied tothe whole toolpath and not on selected tool tracks. They are designed purelyto minimise unnecessary air moves.





7 +lick on the Reverse Order button to reverse the se8uence of the selectedtool tracks.

8 +lick on the Reverse Dire"tion button to reverse the direction of eachselected tool track.

9 pen the 0eads and 0inks dialog and Appl* -

6erti"al ar"9- 0ead in with An.le :$ and Radi(s ; and

0ead o(t with E+tended move with Distan"e #$

The Order and Dire"tion of the toolpath has been edited so that it tracks fromthe outer edges of the form downwards towards the centre of the base.

0ead /n %*ertical Arc and 0ead O(t %Extended Move has beenapplied to the above toolpath to identify the directional differences.

10 'ave ro!e"t As

......\COURSEWORK\PowerMILL-Projects\EditToolpath-EX1





Changing the Order and Direction within Toolpaths – EX21 4rom the main menu, select File - Delete All and Tools - Reset Forms .

2 Open the read-only ro!e" t -


3 'ave ro!e"t As

......\COURSEWORK\PowerMILL-Projects\EditToolpaths-EX2

The ro!e"t includes a 8D Offset finishing toolpath D#$TR#-F/&# controlledby both %o(ndar* and attern segments.

4 'im(late the Toolpath using a slow setting.

bserve the current direction and ordering of the strategy considering potentialimprovements.

4or e ample, the lower area machining would benefit from climb milling inwardstowards the component form and the pocket machining could start central and climbmill outwards towards the sidewall.





5 4rom the Main menu, select 6iew > Tool)ar > Toolpath to display theToolpath Toolbar.

6 'elect all tool tracks in the lower area and select Reverse Order . This part of

the strategy should now climb mill inwards, towards the main component dialog.%f not /climb milling0, then apply Reverse Dire"tion .

7 'elect the tool tracks in the central pocket and again select Reverse Order followed by Reverse Dire"tion . This part of the strategy should now climb millfrom the centre of the pocket outwards.

xtra care is re uired when using the piral option in the selectedfinishing strategy as these are continuous tool trac#s and can only bereversed and not internally reordered (If a spiral trac# is created to 'li%(Mill outwards then it can only be modified to 'li%( Mill inwards).





Moving Start Points'tart points on the tool tracks can be moved to provide a more suitable position forapplying leads. This is achieved by defining a line that crosses the new startpositions on the toolpath.

1 'elect File - Delete All and Tools - Reset forms .2 'elect File - Open ro!e"t

......\PowerMILL_Data\Projects\limiting-example

3 'ave #ro9ect s

......\COURSEWORK\PowerMILL-Projects\MoveStartPoint-EX1

4 'elect an /'O# view.

The toolpath start point needs to be moved to position .

5 'elect a 6iew from top <Z= .

6 ight-click toolpath # and select Edit > Move 'tart oints and from the

tool(ar select Move start point )* "li"kin. a toolpath se.ment .





7 +lick a point along the toolpath segment and then to accept the change.

This has moved the toolpath start point.

8 'ave the ro!e"t to update -......\COURSEWORK\PowerMILL-Projects\MoveStartPoint-EX1

Moving multiple points%t is possible to apply the Move start points option on the toolpath to multiplepositions.


2 pen the ro!e"t

......\PowerMILL_Data\Projects\PunchForm10-Start3 'ave ro!e"t As

......\COURSEWORK\PowerMILL_Projects\PunchForm10

4 'elect a 6iew from top <Z=.

5 ight-click the active toolpath and from the local menu select Edit > Move'tart oints (The Move #tart Points toolbar is displayed).

6 %f not already selected, on the tool(ar , click the Move 'tart oints )*drawin. a line button.

7 n each of the three locations shown below, in the listed order, click and select points on both sides of the tool tracks.





- 4irst move point selection points.

- 'econd move point selection points.

- Third move point selection points.

The final output looks similar to this





$he tool trac#s are coloured blue while the Move #tart Points toolbar isactive.

8 +lick on the Move 'tart oint toolbar to accept the changes.

9 'ave the ro!e"t to update -

......\COURSEWORK\PowerMILL-Projects\ PunchForm10

Feeds and Speeds5ou can modify 4eed ates using the Feeds and 'peeds dialog to retrospectivelyAppl* them to the Active toolpath .






2 'elect File > Open ro!e"t

......\PowerMILL_Data\Projects\ExtraFeedrates-Start

3 'elect File > 'ave ro!e"t As

......\COURSEWORK\PowerMILL-Projects\ExtraFeedrates-Example

4 7ndraw the Model , %lo"k , orkplane , and Tool to display the Toolpath and! %o(ndaries .

5 A"tivate both the Toolpath and %o(ndar* 2 (The middle one of the !).

6 ight-click the Toolpath and select Edit > ?pdate Feed Rate /nside%o(ndar* .

7 3nter value as @$ and click to apply the percentage difference to the FeedRate within the A"tive %o(ndar* .

The Toolpath is split into two different coloured areas that are allocated aseparate Feed Rate as a percentage of the original. The colour codedFeedrates are displayed in an /nformation dialog that appears automatically.





8 The +eedrates /nformation dialog can also be opened by -

a 'electing 6iew Feedrates from the local toolpath ( %&#$-A# ) menu.

b *y double-clicking on a ,ig"t (ul( ad9acent to a toolpath ( %&#$-A# ) in the owerM/00 e+plorer .

$he original 'utting *eedrate assigned to the toolpath was -.0 %%/%in .

9 A"tivate both the Toolpath and %o(ndar* 8 .

10 ight-click the Toolpath and from the local menu select Edit > ?pdate FeedRate /nside %o(ndar* .

11 3nter the value #$$ and click to apply the percentage difference to the FeedRate within the A"tive %o(ndar* .

The central part of the Toolpath area, clear of the side wall, has changed back

to the nominal Feed Rate value.

12 The +eedrates /nformation dialog can also be opened by double-clicking on a,ig"t (ul( ad9acent to a Toolpath in the owerM/00 e+plorer .

%n this case, the nominal Feed Rate is @$ mmBmin , and the modified section(near the intersection of the *ase and 'idewall of the pocket) is reduced by :;<to 22@ mmBmin . The colour of the values displayed in the %nformation dialog isthe same as the colours displayed on the toolpath.





Safe Z and Start Z PositionsThe tool Rapid Move ei.hts can be changed in the dialog and appliedretrospectively to the A"tive toolpath .

Editing Tool Start and End Point PositionsThe tool 'tart oint =End oint can be changed in the dialog and appliedretrospectively to the A"tive toolpath .



PowerMILL 2015 9. Tool Holder Collision Checking


Collision CheckingCollision Checking can either be applied retrospectively or directly during toolpathcreation, as long as a tool Shank and Holder are defined with the Active Tool .

Retrospective Collision Checking (Verify -Toolpath)If the toolpath menu option, Verify > Toolpath - (Collisions ) is applied, twoadditional toolpaths will be created from the original, one being collision safe, andthe other being in collision. At the same time a copy of the Tool complete withappropriate modifications will be substituted into the Original and Collision status toolpaths.

1 Select File Delete all and Tools Reset !orms.

2 Import the Model "#

...\PowerMILL_Data\Models\cowling.dgk

3 Calculate the lock to Min!Ma" limits.

4 Calculate both the Rapid Mo#e Hei$hts and the tool Start and %nd&oints .

5 Create a $ia %mm &all 'ose tool named '( with a length of )* and toolnumber of ) .

9. Tool Holder CollisionChecking



9. Tool Holder Collision Checking PowerMILL 2015


6 Select the Shank tab.

7 Select Add a shank component .

8 !ill in the dialog e actly as shown in the image below.

9 Select the Holder tab.

10 Select Add holder component .

11 !ill in the form for the first Holder element e actly as shown in the imagebelow.





12 Select Add holder component .13 nter an +pper Diameter of ,, , o.er Diameter of ,* , and en$th of

)* .

14 Select Add holder component .

15 nter an +pper Diameter of /* , o.er Diameter of /* , en$th of )* ,and an 0#erhan$ of )( .

If it is required to modify or delete a Holder element, select (left click) onone of them in the assembly illustration and it will turn pale. The currentvalues for that element will be displayed and available for modification.

The same procedure applies to modify a Shank element.

16 Click Close .





17 !rom the main toolbar, select Toolpath Strate$ies and fromFinishin$ open a Raster Finishin$ strategy.

18 nter Toolpath name as '(-RasterFinish , 1n$le 2( , and Stepo#er ) .

19 Select Start Corner # o.er eft .

20 Select Style # T.o .ay .

21 In the eads and inks , set both ead in and ead out with )st choice as Surface normal arc with 1n$le 3* and Radius / .

22 In the Leads and links # inks page, enter a Short! on$ Threshold of 2 ,set Short to Circular 1rc , on$ to Skim , and Default to Incremental .

23 In ead in and ead out pages, untick the option 1dd leads to short links .

24 Click Calculate to process the toolpath and then Close the dialog.





25 In the &o.erMI explorer hold the cursor over the small bo to the left ofthe toolpath lightbulb symbol.

26 *he Safety Status window will appear.

*he new toolpath is gouge free as far as the Tip (cutting part) of thetool is concerned, but up to this stage no collision checking has beenapplied in relation to the Shank and Holder .

27 !rom the Main toolbar select Toolpath Verification .

*he two available, independent Check options are Collisions and 4ou$es .

Shank Clearance and Holder Clearance , allow the user to specify a valuefor an additional, safe thickness around the tool Shank and Holder elements.





28 In the Check bo select Collisions .

29 Input values in the Shank Clearance , and Holder Clearance / .

30 Click 1pply .

*he above &o.erMI Information bo appears with information on thestatus of the original tool and re+uired dimensional changes. *he defaultsettings will result in a modified tool ( '(5) ) being created along with new toolpaths (*he collision and non#collision parts of the original). *he newtool ( '(5) ) will then automatically e ist in both the original and new(collision warning area) toolpath. *he original tool ( '( ) will remain in thenew (collision safe area) toolpath.

31 Click 06 .32 Click 1ccept on the Toolpath Verification dialog.

&o.erMI has created two new toolpaths, '(-Raster Finish5) and'(-RasterFinish5, . A new tool named '(5) has also been created in

the Tools area of the &o.erMI explorer . *his new tool has been createdwith the new valid ad-ustments made i.e. 0#erhan$ ,782

33 1cti#ate the toolpath RasterFinish5) in the %"plorer .

*his toolpath contains the collision free/ segments of RasterFinish , alongwith the original tool '( .





34 1cti#ate the toolpath RasterFinish5, in the &o.erMI explorer .

*his toolpath contains the collision/ segments of the Raster Finish if itwere machined with the original '( tool.

35 1cti#ate the original toolpath, '(-RasterFinish , in the &o.erMIexplorer .

PowerM LL has substituted a newly created Tool , !"#$% (with anextended overhang) into !"#&'aster(inish and !"#&'aster(inish$) .

36 Select File > Sa#e &ro9ect 1s "

......\COURSEWORK\PowerMILL-Projects\ToolCollisionExample





Direct Collision Checking (Automatic Verification)Tool Holder Collision Checking can also be applied during Toolpath calculation.

If the Toolpath is calculated with a Tool definition that includes a Shank andHolder any part of the toolpath segments that would otherwise be in acollision condition will not appear. *hese missing segments can then bemachined later using a modified Tool in con-unction with a Collision Safe

oundary .

1 Select File > Delete 1ll and Tools > Reset Forms .

2 Select an IS0 , view.

3 0pen the &ro9ect "

......\PowerMILL_Data\Projects\ToolCollision_Start

4 Sa#e &ro9ect 1s "

......\COURSEWORK\PowerMILL-Projects\ToolCollision-Auto

5 0ight#click on the RasterFinish toolpath in the &o.erMI explorer .

6 !rom the local menu, select 1cti#ate followed by Settin$s and in the Raster

Finishin$ dialog select the Cop* toolpath icon .

7 Select the 1utomatic Verification page to open the following dialog"





8 *ick the 1utomatic collision checking bo , then input the Shank Clearance as , , and Holder Clearance as / .

9 Calculate the Raster Finishin$ strategy to directly create a collision freetoolpath, RasterFinish5) .

This method does not produce any information for the user orautomatically create a new collision free tool ( !"#$% ).

Machine maximum stockIf the additional option Machine ma"imum stock is ticked then a full toolpathwill be created with a varying increased thickness over the previously

inaccessible areas.

10 0ight#click on the toolpath 'aster(inish$% in the &o.erMI explorer .

11 !rom the local menu, select 1cti#ate followed by Settin$s and in the Raster

Finishin$ dialog select the Copy toolpath icon .

12 1ith the Raster Finishin$ dialog open, select the 1utomatic Verification

page to access the following dialog"





13 *ick # 1utomatic collision checkin$ , input Shank Clearance ,8* , HolderClearance /8* , and tick # Machine ma"imum stock .

14 Calculate the Raster Finishin$ dialog to directly create a continuous,collision free toolpath, RasterFinish5)5) .

n additional strategy with a compatible (collision free) tool is requiredto remove the remaining stock.

Collision Safe BoundaryA toolpath for the remaining areas will re+uire a new $ia % &all 'osed toolwith increased Shank length. *he additional Toolpath will be calculated tolimits set by a Collision Safe oundary based on the current tool ( '( ).

15 nsure that the tool '( is 1cti#e .

16 In the &o.erMI explorer , right#click oundaries , and from the localmenu select Create oundary > Collision Safe .

17 2se the above settings and 1pply the dialog.





18 Select and Delete all segments e cept the shown below.

19 Create an empty &attern and copy the outer oundary se$ment to it.

!ith the outer !oundar* segment selected, use left mouse ke* andCT'L ke* to drag and drop !oundar* ( % ) into Pattern ( % ) from withinthe PowerM LL explorer .

20 0ight mouse click on the new &attern and from the local menu selectInstrument to display the direction with an arro. .

21 Select the &attern segment and if necessary, select %dit 3 Re#erseselected to set it to comply with a climb milling direction.





22 In the &o.erMI explorer , right#click the *ool, '( , and from the localmenu select %dit > Copy Tool (to create '(-) ).

23 0ight#click over the new tool '(-) and from the local menu, select 1cti#ate followed by Settin$s to open the all nosed tool dialog.

24 !or the Tip change the len$th to )( .

25 Select the Holder tab and change the 0#erhan$ to /* .

26 Close the form.

27 1cti#ate the new long reach/ Tool '(5)

28 Select Toolpath Strate$ies on the main toolbar.

29 !rom the Finishin$ options select a /D 0ffset Finishin$ strategy and enterdata as shown in the following form.

30 Select the imit page and select oundary ) with Trimmin$ > 6eepinside .





31 Select the 1utomatic Verification page and tick 1utomatic collisioncheckin$ , input ) for both Shank and Holder clearances , un#tick Machinema"imum stock .

32 Calculate the toolpath and then Close the dialog.

The new toolpath does not exhibit any fragmentation, showing that theactive Automatic Collision Checking has not detected any problems.

33 Select Sa#e &ro9ect to update"

......\COURSEWORK\PowerMILL-Projects\ToolCollision-Auto





Toolpath Gouge/Collision - Safety Status

1hen a Toolpath is calculated the s*m+ol to the left of the light bulb in the&o.erMI explorer indicates the Safet* Status for 4ou$es (*ip4!lutes) orCollisions (Shank45older).

*o display the 6 different levels of Safety Status , position the mouse over a

s*m+ol in the &o.erMI explorer and the information formwill open (shown above right).



PowerMILL 2015 10. Patterns


IntroductionPatterns are 2D or 3D Wireframe entities used primarily for the control andcreation of toolpaths. A selection of Pattern creation and manipulation options areprovided in a dedicated Toolbar (as shown below).

Below is a summary of the Pattern - toolbar options:

Create Pattern (empty). !his will also ma"e the other toolbar optionsactive.

Activate the picked pattern .

Pick curves to add to the active Pattern .

Automatic Pattern Generation (#pen the Pattern Maker form).

Insert File into Active Pattern (e$. d$"% pic% d&f% i$es).

10. Patterns



10. Patterns PowerMILL 2015


Save Active Pattern as a file (d$" pic d&f).

Insert Boundary into Active Pattern .

Insert Active Toolpath into Active Pattern .

Insert odel into Active Pattern ('elected odel).

Curve modellin! .

"ireframe modellin! ( ' '"etcher).

Transform pattern

Curve #ditor .

Clear

The Pattern segments can be edited directly from local menu options, or viathe Curve Editor . Unlike Boundaries , Patterns can contain opensegments.

When an empty Pattern is created it is automatically assi$ned a number and madeActive as shown in the Po$er I%% explorer .

Automatic Pattern Generation!he Automatic Pattern Generation icon opens the Pattern aker dialo$. !hisprovides options for the user to construct a ran$e of wireframe layouts that can beused in the Pattern Finishin! strate$y.

1 'elect File & 'elete All and Tools & (eset Forms .

2 Import the odel :

......\PowerMILL_Data\Models\phone.dgk

3 'elect Block and Calculate usin$ the default settin$s.4 Define a dia *2mm Ball +ose tool named B)*+ .

5 ,eset the (apid ove ,ei!hts .

6 'elect an IS * view to display the model .





7 'elect the -shutout surface as shown above.

8 /n the Po$er I%% explorer % ri$ht clic" on Boundaries % and from the localmenu select the option Selected Surface and enter the values shown below.

9 Apply the dialo$ to create 2 Boundary se$ments.

10 /n the Po$er I%% explorer % ri$ht clic" on Patterns and from the local menuselect Toolbar .





11 /n the Patterns toolbar select% Create a ne$ .empty/ Pattern .

12 /n the $raphics area% select the inner Boundary se$ment.

13 /n the Patterns toolbar select the option to Insert Boundary into Active

Pattern .

14 0ndraw the Boundary .

!he selected Boundary se$ment will be copied as a Pattern se$ment as shownbelow.

15 ,i$ht clic" on the Pattern se$ment and from the local menu% select Curve#ditor .

16 /n the toolbar move the cursor over Transformations and from the

attached vertical toolbar% select the ffset option .

17 'elect 0eep ri!inal % the (ound Corners option% and input 'istance 12 before clic"in$ the Enter "ey.

18 /n the Curve #ditor toolbar% clic" to accept.





19 ,i$ht clic" on the Pattern and from the local menu% select Instrument todisplay the direction arrows on the se$ments as shown in the ima$e above.

20 'elect the inner Pattern se$ment and from the local menu select #dit &(everse Selected (Both Pattern se$ments should now run in the samedirection).

!he Automatic Pattern Generator will be used to create a new Pattern with aseries of se$ments mer$ed between the 2 se$ments from the ori$inal Pattern . !heresultant toolpath will follow the contour of the component form as well as creatin$corner free% tool trac"s with a constant material removal rate.

21 1rom the Pattern toolbar% select Create Pattern to create a new Pattern .

22 'elect Automatic Pattern Generation .

23 With the new (empty) Pattern activated and the ori$inal Pattern displayed%select both visible se$ments.

24 'elect Create Pattern alon$ -one way curves with a Stepover *32

!he form allows the user to create a ran$e of multi se$ment Pattern styles fromeither * or 2 drive curves.

25 lic" Apply % followed by Accept .





!he new Pattern has been $enerated independently between the two selectedse$ments of the ori$inal% de activated Pattern (the above illustration shows alar$er 2mm 'tepover for visual reasons).

!he new Pattern will now be used in a Pattern Finishin! strate$y.

26 /n the Strate!y Selector %Finishin! options% select a Pattern Finishin!

strate$y.27 4nsure that the Boundary is not Active .

28 4nter the data into the above form e&actly as shown below% clic" Calculate % andthen Close the form.





!he Pattern Finishin! toolpath is limited to e&ist within the defined materialBlock .

Exercise29 ,i$ht mouse clic" on the new toolpath from the local menu% and use the #dit &

(eorder options to ma"e the above strate$y start from the outside and ClimbMill towards the centre of the model.

30 Save the Pro4ect .





Pa tterns applied to 3D Offset machining

A Pattern can be used as a curve to be offset across the area of a 5' ffsetFinishin! strate$y.

1 'elect File & 'elete All and Tools & (eset Forms

2 Import the model :

......\PowerMILL_Data\Models\speaker.dgk

3 Save Pro4ect As :

......\COURSEWORK\PowerMILL_Projects\SpeakerPattern-EX1.dgk

4 Define a Dia 5 Ball +ose tool with the name B)6 .

5 Define a Block to the default in6 a& limits.

6 alculate the (apid ove ,ei!hts to the default settin$s.

7 'elect an IS 5 view.

8 'elect the 3 shaded Surfaces as shown in the followin$ dia$ram.

9 reate a Selected Surface % Boundary with allow boundaries to be private un tic"ed% and with a Tolerance value of 232+





10 1rom the Pattern toolbar clic" Create Pattern followed by Insert

Boundary into Active Pattern (/nput Boundary name into the dialo$7).

11 0ndraw the Tool %Block % odel and Boundary to visually isolate the newPattern .

Only the leading edge of the Pattern is required. The remaining parts areto be removed.

12 'elect the Pattern se$ment usin$ the left mouse "ey.

13 ,i$ht mouse clic" on the Pattern and from the local menu% select Curve #ditor to open the followin$ toolbar:

14 'elect the option Cut Item .

While performing the next operation it is essential to zoom in as close as possible to the end of the pattern segment

15 ove the cursor over the left hand end of the leadin$ ed$e to locate the 0eyPoint and then left clic" to cut the se$ment at this point.

16 'elect the leadin$ ed$e% se$ment a$ain% locate the 0ey Point and cut e&actly atthe ri$ht hand end of the leadin$ ed$e.





17 lic" on the option Cut Item a$ain to de select it.

18 'elect the Pattern se$ments away from the leadin$ ed$e% and 'elete .

19 lic" the $reen tic" to Save the above new se$ment and close the Curve#ditor toolbar.

20 ,i$ht mouse clic" on the Pattern se$ment and from the local menu% selectInstrument to display the direction of the se$ment.

21 /f it is not runnin$ in the direction (shown above)% ri$ht mouse clic" on thePattern se$ment and from the local menu select #dit & (everse Selected .

22 ,e draw the Tool % odel and the Active Boundary .





23 'elect a 5' ffset Finishin! strate$y and enter data into the dialo$ e&actly asshown below.

24 lic" Calculate to create the toolpath and then Close the dialo$.

%eads and %inks are not displayed to provide a clearer view of the toolpath .

!he above toolpath starts at the lowest point followin$ the Pattern while offsettin$across the limitin$ Boundary in a Climb illin! direction. With the addition ofsuitable %ead In and %ead ut moves this is an ideal strate$y for High SpeedMachining applications.





/f a Pattern is not selected in the 5' ffset dialo$% machinin$ strate$y follows theshape of the Boundary se$ment% as shown above.


Exercise - 3D Offset Finishing controlled by Pattern/t is not compulsory for the Pattern for controllin$ the toolpath to be coincidentwith the limitin$ Boundary . /n the followin$ e&ercise a 5' ffset Finishin! will becontrolled by a Pattern that runs centrally alon$ the base of a curved recess:

1 'elect File & 'elete All and Tools & (eset Forms

2 pen the Pro4ect :

......\PowerMILL_Data\Projects\PatternBlock_Start

3 lic" 0 to close the PowerMI !arning and Save Pro4ect As :

......\COURSEWORK\PowerMILL-Projects\PatternBlock_ex1

4 Calculate the Block usin$ the default settin$s.





5 Calculate the (apid ove ,ei!hts to the default settin$s.

6 /n the 7ie$in! toolbar switch on display "ireframe .

7 reate a Pattern usin$ Insert odel on the wire"rame arc (included with theodel ) runnin$ centrally alon$ the recessed form.

8 'elect the 8 surfaces that define the recessed form and create a SelectedSurface %Boundary usin$ a 232* tolerance % with the B)*6 tool active.

9 reate a 5' ffset Finishin! strate$y that is limited Inside the Boundary with the order and shape of the tool trac"s controlled by the Pattern .

10 Save Pro4ect As :

......\COURSEWORK\PowerMILL_Projects\PatternBlock-EX1





Deep Pattern machining/f Pattern Finishin! is applied with a 9ve Thickness it will only create tool tracks where the 9ve Thickness value is less than the tool %tip radius . As an e&ample%this ma"es it impossible to use a 9ve Thickness value less than ero where an #nd

ill is bein$ used.

/t is% however% possible to produce a Pattern Finishin! strate$y that machinesdeeper into the model if A8ial ffset is used in place of a 9ve Thickness value.!his is achieved by first pro;ectin$ the Pattern onto the surface (relative to the tool$eometry). Pattern Finishin! is then applied usin$ the #rive Curve option with a9ve% A8ial ffset value while !ou!e checkin! is untic"ed.

The strategy produced !ill not be based on a "# offset of the model form buta series of copies of the #rive Curve stacked do!n!ards.

1 'elect File & 'elete All and Tools & (eset Forms .

2 pen the read only Pro4ect :

...... \PowerMILL_Data\Projects\DeepPattern_Start

3 lic" 0 to close the Po$er I%% "arnin! and Save Pro4ect As :

......\COURSEWORK\PowerMILL-Projects\DeepPattern-EX1

!he Pro4ect consists of component surfaces and a Pattern on 92 representin$ thete&t -,< ready to be en$raved into the component form to a depth of -5 .

4 Calculate a Block %#e"ined B$ - Bo8 % usin$ %$pe - odel .

5 reate a Dia 8 Ball +osed tool with the name B)1 .

6 Calculate the (apid ove ,ei!hts to the default settin$s.

7 /n the Po$er I%% explorer % ri$ht clic" over the Pattern 1 and from the localmenu select% #dit & 'rop to pro;ect it downwards onto the model.

This pro$ects the Pattern do!n %, !hile compensating for the tooling parameters.





8 1rom the main toolbar% select Toolpath Strate!ies and in the dialo$ selectFinishin! followed by the Pattern Finishin! option.

9 4nter the data into the dialo$ e&actly as shown% usin$ Base PositionAutomatic with %hickness -5 and then clic" Calculate .

The %hickness of &'() exceeds the Tip &adius of the #ia ' (all )osed toolhence instead of a toolpath appearing, the follo!ing PowerMI Error formis displayed.

10 lic" 0 to close the PowerMI Error messa$e and recycle the PatternFinishin! toolpath usin$ the data as shown in the followin$ ima$e.





Base Position 'rive Curve

Axial *""set -532

+ouge Check 9 un-ticked

%hickness 2

11 'elect the ultiple cuts pa$e and input data e&actly as shown below.

Mode ffset do$n

,pper limit 9 Ticked with value -*32 (1irst pass at *mm below the Pattern )

Maximum Stepdown *32

12 lic" Calculate to create the toolpath and then Close the dialo$.





!he ,eversed letterin$% attern -,< is now recessed into the unch form to a depthof 3mm.

The %oolpath !ill initially be identified in the PowerMI explorer !ith a$ellow warning .

13 ,i$ht mouse clic" on the Toolpath and from the local menu select 7erify =Toolpath .

14 /n the Toolpath 7erification dialo$ (with the default Check 9 Gou!es set)select Apply .

#nce verified for !ou!es % the above %oolpath B)1-#n!rave will then be identifiedin the Po$er I%% explorer with a red $arnin! .








PowerMILL 2015 11. Curve Editor


IntroductionThis is a wireframe constructor within PowerMILL that provides the user with apowerful set of tools for the creation and modification of Boundaries and Patterns .It is accessed via the local Boundary or Pattern menu option, Curve Editor.. .During construction, the Intelligent Cursor option allows geometry items to besnapped onto key points on a displayed CAD model.

Input of Drawing detail as a Pattern using the CurveEditor

An empty Pattern can be inserted into the Curve editor thereby providing the userwith an effective way to input Drawing Detail which could in turn be used in thecreation of 2.5D Feature ets.

11. Curve Editor



11. Curve Editor PowerMILL 2015


1 elect File ! Delete All and Tools ! Reset For s .

2 In the PowerMILL explorer select !orkplanes ! Create !orkplane .

3 The !orkplane editor toolbar will become active as soon as a new workplane is created on the global datum.

4 elect the green tic" to e#it the !orkplane Editor toolbar.

5 A"tivate the !orkplane .

6 elect a view down $.

7 %rom the PowerMILL explorer , create an empty Pattern , right mouse clic" onit and from the local menu select Curve Editor .

8 %rom the Curve Editor select Re"tangle option.

9 Input # in the Command Input bo# &located to the right and below thegraphics area' and press the return "ey to accept.

This will fi# the corner of the Re"tangle o$ Lines to the active ()$ datum.

10 Input %&& %## in the Co and Input bo# and press the return "ey to accept

the ( and ) dimensions of the rectangle.

11 elect the corner Radius option and input %# .





12 Create a new Re"tangle o$ lines using %## '& to define the start corner.

13 In the data input bo#, switch from A(solute to Relative input andenter )# &# for the ( and ) dimensions.

14 %rom the Create a "ir"le options select the $ull Cir"le option.

15 Input a Radius value of '& .

16 Input &# &# in the Co and Input bo# followed by the return "ey.

17 Create another Cir"le with a centre at &# *# and a radius value of + .

18 Clic" on to close the Cir"le "reation options.

19 elect the Dia * Cir"le .





20 +ith the new Dia * Cir"le selected, open the Trans$or s options and select

Create pattern o$ o(,e"ts .

21 n the dialog, select the Cir"ular tab and enter Angle +# , -u (er %' and

select Reposition rotation a is , and drag it to the centre of the largecircle.

22 elect A""ept on the Multiple Trans$or dialog.





The geometry creation is now complete and is ready to be returned to thePowerMILL Pro,e"t as the contents of the Pattern .

23 -eft clic" in the graphics area away from the segments to deselect them.

If any segments are selected then the remainder will no longer exist onreturn to the main PowerMILL window.

24 elect to accept changes and e#port the wireframe bac" to PowerMILL toreplace the original boundary.

25 elect File /ave Pro,e"t As /

......\COURSEWORK\PowerMILL-Projects\2DModel





Boundary modifications using the Curve EditorA /0allow Boundary will be created in the following e#ample and although correctto the settings applied, i t will benefit from further modification to provide improvedmachining strategies. The modifications aim to ma"e the toolpaths, continuouslyfollow the lower, component contour by bridging the gap between the 2 outersegments as well as smoothing any 0agged sections of the segments. The easiestand most effective method is to ma"e use the Curve Editor .

1 elect File 1 Delete All and Tools 1 Reset For s .

2 I port the Model /

......\PowerMILL_Data\models\cowling.dgk

3 Cal"ulate a Blo"k using Defined by 1 Bo and Type Model .

4 Create a 1all ose cutter of Diameter 34mm named B-%# .

5 Cal"ulate the Rapid Move 2eig0ts using the default settings.

6 se the default /tart and End Point values.

7 In the PowerMILL explorer , right!clic" Boundaries and from the local menuselect Create Boundary 3 /0allow

8 Input Tolerance #.#'





9 et li it tool "entre to (lo"k edge .

10 n!tic" Allow (oundary to (e private .

11 elect Apply followed by A""ept .

12 ndraw the odel to view the new Boundary .

The Boundary will be modified so that the gap is removed between the 2 outer,closed, segments to form separate inner and outer segments. In addition to this,two of the other segments, which contain 0agged sections, will be smoothed.

13 6ight!clic" Boundary 1 in the PowerMILL explorer and from the menu optionsselect Curve Editor .

The Curve Editor toolbar will appear above the graphics area.

Some licensed icons are temporarily greyed out, only becoming availablewhen a related entity is selected.

14 elect a view down 4 for a top view of the inserted boundary.

15 Clic" Line from the toolbar then select Create a single line .

Note It is essential that the Intelligent Cursor is active !tic"ed# $

If not, this is set in the Curve Editor 5ptions menu/!

!! Intelligent Cursor !! /napping 5ptions !! &Tic" all bo#es'.

16 sing the left mouse button, snap & 6ey points ' to create single lines across theends of the four gaps, as shown in the image below.





17 elect the /ingle Line option to switch it off.

18 To remove redundant spans on the curves, clic" the Li its option to accessIntera"tively li it wire$ra es .

19 Clic" Intera"tively li it wire$ra es and using the left mouse button,select the parts of the curve &arrowed' to be removed.

20 elect the Intera"tively li it wire$ra es option again to switch it off.

21 Zoom into the middle of the area covered by the 7 inner segments.

Note the %agged effect along these curves.





22 Create 8 single lines , snapped to "ey points and pointing outwards from thecurve outside the 0agged regions &as shown above'.

These will be used as mar"ers to provide a start and end point for new,replacement smoothed curves along the 0agged sections. The mar"ers will thenbe used as the limit to trim away the unwanted, 0agged sections of the original

curve.

23 Clic" Curve on the tool(ar then select Create a Be7ier Curve from theCurve toolbar.

24 %or the upper section, generate a new, smoother, "urve by snappingstrategically placed "ey points within this region, starting and ending bysnapping to the ends & 6ey Point ' of the mar"er lines.

&he selection of suitable "ey points re'uires a certain amount of s"ill on the part of the user. (here it is re'uired to follow the original form closely inputseveral, e'uispaced points. (here the original shape needs to be smoothedout input the minimum of e'uispaced points along the form.

25 6epeat this process for the lower section.

26 elect the upper, original curve and select the Cut Ite option.

27 Clic" the key points at the lower end of each line to cut the original curve.





28 6epeat the above process on the lower, original curve then select and Delete

all the unwanted segments between the 2 pairs of lines .

29 Then, select and Delete the 8 vertical lines.

30 Create a new smooth Be7ier Curve to replace the one indicated below.

&he Curves used in the above wireframes will consist of open or closedsegments, but if they are to be used to recreate a boundary they must formsingle entity, closed loops. )nly closed forms will appear as boundary segments when returned to PowerMILL .

31 elect all (oundary segments by dragging a bo# over them with the left handmouse "ey depressed.





32 elect the option Merge selected segments to 0oin together all groups of"urves that butt up to each other.

&he wireframe will now consist of five single segments as reported in thePowerMILL Information box !above right#.

33 -eft clic" in the graphics area away from the segments to deselect them.

If any segments are selected then the remainder will no longer exist onreturn to the main PowerMILL window.

34 elect to A""ept changes and e#port the wireframe bac" to PowerMILL toreplace the original boundary.

The modified Boundary is positioned bac" over the model close to its original 7Dform. The new smoothed contours are now a more suitable shape for use in the +D5$$set Finis0ing strategy.

35 9enerate a Constant 4 Finis0ing toolpath with /tepdown 3 and in the Li it page set the Boundary ! Tri ing option to 6eep outside & teep areas'.

36 9enerate a +D 5$$set Finis0ing toolpath with /tepover 3 and in the Li it page set the Boundary ! Tri ing option to 6eep inside & hallow areas'.

37 elect File /ave Pro,e"t As /

.....\COURSEWORK\PowerMILL-Projects\Boundary-mod





These are the resultant toolpaths with the Leads and Links undrawn.

&he techni'ues used in this example can e'ually be applied to Patterns ,which also have the added advantage on being able to exist both as open orclosed segments ! Boundaries cannot contain open segments#.

&he same Curve ditor toolbar is accessed via the local Pattern menu.



PowerMILL 2015 12. 2D machining


IntroductionPowerMILL offers a range of 2D strategies that include 2D Curve machining,Chamfer Milling, Face Milling , and 2.5D Feature machining. The originalwireframe can either be Pattern or Model entities.

Feature MachiningFeatures are wireframe entities that are extruded along Z. During creation they arespecifically defined as a Pocket , Slot , Boss, Hole, Circular pocket , or Circularboss . It is also possible to extract ole features directly from the D model. oleFeatures can also be created during !" #rea Clearance strategies to enable thepre!drilling of plunge mo"e, positions. It is essential that a Feature Set includes allseparate Features that need to wor# together to create a $%&" Feature machiningstrategy.

$n completion of a Feature Set , the % Feature Set options in the $%&" #reaClearance strategies will create roughing, semi finishing, and finishing strategies.

"rilling strategies can only be applied to ole Features . & comprehensi"e, list ofcycle types are supported that include' (tandard drilling, )oring, Helical milling,Tapping and Thread Milling.

The six different types of Feature include*!

Pocket *! Machining will only occur fully inside this type of closed Feature .

Slot *! Machining will occur with the tool running central, left, or right of thistype of open+closed Feature .

Boss *! Machining will only occur fully outside this type of closed Feature .

ole , this type of Feature is specifically used by the "rilling strategies.

Circular Pocket ! a circular poc#et is defined from points, circles or cur"es.

Circular Boss ! a circular boss is defined from points, circles or cur"es.

It is not possible to change an existing a Feature to one of a different type.

12. 2D Machining



12. 2D Machining PowerMILL 2015


Creating Features from Pattern segments1 (elect File ' "elete #ll and (ools ' )eset Forms .

2 *pen the ead!$nly Pro+ect *

......\PowerMILL_Data\Projects\2D-Drawing

The imported Pro+ect contains a Pattern defining 2D geometry ready to beused to create a Feature Set .

3 (elect File ' Save Pro+ect #s *

......\COURSEWORK\PowerMILL-Projects\2DPatternExample

4 In the PowerMILL explorer , right!clic# on Feature Sets and from the localmenu, select Create Features .

The Feature dialogue will appear in the graphics area.

5 (elect the large, outer, rectangular Pattern segment and enter "alues exactlyas shown -using Type Boss in the abo"e Feature dialog before clic#ing #ppl -Do not close the dialog .





The first Feature is the outer component body defined as a Boss -as shownabo"e .

6 (elect both, the rectangular segment -with corner fillets and the largecircular segment.

7 /nter "alues exactly as shown in the abo"e Feature dialog -using Type Pocketbefore selecting #ppl -Do not close the form .

If you close the Feature dialog it can be re-opened in the PowerMILLexplorer by a right click on the Feature and then from the local menuselect Create Features .

8 0lose the Feature creation dialog.

9 ight mouse clc# on the new Feature Set 1 - and from the local menu selectCreate oles .





10 (elect all of the Dia circles -32 and enter "alues exactly as shown in theabo"e left Feature dialog -using Type ole before selecting #ppl .

The contents of the Feature Set - - should be similar to the abo"e illustration-4ote* & naming system has been deployed where a Boss is prefixed with a B, aPocket with a P , and a ole with an .

11 0lose the Hole creation dialog.

The Feature Set is now complete and ready for the creation of suitable 2.5Dmachining and Drilling strategies.

2D Feature Set Machining1 Define a Dia 35 ! tiprad 3 ! 6ength 75 tool named "-.()- .

2 0lic# to open the Block dialog, set the ( pe as Feature and the selectCalculate .

3 0lic# to open the )apid Move eights dialog and select Calculate .





4 0lic# to open the (oolpath Strategies dialog and select $%&" #reaClearance .

5 (elect Feature Set #rea Clearance and input the data exactly as shown in thefollowing dialog.

6 In the *ffset page tic# Spiral .





7 In the Leads and Links 1 Lead in page select*! st choice 8 )amp

!amp "ptions 8 Follow Circle 1 Circle #iameter $TD%& .%/&

8 (elect Calculate to process the toolpath and then select Cancel to close thedialog.


10 (elect Feature Set Profile and input data exactly as shown in the followingdialog.





11 (elect the Lead In page and for -st Choice select Pocket Centre and then

select the Lea# out same as lea# in option .

12 (elect Calculate to process the toolpath and then Close the dialog.

13 0reate a Dia "rill of 6ength 37 and named "rill! .





14 0lic# to open the Strateg selector dialog and select the "rilling tab.

15 9rom the list, select Single Peck to open the "rilling dialog -below .

16 (elect Calculate and all of the contained ole Features will automatically beselected before the "rilling toolpath is processed.

17 (elect Cancel to close the dialog.

18 0reate a Dia "rill of 6ength 75 and named "rill/ .





19 0lic# to open the Strateg selector dialog and select the "rilling tab.

20 9rom the list, select Break Chip to open the "rilling dialog -below and thenclic# Select to open the Feature Selection dialog.

21 (elect Calculate and all of the contained ole Features will automatically beselected before the "rilling toolpath is processed.

22 (elect Cancel to close the dialog.





23 un a full 0iewMILL simulation on all % toolpaths.

24 Save the Pro+ect .

2D Machining Exercise9or this exercise the following 2D drawing will be used along with the imported 2Dwireframe Pattern *

1 (elect File 8 "elete #ll and (ools 8 )eset Forms

2 0reate an empty Pattern and Insert 1 File *

.....\PowerMILL_Data\Models\2d_Wizard_Example.dgk

3 Save Pro+ect #s *!

.....\COURSEWORK\PowerMILL_Projects\2D_Wizard_EX1





4 0reate a Feature Set - - and create appropriate Features using the abo"edrawing dimensions.

a The outer s:uare and small tapered, central upstand are created as BossFeatures .

b The intermediate s:uare is created as a tapered Pocket Feature .

c The four Dia 37 circles are created as ole Features .

d The single red line on the drawing is used to define a Slot Feature -Thisshould be created in a separate Feature Set - -2- .

5 0reate a Dia -. with ! (ip )adius tool named "-.()! - oughing, (emi!finishing within the main ;oc#et 9eature including the small )oss .

6 0reate a Dia -. (apered (ipped tool named "-.(r!#& , with Tip adius ! ,Taper &ngle & Deg, 6ength $& , Taper Diameter 3%& -9inal 9inishing of taperedwalls Main ;oc#et and small )oss .

7 0reate a Shank of Dia -. ! 6ength !. .8 0reate 2 older with *verhang &. and entities*!

a 6ower Dia $. ! <pper Dia !. and length $& .

b <pper+6ower Dia !. and 6ength $& .





To calculate the Taper Height based on the Taper Angle and base Taper

Diameter, the anual Input icon , ad!acent to the Taper Height, is clicked

to apply the Calculate option to this parameter.

9 0reate a Dia 37 "rill named "rill-& .10 0reate an 4nd Mill of Dia 35 named 4M-. .

11 &cti"ate the tool "-.()! .

12 &cti"ate, Feature Set - and create a Block -Type 1 Feature .

13 Calculate default )apid Move eights ready to create the 2D Feature machining strategies.





Main Block and Central Pocket"-.()! ! 9eature (et &rea 0learance 1 $ffset Model


15 (elect Feature Set #rea Clearance and input the data exactly as shown in thefollowing dialog.

16 Calculate the toolpath and perform a 0iewMILL simulation as shown below.





"-.(r!#& ! 9eature set ;rofile


(elect Feature Set Profile and input the data exactly as shown in the followingdialog.

18 Calculate the toolpath and continue the 0iewMILL simulation -as shownbelow .





"rill-& 1 Drilling

19 0lic# to open the (oolpath Strategies dialog and select "rilling .

20 (elect "eep "rill and input the data exactly as shown in the following dialog.

21 Calculate the toolpath and continue the 0iewMILL simulation -as shownbelow .





4M-. ! 9eature (et ;rofile

The " dimension of the existing #lock $ill need to be ad!usted to fully,include the %lot Feature.

22 $pen the Block dialog and input /. for the Ma5 6 "alue before selecting#ccept -Do 4ot select 0alculate in the )loc# dialog .

23 &cti"ate Feature Set -2- .


25 (elect Feature Set Profile and input the data exactly as shown in the followingdialog.

26 (elect the 'lot Feature only and then Calculate the toolpath.

27 0reate 2 more copies of this strategy using 'lot Cutting 7eep left and 7eepright respecti"ely.





28 0ontinue the 0iewMILL simulation on the last toolpaths -as shown below .

The re:uired Slot width is achie"ed by creating separate toolpaths usingthe different Slot cutting options, starting with Centreline , followed by (eep le)t , and then (eep right .






Creating Features directly from holes in the Model&s well as being able to use imported 2D geometry , Hole Features can beautomatically defined from selected Holes in the 3D Surface or Solid model .

1 (elect File 8 "elete #ll and (ools 8 )eset Forms .

2 (elect File 8 Import Model *

......\PowerMILL_Data\Models\3Axis-Drilling


......\COURSEWORK\PowerMILL-Projects\DrilledHoles-Example

4 Ma#e sure the Block is not defined at this stage, as the top of the oleFeatures will be created at the nearest Z dimension -Max or Min of the Block .This is more than li#ely to result in some holes being created the wrong way up

-It is howe"er possible to re"erse a ole Feature .5 #ctivate the *or+plane MC1datum .

6 (elect the whole model .

7 In the PowerMILL explorer , right!clic# on Feature Sets and from the localmenu select Create holes .





8 Input data into the Feature dialog exactly as shown on pre"ious page, and clic##ppl .

9 <ndraw the model .

& ole Feature is created for each of the selected, Hole elements within themodel -including the 0hamfers and 0ounter!bores as separate Features .

EXERCISE10 Define suitable tools, then "rill and Counter Bore the oles using the "rilling

dialog options.






Hole Cappingole Features can be used as the basis for capping holes in the D model . If the

intersection of the hole and the top face is non!planar, PowerMILL will cap the holewith a surface that follows the tangency of the surrounding D model .

ExampleThe following example illustrates the process of capping cylindrical ole Features defined from a !" model .

1 (elect File ' "elete #ll and (ools ' )eset Forms .

2 Import the model *

......\PowerMILL_Data\Models\Block_with_holes.dgk

3 Calculate a Block using De)ine# ,y ! Bo5 and Type ! Model -In this case theole Features will be created upside down .

4 (elect the whole model by dragging a box o"er it while the left mouse button isdepressed.

5 (elect )ecognise oles in Model .

6 In the Feature dialogue enter -ame root and select #ppl .





In this case the tops of the ole Features are positioned at the shortest

distance from the face of the Block . This results in all of the ole Features being created upside down.

If the loc+ had not been defined prior to this, then the Hole Features $ould ha&e been created the 'right $ay up( relati&e to the ) Axis.

It is also possible to control the resultant direction from within the Create oles dialogue. This is achie"ed if = 8se active workplane onl > is tic+e# along withselecting the option = Find holes going down >.

Any Hole Features that are created to a different orientation from theoriginal ) Axis, $ill automatically be assigned to a separate Feature 'et and associated *or+plane .

In this case the holes were deliberately created upside down to demonstrate the)everse oles editing option.

7 ight!clic# Feature Set - and in the menu clic# Select #ll and then from thesame menu, select 4dit 8 )everse Selected oles .

8 9inally, select the top surface of the Model and in the PowerMILL explorer ,right!clic# Feature Set - and from the local menu select 4dit ! Cap oles .





The new Capping Surfaces will be generated -Tangential to the selected topsurface in a new model called Capping Surfaces created along with a new level of the same name.

9 0lic# the light ,ul, to undraw Feature Set - - .

10 /xpand Levels by clic#ing on the 9 symbol - .

11 0lic# the light ,ul, to undraw main surfaces - .

The new Capping Surfaces may be created inside out -(urface 4ormals re"ersed .If re:uired they can be selected and from the local Surfaces menu, )everseSelected can be applied.

The Capping 'ur)aces are automatically assigned to the ne$ Le/el foreasy selection.

120lic# on the light ,ul, on the loc+ with holes le"el to re!display the mainmodel.





Internal Thread Milling

(hread Milling is included as one of the options in the "rilling dialog.

If the C cle ( pe ! (hread Milling option is selected, the tool plunges centrally toa specified depth, leads on to the sidewall, and then pitches upwards before leadingoff.

?ithin the options it is possible to apply a number of passes -stepping outwards byan allowance "alue to a"oid tool o"erload. It is also possible to choose either a

ight Hand or 6eft Hand thread.

1 (elect File ' "elete #ll and (ools ' )eset forms .

2 *pen the Pro+ect *

....\PowerMILL_Data\Projects\ThreadMILL_2014-Start

3 (elect File ' Save Pro+ect #s *

.....\COURSEWORK\PowerMILL-Projects\ThreadMILL-Example1

4 #ctivate the Threa# Milling Tool named M:.1Coarse1Pitch1& .

5 #ctivate the Feature Set named Pocket -This defines the large central hole .





6 (elect (oolpath Strategies and in the Strateg Selector dialog, select the"rilling tab followed by the (hread Mill option %

7 In The "rilling dialog using Cycle Type ! (hread milling , set both !a#ial and 0xial (hickness 1! , Pitch & , ;ame M:.1) 1Int(hread , lea"ing all otherparameters as default -as shown below .

8 (elect the Cutter Compensation page.

9 Tic# the C-C cutter compensation box and select Type (ool wear .

10 Calculate the form and then Close the dialog.





11 Calculate a new Block using "efined b ! Bo5 and ( pe ! Model .

12 ight!clic# the ;C Program MC10ll and in the local menu select Simulatefrom Start .

13 $pen a new 0iewMILL session and run a simulation of all toolpaths. -Do notacti"ate the toolpath, otherwise the current Block definition will change .

The completed 0iewMILL simulation is as shown abo"e.

14 Disconnect 0iewMILL from the simulation -but do not apply 45it 0iewMILL ,and return to the PowerMILL window.

External Thread Milling

15 #ctivate the Feature Set named Boss -This defines the outside of the centralboss .

16 (elect (oolpath Strategies and in the Strateg Selector dialog, select the"rilling tab followed by the 45ternal thread option.





17 In The "rilling dialog, set the Cycle Type to 45ternal (hread , both !a#ial and 0xial (hickness 1! , Pitch & , -ame M:.1) 1Int(hread , lea"ing all otherparameters as default -as shown below .

18 (elect the (hreading page and select the %se a 5 #egree arc lead option.

19 Calculate the form and then Close the dialog.

20 e!open and re!connect the 0iewMILL session and run a simulation of thelatest toolpath M:.2) 145t(hread .





21 (elect File ! Save Pro+ect .





2D Curve MachiningPowerMILL contains % strategies that directly operate on 2D Pattern segments.These include*

Face Milling .

$" Curve #rea Clearance .

$" Curve Profile .

Chamfer Milling .

Example 11 (elect File 8 "elete #ll and (ools 8 )eset Forms .

2 *pen the Pro+ect *

......\PowerMILL_Data\Projects\2DCurve-2015mc-Start

3 (elect File 8 Save Pro+ect #s *

......\COURSEWORK\PowerMILL-Projects\2DCurve-Machining

4 #ctivate the Pattern named Curve#ll .

5 Calculate a Block using "efined b 1 Bo5 and ( pe ! #ctive Pattern -Do notclose the dialog .

6 In the Minimum < co!ordinate box input ! $$ before selecting #ccept to closethe dialog.





7 In the )apid Move eights dialog select Calculate .

8 #ctivate the Face Milling tool named "&.(/ .

9 9rom the $%&" #rea Clearance options select Face Milling and enter data intothe dialog exactly as shown below.

10 In the Leads and Links 1 Links page and set the 'hort3Long threshol# as:. and 'hort as Circular #rc .

11 0lic# Calculate to create the toolpath and then Close the dialog.





12 #ctivate the Tip !a#iuse# tool named "-/(! .

13 In the $%&" #rea Clearance options select $" Curve #rea Clearance andenter data into the form exactly as shown below.

14 (elect the Cut distances page and input Stepdown -. .





15 In the Leads and Links 1 Lead in page select*! st choice 8 )amp

!amp "ptions 8 Follow Circle ! Ma5 =ig angle : ! Circle #iameter $TD%& .%/&

16 9rom the main Curve area clearance page, Cur/es #e)inition , select

Interacti/ely mo#i)y machina,le sections .

These options enable the user to ha"e full control of direction of cut and the areasto be machined.

*hile the Cur/e 0rea Clearance form is open, the areas to be machined

are displayed as a shaded pre&ie$.

17 (elect to exit the Interactivel modif machinable sections toolbar.

18 (elect Calculate to create the toolpath and then Close the dialog.





19 #ctivate the 4n# Mill named 4M-/ .

20 9rom the $%&" #rea Clearance options select $" Curve Profile and enter datainto the dialog exactly as shown below.

21 (elect the Cut distances page and input Stepdown $& .

22 (elect the Lead in page and for -st Choice select Pocket Centre and then

select the Lea# out same as lea# in option .

23 0lic# Calculate to process the toolpath and then Close the dialog.





For the leads to $ork in this case it is necessary to apply 4#it - Mo/e 'tartPoints

24 9rom the local Toolpath menu select 4dit 1 Move start points .

25 (elect the mode as = clic+ a toolpath segment > and left clic# a more suitablestart+end point on the toolpath segment.

+ote In this mode it is also possible to drag a purple sphere along asegment to mo&e the start end point.

26 (elect the green tick to accept the updated start+end point and close thecontext toolbar.





27 #ctivate the 0hamfer Tool named "$&(r-#:& .

28 9rom the $%&" #rea Clearance options select Chamfer milling and enter datainto the dialog exactly as shown below.

29 (elect the Cut distances page and input ;umber of cuts as - .

30 0lic# Calculate to process the toolpath -Do not close the dialog .





The resultant Chamfer milling strategy has appeared -incorrectly on the outsideof the Pattern segments.

The toolpath needs to be recycled with the Chamfer Milling tool trac#s changed toappear on the inside of the Pattern segments.

31 In the Chamfer milling dialog, select the !ecycle icon to enable changes to bemade to the abo"e strategy.

32 (elect Interactivel modif machinable sections to access the 4#itMachina,le 'ections toolbar.

33 (elect the )everse machining side option, followed by to accept thechanges and close the toolbar.

34 In the main Chamfer milling dialog, select Calculate to create the toolpathand then Close the dialog.

The Chamfer milling options selected result in the angled part of the toolo"erlapping the base of the chamfer by 3mm.





& D model of the finished component has been imported to pro"ide a "isualchec# of the Chamfer machining .

35 un a 0iewMILL simulation of the whole machining process.





Cutter Compensation Example?here applicable a Cutter Compensation page is a"ailable in a $%&" MachiningStrateg dialog explorer options.

1 (elect File ! "elete #ll and (ools ! )eset forms .

2 In the PowerMILL explorer right clic# on Patterns and from the local menuselect Create Pattern .

3 ename the Pattern as Profile- .

4 ight clic# on the new Pattern and from the local menu select Curve 4ditor .

5 (elect )ectangle from the lines options.

6 In the data input box -below the graphics area input . to set the 3st corner ofthe rectangle, followed by -.. &. to define the @ A dimensions.

7 (elect )ectangle from the lines options again to deselect it.

8 (elect the green tic+ to close the Curve 4ditor and accept the rectangularPattern .

9 In the PowerMILL explorer right clic# on >orkplanes and from the localmenu select Create >orkplane .

10 In the >orkplane 4ditor toolbar, select the green tic+ sa"e.

11 #ctivate the new >orkplane .

12 0reate a Dia 35 4nd Mill named 4M-. .

13 Calculate a Block using "efined b 1 Bo5 and ( pe 1 #ctive Pattern .

14 Input the "alue Min as 1$. and then loc# both Min < and Ma5 < "alues.

15 Input 45pansion -& and then select Calculate to add stoc# to the @ and Adimensions of the Block .





16 In the )apid Move eights dialog select Calculate .

17 In the Strateg Selector form select the $%&" #rea Clearance options.

18 Then select the $" Curve Profile strategy and enter data as shown in thefollowing illustration.

19 (elect the Cut "istances page and input $. for both the Stock depth and theStepdown .

20 eturn to the Curve Profile page and select the 4#it Machining 'ectionsoptions.

21 If re:uired, select )everse machining side to mo"e the profiling pass tothe outside of the Pattern .





The abo"e pre"iew shows the cutter being switched from the inside to the outside ofthe Pattern prior to calculating the toolpath.

This toolpath $ill not contain any data that relates to Tool Compensation output.

22 (elect the green tic+ to accept the changes and exit 4dit Machining Sections .

23 Calculate the Curve Profile toolpath.

24 $pen the Leads and Links form and select Lead in 1 ori=ontal #rc 1 #ngle--. and )ad -. .

25 0opy the Lead In settings to Lead *ut .

26 (elect 45tensions and input an 45tended move of -. for both Inward and*utward .

27 #ppl the Leads and Links settings to the acti"e toolpath.

28 ight clic# on the acti"e toolpath - 4M-.1Profile1;oComp and from the localmenu select Settings to open the Curve Profile dialog.

29 $nce the Curve Profile dialog is open select the Ma+e a Copy option.

30 )ename the new toolpath as 4M-.1Profile1FullComp .

31 (elect the Cutter Compensation page, tic# the C;C cutter compensation box, and select ( pe as Full radius .





32 Calculate the new Curve Profile toolpath, but do not close the form.

33 To test the "alidity of the applied tool compensation the (oolpath toolbar needs

to be acti"e - Main pulldown menu*! 0iew 1 (oolbar 1 (oolpath .

34 In the (oolpath toolbar select the "raw compensated toolpath option.

If Full Compensation is successfully applied it is displayed as a thicker greentoolpath but offset inwards to the same ?6 dimensions as the Pattern -If thetoolpath is displayed in red then the compensation is not geometrically "alid .





35 (elect the Make a Cop option again.

36 )ename the new toolpath as 4M-.1Profile1>earComp .

37 (elect the Cutter Compensation page, tic# the C;C cutter compensation box, and select ( pe as (ool wear .

38 Calculate the new Curve Profile toolpath, and then Close the dialog.

39 In the (oolpath toolbar select the "raw compensated toolpath option.

If >ear Compensation is successfully applied it is displayed as a thicker green"ersion of the original toolpath.


......\COURSEWORK\PowerMILL-Projects\ToolCompExample





Viewing the NCData output files for a heid controller41 In the PowerMILL explorer , right mouse clic# on ;C Programs and from the

local menu select Preferences .

42 $pen the folder containing the Machine "ption File and from the list select thefile heid%opt and clic# the *pen tab.

43 Close the ;C Preferences dialog.

44 In the PowerMILL explorer right mouse clic# on (oolpaths and from the localmenu select Create Individual ;C Programs .

45 ight mouse clic# on ;C Programs and from the local menu select >rite #ll .

46 Minimise the PowerMILL window to access the Des+top options and select>indows e5plorer -$r for *in#ows 6 use File e5plorer .

47 $nce *in#ows explorer has opened browse to C@AtempA;CPrograms .

48 In >indows explorer , right mouse clic# on an -C#ata output file and from thelocal menu select *pen with 1 >ordPad .

49 epeat stage 3!13: for all -C#ata output files and compare the output.





Full Compensation Wear Compensation

The output file using Full Compensation is exactly matching the geometryof the // 0 1/ rectangular 2attern.

The output file using *ear Compensation is offset by /mm 3the cutterradius4 outside the // 0 1/ rectangular 2attern.


......\COURSEWORK\PowerMILL-Projects\ToolCompExample

Protected Cutter Compensation

?ith ( pe 1 Full radius selected any internal -conca"e corners will re:uire asuitable Minimum radius "alue included to allow for corner radii that are less thanthe re:uired full offset "alue.





2D Curve Machining Example – Inc. Clamp Avoidance1 (elect File 8 "elete #ll and (ools 8 )eset forms .

2 *pen Pro+ect *

......\PowerMILL_Data\Projects\2DCurveProfileSplit-Start

The imported Pro+ect also contains a Dia27 4nd Mill and a Pattern defining the 2Dgeometry used in the existing 2D Machining (trategy.

3 (elect File 8 Save Pro+ect #s *

......\COURSEWORK\PowerMILL-Projects\2DCurveProfileSplit-EX1

The existing 2D 0ur"e profile toolpath is clearly passing straight through the definedclamp positions. This will be fixed by applying the (plit (ection option that isaccessed from the 2D 0ur"e ;rofile form.

4 (elect a 0iew down < .

5 9rom the Main pulldown menus select, "raw ! Cursor ! (ool and "raw 1Cursor 1 Cross air -$r use the shortcuts Crtl T and Ctrl H .

6 /nsure that the Pattern ! *uterForm is displayed - PowerMILL explorer , lightbulb on .





7 ight clic# on the toolpath 4M$&1FullProfile and from the local menu ensure#ctivate is tic#ed, and then select Settings .

8 $nce the Curve Profile form is open select the Ma+e a Copy option.

9 )ename the new toolpath as 4M$&1SplitProfile .

10 $n the Curve Profile page select Interactivel modif machinable sections.

11 ?hile the abo"e toolbar is open, mo"e the cursor to a point on the left hand sideof the Pattern segment, and then right clic# to open the local menu.

12 9rom the local menu select Split Section and an extra start an# en# point willbe created on the Pattern at this point.

13 9rom the main pull down menus select "raw 1 Cursor 1 Cross air -0trl H .





The cross hair $ill be displayed on the cursor to assist $ith alignment ofstart and end point.

14 <sing the left mouse #ey, drag the new green ! start point along the Pattern toa position to the right of the upper left clamp -as shown below .

15 6ocate and drag the corresponding re# ! end point to a position to the right ofthe lower left clamp -as shown abo"e .

16 epeat the process on the other -6eft hand span and drag the start and endpoints to the left hand side of the Pattern -as shown abo"e .

17 (plit the toolpath again twice, to the left of both the upper and lower rightclamps -as shown below .

18 Mo"e the new start and end points to form % distinct spans along the Pattern asshown in the following diagram.

For accurate alignment use the displayed cross hairs and key points.





19 $nce the % new spans ha"e been aligned, select the green tic# in the 4ditMachining Sections toolbar to accept the modifications.

20 )ac# in the Curve Profile machining form select Calculate to process the new/M27!(plit;rofile toolpath and then Close the dialog.

To chec# "isually chec# the toolpath for collisions, a triangle model of the stoc#along with the clamps will be imported and used as the 0iewMILL bloc#.

21 (elect an IS*- "iew.

22 ight mouse clic# on the toolpath 4M$&1SplitProfile in the PowerMILLexplorer and from the local menu select Simulate from start .

23 $pen the Block form and select "efined b (riangles and CoordinateS stem 1 lobal (ransform -(ee diagram on next page .

24 (elect the Load block from file option and browse to the model*!

....\PowerMILL_Data\Triangles\2DCurveprofileSplit.dmt

25 #ccept the Block form.





The Block will appear as shown below - *pacit slider set to full

26 0onnect 0iewMILL to the toolpath simulation and run with the )ainbow Shaded Image option set.

The tool is no longer crashing through the clamp positions.

27 (elect File ! Save to update the stored Pro+ect .



PowerMILL 2015 13. NC Programs


IntroductionOnce a series of toolpaths have been generated their names can be listed in an NC Program file to be post processed as an output file for a specific NC machine control . Any number oftoolpaths can be included and reordered as required depending on the limitations of theparticular NC machine along with the associated post processor.

If the NC machine has a tool change facility then toolpaths created with different cutter sizescan be included in the same NC Program .

If the NC machine does not have a tool change facility then only toolpaths created with thesame cutter can be included in the same NC Program .

1 Select File > Delete All and Tools > Reset Forms .

2 Open the ‘read only’ Project

......\PowerMILL_Data\Projects\NCProgram-Start

3 Select File > Save Project As !

......\COURSEWORK\PowerMILL-Projects\NCProgram-ex1

13. NC Programs



13. NC Programs PowerMILL 2015


Defined PowerMILL Paths – NC Program output4 "rom the top pulldown menu bar# select Tools > Customise Paths .

5 In the PowerM !! Paths dialog# select NC Program Output followed by A""

path to top o# list .

If not already defined# it is now required to set up a path to where the PostProcessed files $ NCPrograms % are to be stored.

6 In the PowerM !! Paths dialog# Select NC Program Output and $if it is notalready displayed% add the new path C$%Temp%NCPrograms .

If this method is used the destination folder for NCPrograms must existon your pc otherwise it will not be possible to output the NCProgram files.

7 &lic' O& to accept and close the above dialog '

8 &lose the PowerM !! Paths dialogue.





Use Project On - NC Program outputAn alternative method to control the destination for NC"ata output is to use the activeProject as the default# destination for outputting NC Data files. In the NCPrograms (Pre#erences form# switch Use Project to ON .

On applying the )rite command on an NC Program a folder named NC Programs will becreated in the currently active Project folder. (his will not wor' if a PowerM !! Project hasnot yet been created $ Save Project %.

Setting the NC Preferences1 In the PowerM !! explorer # right!clic' NC Programs and select Pre#erences .

2 In the NC Pre#erences dialog# select the folder icon to access the machine tool#Option File list.





3 "rom the Select Machine Option Filename dialog $below%# select thehei"*+,'opt and clic' the Open tab.

(he selected option file translates the output to the correct )achine (ool outputformat.

It is not unknown to have more than one Option File for the samemachine tool to allow for different operational requirements.

4 &lic' Accept on the NC Pre#erences dialog.

Creating the NC Program1 In the PowerM !! explorer # right!clic' on NC Program and from the local

menu# select Create NC Program .

2 *nter the name -o./,*,/Top and clic' Accept .





3 In the PowerM !! explorer select the 01( bo+ by NC Programs to toggle thedisplay of the contained NCPrograms .

One or more Toolpaths can be added to the active# NC Program .

4 Select the Area Clearance icon with the left mouse button and 'eeping it helddown drag the mouse to the right $(he cursor will display ghosted icons%.

5 &ontinue to drag the toolpath onto the active NC Program # -o./,*,/Top andrelease the mouse button. In the PowerM !! explorer # NC Programs areaselect the ,-! bo+ by -o./,*,/Top to toggle a display of the contents$Roughing/2, %.

6 rag the other toolpaths into the last file in the active NC program area tomaintain the required machining order.





Add to – NC Program (alternative method)It is also possible to add several toolpaths to the active NC Program . In thePowerMILL e3plorer # select one or more toolpaths and then Right Mouse

Click on one to open the local oolpaths menu.

Select A"" to / NC Program and all of the selected toolpaths will be added tothe NC Program list.

7 0ight!clic' on any of the toolpaths in the current NC Program to access the localToolpath options# but do not apply any of the options at this stage.

8 0ight!clic' on the NC Program $-o./,*,/top % and select Settings .





You can open and edit! the NC Program form current by selectingSettings from the local right click menu.

"everal of the settings assigned to a specific toolpath can be changed inthe above dialog. #he toolpath row is selected and relevant values #ool$umber% Coolant% etc! are then modified before clicking Apply . #hese localedits do not affect the original toolpath.

9 &lic' Accept .





10 0ight!clic' on the NC Program # -o./,*,/Top and select )rite to create the1ost!1rocessed output file.

uring the translation an n#ormation window appears containing a progressreport.

2ewly created Toolpaths are automatically added to the !ctive NC program .It can be useful to Create and Activate an NC Program prior to toolpathcreation to save having to drag them in later as a separate operation.

11 e!activate the NC Program # -o./,*,/Top in the PowerM !! explorer .

12 Activate the e+isting ia 24 3all nose tool named 24/5 .

13 Calculate a 6D O##set Finishing toolpath# named 6Do##set(test2 using thesettings and values as shown below.





It is not always required to output all toolpaths in one NC Program . &s aresult it is possible to create an NC Program directly from an individualtoolpath entity.

14 0ight!clic' on the toolpath named 6Do##set(test2 and select Createn"ivi"ual NC Programs .

15 A new NC Program is created. Select the + symbol to the left of NC Program 1 toaccess its contents $the + symbol will change to a - symbol%.

#he NCProgram icon for "#o$$set%test& will remain blue until theoutput file is processed 'rite !. #he icon will then turn to green.





Viewing the NC-Data outputOnce 1ost!processed# the NC Data output file can be viewed directly from the local menu.

0ight!clic' on the NC Program # -o./,*,/top and from the local menu# select7iew File .

An n#ormation dialog will open to enable the user to view $but not edit% thecontents of the 2& ata output file.

Manually Editing the NC-Data outputIf the user needs to edit the code manually# then the 2&! ata output file will have to be editedin 4ordpad.

1 "rom )in"ows 83plorer # browse to C$%temp%NCPrograms to where the NC(Data files are downloaded.

2 0ight!clic' on one of the NC(Data files and from the local menu# select Open)ith > )or"pa" .

3 "rom the main $top% toolbar select File > Save to update the Project followedby Close .



PowerMILL 2015 14. Setup Sheets


IntroductionAll the Setup data required from a PowerMILL Project such as cutterdefinitions , images and information relating to toolpaths can be downloaded asHTML files and then printed out as required. This is essential for the CNC Operatorswho will be running the programs.

1 Select Delete > All and Tools > Reset forms .

2 Open the Project :

......\PowerMILL_Data\Projects\SetupSheet-Start

3 Select Save Project As :

......\COURSEWORK\PowerMILL_Projects\SetupSheet-ex1

4 From the main pulldown menus select Tools > Options > Setup Sheets >Setup Sheets , and tick the bo Load Setup Sheets ith Project .

5 Accept the form.

14. Setup Sheets



14. Setup Sheets PowerMILL 2015


6 !n the Po erM!LL explorer right"clic# on "# Pro$rams and select SetupSheets > Settin$s%

7 !n the Project Settin$s dialog, enter the information as shown below and select#lose .

There are 2 other tabs for the user to input further information as UserDefined Settings and Project Notes .

8 Activate one of the toolpaths to reinstate the original setup $%loc#, &or#plane,'apid (o)e *eights, etc+.





9 nsure that no tools or toolpaths are )isible and onl- the shaded model andwireframe &lock $minimum Opacit' + are displa-ed in an !SO ( )iew.

10 'ight"clic# on the NC Program named M#)All and from the local menu selectSetup Sheets > Snapshot > #urrent *ie .

An image of the model has now been captured and will be automaticall- used onthe front page of the setup sheet.

11 ndraw the model lea)ing the wireframe +lock as the onl- displa-ed item.

12 nsure that the "#Pro$ram " M#)All is displa-ed $light bulb icon on+.

13 'ight"clic# on the "# Pro$ram " M#)All again and select Setup Sheets >Snapshot > All Toolpaths > !so *ie .





!mages of all the toolpaths in the selected "# pro$ram ha)e now beencaptured.

ach toolpath will ha)e a separate page on the Setup Sheet .

14 'ight"clic# on the "# Pro$ram " M#)All again and select Setup Sheets )Previe .

This action will create the Setup Sheet , HTML files.

The Po erM!LL Setup Sheets, !nde- is displa-ed on the left side of thescreen.

15 !n the abo)e Index dialog left clic# on Project Setup Sheet)e-( to displa- thefollowing sheet.

16 From the !nde- page select the Toolpath and Summar' pages in turn and)iew the content.









Each HTML page can be printed out as individual items. Right-click on the page and from the local menu, select Print Picture .

The / st sheet of the Summar' Pa$e is as shown below.

17 'ight"clic# on the "# Pro$ram " M#)All and select Setup Sheets > .-port .

E port stores all the !etup !heets as HTML documents into the current"ro#ect $older.

!etup !heets can be printed internall% from "o&erM'LL or e ternall% fromthe E ported HTML documents.





Customising Setup Sheets%- editing the HTML templates it is possible to customise the output of the SetupSheets .

The use of HTML editing software is the recommended method to implementchanges to the Setup Sheet output. There are free downloads a)ailable from theweb. Microsoft /ord can also be used but this can gi)e unpredictable results.

(l&a%s create a cop% of the template document so that the original is stillavailable if things go &rong.

!n the following e ample an alternati)e template will be substituted into the SetupSheet Toolpath Template search paths.

1 'ight"clic# on the "# Pro$ram named M#)All and select the option SetupSheets 0 Paths .

2 On the Paths tab select the folder icon in the Toolpath 0 /rite field.





3 %rowse to 0000001Po erM!LL2Data1setup)sheets and Open theToolpath3 .html file $customised template+.

4 Clic# #lose on the Setup Sheets dialog.

5 'ight"clic# on the "# Pro$ram named M#)All select the option, Setup Sheets 0 Previe and re"run the Setup Sheets using the new template.

6 On the !nde- page select the new page for the toolpath Rou$hin$2(45

$Shown below+



PowerMILL 2015 15. Specialist Finishing


Projection Machining.Projection Finishing provides greater control of the projection direction ofmachining strategies onto a component. Applications include the machining ofundercut features using specialist tooling and a more accurate finish for featurespositioned at complex angles to the tool axis. Projection Finishing is also anessential strategy for use with Five Axis tool alignment applications.There are five different strategies Point , Line , Plane , Curve , and SurfaceProjection .

The simplest way to understand the principle of projection machining is to regardthe first four strategies comparable to beams of light radiating into or away from adefined source.

A Point strategy is similar to light radiating from a single light bulb.

A Plane strategy is similar to light radiating from a rectangular floodlight.

A Line strategy is similar to light radiating from a fluorescent tube.

15. Specialist Finishing



15. Specialist Finishing PowerMILL 2015


A Curve projection strategy is similar to light radiating from a curved neon tube.

A Surface projection projects the tool Inwards or Outwards along the normalsof a selected surface.

In the Finishing dialog, the projection Direction can be toggled betweenOutwards and Inwards from the user defined plane.

In the Projection Finishing forms, angular definitions are input using Azimuth and levation . By using a combination of the two any complex 3 angle can bedefined.

Azimuth Angle !" #tarting from !" # $ this is the angle anticloc$wise aroundthe % axis.

This is shown on the chamber model, with a view loo$ing down the %"axis.

levation Angle " this is the upward angle from the "& plane

This is shown on the chamber model, with a view loo$ing down the &"axis.





Plane Projection ExampleAll five Projection Finishing strategies can be used to machine undercut featuresif used with suitable tooling such as isc or #pherical. The following example showsan undercut application using the Plane Projection strategy.

1 #elect File ' Delete All and (ools ' )eset Forms .

2 #elect File ' O*en Project !

......\PowerMILL_Data\Projects\Heatsink-Ucut2-Start

3 Save the Project As !

......\COURSEWORK\PowerMILL_Projects\ Heatsink-Ucut2-EX14 (pen the +loc, form and with Defined -. ' +ox and (.*e ' /odel set select

Calculate .

5 Simulate the 0CProgram )all of the existing toolpaths* in 1iew/ILL .





6 +eturn the 1iew/ILL simulation to the 0o'Image view .

7 isconnect 1iew/ILL from the toolpath simulation .

8 Activate the D23'45'(6 isc utter.

9 In the +loc, dialog lock all - of the " and % values.

10 Calculate the & values of the +loc, with an x*ansion value of 7$ .

11 In the Strateg. Selector " Finishing dialog, select Projection Plane Finishing and fill in the pages of the dialog exactly as shown below.

The Location is the local datum for the projection strategy. All other coordinatesentered in the dialog are relative to this point.





The values for the Start and nd heights can be obtained by viewing the modelin the " direction and using the cursor position to display % values at the bottomright of the screen.

12 #elect Preview to view the Plane Projection pattern.

The Projection Plane 8 Preview is displayed as shown and the user candynamically alter the view to visually chec$ for potential adjustments.

hen using projection finishing, ) Point , Line or Plane *, the Anchor Point must be positioned )along the projection direction* away from the model by atleast the cutter radius.

13 #elect Calculate to create the toolpath and then Close the dialog.





(bserve that the tool is gouging through the fins when it retracts at the end ofeach pass. This is confirmed by the red toolpath, icon displaying an exclamationmar$ in the explorer.

In this case suitable Leads and Lin,s will be applied to easily rectify theproblem.

1 (pen the Leads and Lin,s dialog and select the Lead in tab.





2 Input the following in the Lead in page!

9st Choice " Straight

Distance 73

Angle $

3 #elect the Lead Out the same as Lead in tab.

4 A**l. and Acce*t the dialog.

The toolpath Lead moves are now updated and the red warning icon in thePower/ILL explorer has automatically updated to white .

5 Save , but do not close, the Project as it is to be continued in the next section.

Surface Projection ExampleSurface Projection will be used for the finishing strategy as it will provide aconsistent ste*over within the undercut regions. To allow this a specially created,single, reference surface will be imported )To create this surface the user wouldre/uire the services of a suitable A pac$age such as PowerS4AP *. Thereference surface does not necessarily have to represent the true shape of thefinished component. In practice it could be positioned inside, outside, or flush withthe actual model surfaces to be machined. In this example the reference surface is flush with the existing model.

1 Im*ort the additional model !

......\PowerMILL_data\models\heatsink-ref.dgk

The new imported surface appears as a separate item in the /odels section of thePowerMILL ex*lorer . This will be useful when selecting it as the referencesurface to be used with the Surface Projection dialog.





2 0rom the main pull down menus select 1iew " (ool-ar " Command to openthe command in*ut window below the graphics area and type in the following3 lines!"

EDIT SURFPROJ AUTORANGE OFF

EDIT SURFPROJ RANGEMIN –1

EDIT SURFPROJ RANGEMAX 1

This is to restrict the tool projection distance to within 1.2mm of the referencesurface. (therwise it would be projected from infinity onto non"undercut faceson the outside of the model.

The default setting is restored by typing:-

EDIT SURFPROJ AUTORANGE ON

3 0rom the (ool*ath Strategies dialog, select Projection Surface Finishing .

4 In the Power/ILL explorer , right"clic$ the model, 4eatsin,'ref and from the

local pull down menu clic$ Select Surfaces .





5 In the Surface Projection Finishing dialog input the settings and data exactlyas shown below.

6 #elect Ordering as One wa. .

7 #et the Start Corner as! /ax : max 1

8 #elect Preview .





The Preview pattern for the strategy is displayed on the reference surface )for clarity, a stepover value of 3 was used in this illustration*.

9 Calculate the toolpath and then Close the dialog.

The unidirectional toolpath is shown here without the defined Leads andLinks displayed.

A suitable Lead In and Lead Out must be applied to prevent the toolfrom gouging through the overhang.

The application of Surface Projection 0inishing has produced a strategy with aconsistent stepover across all of the undercut areas.

10 #elect File ' Save to update the stored Project .







8 Activate the (D;$ cutting tool.

9 0rom the (ool*ath strategies dialog, select Projection Line Finishing .

10 0ill in the pages of the strategy dialog exactly as shown below.

The values for the Start and nd heights were obtained by dynamically movingthe cursor over the model to obtain the % values in the cursor coordinateboxes at the bottom right of the graphics area.

11 #elect Preview .







15 Input the following information!

1st Choice ' 4orizontal Arc

Distance ' 3

ngle ' @$

!adius ' 9$

16 #elect the Lead out the same as lead in tab.

17 lic$ A**l. and then Acce*t to close the dialog.

The extension value in Leads and Links must be more than the tool

radius to prevent gouging.The red warning icon in the PowerMILL explorer will now have changedto green .






Point Projection Example1 #elect File ' Delete All and (ools ' )eset Forms .

2 #elect File ' Im*ort /odel !

......\PowerMILL_Data\Models\radknob.dgk

3 #elect File ' Save Project As !

......\COURSEWORK\PowerMILL_Projects\PointProj-ex14 In the Power/ILL explorer , right"clic$ or,*lane 9 and from the local menu

select Activate followed by or,*lane ditor to display the following toolbar!

5 0rom the toolbar select (wist a-out & to open the (wist dialog.

6 In Angle , enter 9B$ and clic$ Acce*t .

7 lic$ the reen tic$ to accept the changes and close the toolbar.

The or,*lane is rotated 9B$ degrees about & to provide vertical machiningaccess to the inner wall. 6owever, machining is currently impossible due to thepoc$et being shielded by an untrimmed planer surface )shown part shaded*.This example will apply Com*onent (hic,ness options to set this surface tobe ignored while applying the machining strategy.

8 reate a ia 95 ball nosed cutter named +095 .

9 Calculate a +loc, using Defined -. " +ox and (.*e " /odel .10 Calculate the )a*id /ove 4eights using the default settings.

11 0rom the Strateg. Selector dialog, select Projection Point Finishing .





12 0ill in the page of the dialog exactly as shown above and select Preview toobserve the Point Projection setup.





13 In the main page of the Point Projection Finishing dialog select the

Com*onent (hic,ness icon and in the dialog select the Surfaces tab.

14 lic$ on any of the 7 rows to display a coloured box at the start. In the graphicsarea, ensure that the only the untrimmed planar, surface is selected.





15 lic$ the Ac uire Com*onents icon to add the selected, planar surface to

the row.16 #elect Ignore in the /achining /ode box.

17 A**l. and Acce*t the Com*onent (hic,ness dialog.

18 Calculate the Projection Point Finishing toolpath and then Close the dialog.

The inside of the poc$et has successfully been machined. This would not havehappened if the untrimmed surface, bloc$ing access had not been included in aCom*onent (hic,ness list with the /achining /ode set to Ignore .






Curve Projection Example1 #elect File ' Delete All and (ools ' )eset forms .

2 #elect File " Im*ort /odel and select!

......\PowerMILL_Data\Models\ crvproj_3D.dgk

)8ote the model also includes a wireframe curve running centrally along the

slot*.3 #elect File ' Save Project As !"

......\COURSEWORK\PowerMILL_Projects\CurveProj-Ex1

4 alculate the +loc, using Defined -. ' +ox and (.*e ' /odel .

5 efine a ia 95 Ball 8osed tool called +095 .

6 alculate )a*id /ove 4eights using the default settings .

7 In the Power/ILL explorer , right"clic$ Pattern and from the local menu select

Create Pattern .8 #elect the wirefra"e curve )coloured green* running centrally along the slot

on the /odel )8ote9 The ireframe view must be active for the curve tobe visible*.

9 In the Power/ILL explorer , right"clic$ on the new Pattern ) 9 * and in thelocal menu select Insert ' /odel .

10 0rom the Strateg. Selector dialog, select Projection Curve Finishing .





11 0ill in the page of the dialog exactly as shown below and select Preview toobserve the Curve Projection setup.





:isually the *review is somewhat of a mess, containing crossovers and loopsalong the path. The actual toolpath however should not suffer the sameproblem, with the projection distance to the machining areas being a lot shorter)well before loops or crossovers start to appear*.

12 Calculate the Projection Curve toolpath and then Close the dialog.

The Curve used as the basis for the strategy will in the majority of casesbe created in a CAD package as part of the Model . n these cases theimported wirefra"e curve must then be inserted into a Pattern .






Swarf Finishing#warf 0inishing is specifically designed to machine down one or more surfaceswhere a linear transition exists along the tool alignment direction. It will not wor$where the transition is concave or convex.

0or 3 Axis applications the tool axis must be set to 1ertical .

The strategy can be set to create either single )default* or multiple passes, exactlyfollowing the upper edge, lower edge, or both )merging*.

In the following example the #par sidewalls will be selected and #warf machined.This will provide a strategy similar in appearance to onstant % but applied locally tothe selected surfaces and guaranteed to run the final pass exactly along the bottomedge )subject to gouge chec$ing*.

1 #elect File ' Delete All and (ools ' )eset forms .

2 0rom File ' O*en Project select the )read"only* Project !

......\PowerMILL_Data\Projects\3Axis_SwarfStart1

3 0rom File select Save Project As !

......\COURSEWORK\PowerMILL-Projects\3AxisSwarfExample

4 In the Power/ILL explorer , activate the wor,*lane "c#Datu" .

5 In the Power/ILL explorer , activate the ia ;< =nd >ill ) /95 *.

6 alculate a +loc, using Defined b$ " +ox and %$pe " /odel .

7 alculate the )a*id /ove 4eights using the default settings.





8 In the Power/ILL explorer , clic$ the ? ! @ adjacent to Levels and Sets toaccess all of the existing Levels .

9 +ight"clic$ on the Level &warf#MC and clic$ Select Surfaces from the localmenu.

All Surfaces on Level &warf#MC will be selected )light blue* to be included in theSwarf strategy.

10 In the Strateg. Selector , select the Finishing tab, and then select the SwarfFinishing strategy.

11 =nter data exactly as shown in the following pages of the dialog.





12 #elect Calculate to create the Swarf Finishing toolpath and then Close thedialog.

The tool tracks that machine the base of the selected surfaces have progressively offset upwards !by the stepdown value" until fragmentationoccurs when the upper edge is e#ceeded. This can be prevented by using$Mode Merge instead of Offset Up .

13 In the Power/ILL explorer , right"clic$ the tool*ath 'M1(#&warf)Offset*p and select Settings .

14 #elect the Cop$ %oolpath icon from the dialog .

15 )ename the new (ool*ath as /95'SwarfE/erge .

16 In the page labelled /ulti*le Cuts change the /ode to /erge and with allsurfaces on the Level &warf#"c selected, Calculate the strategy.





Merge will use a variable stepdown to e#actly track the selected surfaces $upper and lower edges and minimi%e the number of lift moves.

17 +ight"clic$ the last tool*ath 'M1(#&warf)Merge , in the Power/ILLexplorer and select Settings .

18 #elect the Cop$ %oolpath option.

19 )ename the new tool*ath as /95'SwarfESinglePass .

20 (n the /ulti*le Cuts page, change the /ode to Off .





21 ith all surfaces on the Level &warf#"c selected, Calculate the strategy.

22 lose the Swarf Finishing dialog.


......\COURSEWORK\PowerMILL-Projects\3AxisSwarfExample





Parametric Offset FinishingParametric Offset Finishing creates a strategy that trac$s between two individualPatterns with a stepover that adjusts to the shape of the selected surfaces . Thetool trac$s can be created parallel )along* or span between )across* the Patternsegments.

1 #elect File ' Delete All and (ools ' )eset forms .2 O*en the read"only Project !


3 lic$ O in the PowerMILL +arning dialog and Save Project As !

......\COURSEWORK\PowerMILL-Projects\ParaOffset-ex1

4 Activate the ia ;< +ad 3 (i* )adiused tool named D95(); .

5 ith the new tool active , and the surfaces shown )below left* selected, createa Selected Surface +oundar. .





6 reate an empty Pattern , named *pper and Insert the upper +oundar. segment into it.

7 reate another empty Pattern , named Lower and Insert the lower +oundar. segment into it.

It is not necessary for both of the Pattern segments to run in the samedirection as the *pper one will control the toolpath direction.

8 >a$e sure that no +oundaries are Active .

9 (pen the Parametric Offset Finishing dialog and fill in as shown below.





10 #elect Calculate to create the toolpath and then Close the dialog.


12 o not delete the Project as it will be continued in the next section.





Parametric Spiral MachiningThis strategy starts from a Pattern and merges a spiral toolpath towards anOuter limit which is either defined by the +loc, or to one or more surfaces ac/uired to a Level or Set .

The direction of the toolpath created in the Parametric S*iral Finishing strategyis controlled by the Cut Direction nticlockwise Clockwise . The direction of thecentral Pattern has no control over the toolpath direction.

If the Poc,et option is ticked the resultant tool*ath will start at the Outer limit .

1 In the Power/ILL explorer right mouse clic$ on Levels and Sets and fromthe local menu select Create Set .

2 #elect the upper base Surface and from the new Set ) 9 *, local menu selectAc uire Selected /odel eometr. .

3 >a$e sure that no +oundaries are Active or displayed.

4 (pen the Parametric S*iral Finishing dialog and fill in as shown below.





5 #elect Calculate to create the tool*ath then Close the dialog.










Wireframe Profile Machiningireframe Profile machining is designed to machine to the left or right of the

selected curves of a 3 ireframe. The following example is a pressing thatre/uires the outer form and recesses to be finish profiled. As the main importedmodel is in #TC )triangle* format it is incompatible with +oundar. options thatoperate on selected surfaces . It is also impossible to create the necessary 3

ireframe curves direct from the S(L model in Power/ILL . To resolve, the

stored 3 urves will be imported into a pattern to be applied in the ireframeProfile /achining strategy.

1 #elect File " Delete All and (ools " )eset Forms .

2 #elect File and Im*ort the /odel !

......\PowerMILL_Data\Models\3D-Curve-TriModel.stl

3 #elect File ' Save Project As !......\COURSEWORK\PowerMILL-Projects\3D-WireframeProfile

4 reate a ia 2 =nd >ill named /3 .

5 reate an empty Pattern , right"clic$ on it, and from the local menu, selectInsert ' File !

......\PowerMILL_Data\Models\3D-Curve-Wire.dxf

6 )ename the Pattern as ;Dwire .

7 ith the left mouse clic$ on the model to select it.

8 In the Power/ILL explorer , right"clic$ on or,*lanes and from the localmenu, select Create and Orientate or,*lane " or,*lane at +ottom of

Selection .9 )ename the or,*lane as /C'Datum .

10 +ight"clic$ on the or,*lane ) /C'Datum * and from the local menu, selector,*lane ditor to open the or,*lane diting toolbar.

11 lic$ (wist a-out % to open the following dialog.







The final tas$ prior to machining is to chec$ the directions of the Pattern segmentsand to reverse any that will cause the tool to machine on the wrong side of aprofile.

17 +ight"clic$ on the Pattern ) ,Dwire * and from the local menu, selectInstrument to display directional arrows on the individual segments.

Two of the segments )indicated above* must be reversed for the ireframeProfile /achining to Cli"b Mill to the left of the direction while remaining insidethe aperture forms on the S(L model .

18 #elect the segments )arrowed on the previous diagram* and from the localPattern menu apply dit ' )everse Selected .

19 Calculate the )a*id /ove 4eights using the default settings .

20 #elect the Strateg. Selector and select the Finishing tab in the dialog.





21 #elect the ireframe Profile /achining strategy and enter data exactly asshown on the following pages of the dialog.

Curve side controls which side of the Pattern segment direction the tooloperates.

Axial offset controls the depth of machining below the wireframe curves .

22 #elect Calculate to create the tool*ath and then Close the dialog.





The ireframe Profile /achining performs the profiling of the 4atternsegments in 3 .








PowerMILL 2015 16. Component Thickness


The Component Thickness dialog enables the user to apply varying Thickness and Machining Mode to different parts of the component. This can either be pre-defined in the Thickness Preference dialog or applied independently within anindividual toolpath.

The Component Thickness tab allows individual surfaces or solid faces to beassigned with different thickness values ( Axial and Radial ) within a toolpath .

Other important features in this dialog include the Machining Mode options,Ignore or Collision to control machining status on selected parts of thecomponent. This is available from the pull-down list consisting of three options:

Machine (default) is used to define specific areas of the component to be

machined with a different Thickness to that that in the main strategy dialog. Collision is used to define areas of the component to be completely avoided by

the machining process (such as a clamp).

Ignore is used to define areas of the component to be made invisible to themachining process so that the toolpath will pass through them (such as ablanking surface used to prevent toolpath moves into a hole or pocket duringearlier machining strategies).

The Component Thickness options are also available in Boundary creationoptions that include an active Tool as part of the calculation.

16. Component Thickness



16. Component Thickness PowerMILL 2015


Component Thickness Example1 elect File ! Delete all and Tools ! Reset Forms .

2 "rom File ! Open Project select the read-only Project :

.....\PowerMILL-Data\Projects\CompThic_Start

The Project contains an unprocessed #nterleaved Constant machining strategyalong with a $ia % &all 'osed tool and all essential parameter settings.

3 elect File ! !a"e Project #s :

.....\COURSEWORK\PowerMILL-Projects\CompThickness-1

To make selection easier the Clamps will be transferred to a new Level( Clamps ) while the split surfaces will be copied to a new Set ( !plits ).

4 #n the Po$erMI%% explorer , create a new %e"el and rename it as Clamps andthen create a new !et and rename it as !plit .

5 ith the clamp surfaces selected, right-click on the %e"el named Clamps inthe Po$erMI%% explorer and from the local menu select, #c&uire !electedModel 'eometry .

It will be easier to select and Blank ( Ctrl J ) all the other surfaces firstbefore simply dragging a box over all of the remaining clamp surfaces .





6 ith the split surfaces selected, right-click on the !et named !plits in thePo$erMI%% explorer and from the local menu select, #c&uire !electedModel 'eometry .

7 #n the Po$erMI%% explorer switch off the light bulb ne t to the !et named

!plits (This is to prevent them still being displayed if the light bulb for the %e"el General is still switched on).

8 #n the Po$erMI%% explorer , right-click on the unprocessed, Toolpath BN8 a! and in the local menu, select !ettings to open the !teep and !hallo$Finishing dialog.

9 elect Component Thickness to open the following form.





ith the Machining Mode set to Collision , a Thickness value of ( will be applied.*t this safe distance the active tool will either retract or profile around the clamps.

10 elect the +st row of the Component Thickness table and a s uare, colourcoded symbol (in this case blue) will appear at the start of the row.

11 ith the +st row still selected, change the Machining Mode to Collision with aThickness value of ( .

12 elect !mart !election to open the following dialog:

13 witch !elect )y from Colour to %e"el or !et .

14 ith Clamps selected in the %e"els or !ets bo click to ac uire the clampsurfaces to the +st row of the main dialog, and then Close the Selection dialog.





The Clamp Surfaces are ac uired to the +st row.

15 #pply the Component Thickness dialog to update the settings.

In the above Component "hickness dialog, it is not necessary to use the8 available rows in se uential order!





16 elect the nd row and a s uare, colour coded symbol (in this case purple) willappear at the start of the row.

The Thickness value of *+, will control how much stock is left on the ac uired split surfaces for this strategy.

This is in addition to a "hickness value specified in the main machiningstrategy dialog. In the above Component "hickness dialog the sum ofthese is displayed in the "otal "hickness column.

17 ith the nd row still selected, keep the Machining Mode as Machine but witha Thickness of * .

18 #n !mart !election select !plits in the %e"els or !ets bo and click the

arrow icon to assign them in the second row of the main dialog.





19 elect the th row and a s uare, colour coded symbol (in this case orange) willappear at the start of the row.

The cap surface must be ignored during the creation of this toolpath.

20 ith the th row still selected, change the Machining Mode to Ignore with aThickness value of , .

21 /se the left mouse ke# to manually select the cap surface and click on

#c&uire Components to include it in the th row.

22 #pply the Component Thickness dialog.

hile the Component Thickness form is open, Toolpath Thickness !hade modewill be active. *c uired surfaces are shaded in the same colour as the row.





23 #n the -ie$ing toolbar select the Toolpath Machining Mode !hade .

This time, relevant parts of the model are colour coded in Red ( Ignore ) or $ello% (Collision ). here applicable, these colour codes also appear at the end of a row.

24 #ccept the Component Thickness dialog.

25 elect Calculate to create the toolpath and then Close the dialog.

26 elect File ! !a"e to update the stored Project .

27 $o not close the Project as it will be continued in the ne t section.





Cloning the Component Thickness settings from anexisting Toolpath

* Corner Finishing strategy BN& a! will now be created using 0cloned1Component Thickness settings as used in BN8 a! .

1 "rom the Toolpath !trategies select the Finishing option, Corner

Finishing , and input settings e actly as shown below:

2 elect Calculate and have a look at the resultant toolpath in the graphics area.







The Component Thickness settings originally used in B./0a* are now cloned into the strategy dialog for BN& a! .

The process is not complete until the Appl# button has been clicked.

6 elect #pply followed by #ccept to fully update the Component Thickness settings in the strategy BN& a! .

7 Calculate the Corner Finishing strategy and then 2lose the dialog.

8 elect File ! !a"e Project

This will update:-






Modification of existing strategies to allow forinterchangeable clamping bolts.

The following Project already includes some !trategies to create the 3$component form on a pre-machined material Block . *ll e cept the initial 'ace(illing strategy need to be modified to accommodate interchangeable pairs ofclamping bolts aligned along 4 and 5 respectively.

1 elect File ! Delete all and Tools ! Reset Forms .

2 "rom File ! Open Project select the read-only Project :

.....\PowerMILL-Data\Projects\CompThic-2_Start

The individual parts (2omponent 6odel, 2apping urfaces, "i ture 7late, and2lamping &olts) are already ac uired to suitable %e"els .

3 elect File ! !a"e Project #s :


4 elect an I!O * view (as shown in the above image).

5 #n the Po$erMI%% e1plorer , right mouse click on the Toolpath)(*& 'ace(ill "op and from the local menu select #cti"ate .

6 #n the Po$erMI%% e1plorer , right mouse click on the Toolpath)(*& 'ace(ill "op and from the local menu select !imulate from !tart .

"efore performing a +ie%(,LL simulation the Block will be modified touse a model of the pre#machined material.





7 "rom the main toolbar select the Block dialog.

8 elect Defined )y ! Triangles and Coordinate !ystem ! 'lo)al before

selecting the option %oad )lock from file .

9 #n the -pen Block from "riangles dialog browse to:-C:\Training_Data\PowerMILL_Data\Triangles\CompThic-2_Block.stl andselect Open .

This Block definition is an accurate model of the pre-machined component.

10 Toggle into -ie$MI%% and select the Rain)o$ !haded Image .

11 #n the !imulation toolbar select the .la# button.

12 elect the .o Image option to return to the Po$erMI%% %indo% and for

the time being disconnect -ie$MI%% from the !imulation .





13 "rom the main menu select the Block option and in the dialog move theOpacity slider all the way to the left (wireframe).

14 #n the -ie$ing toolbar select the option Multicolour !hade .

15 #cti"ate the Toolpath /!0"R1 Rgh! .

This toolpath will be modified to Ignore the purple , clamping bolts along the 4-* is (These are to be physically removed when this toolpath is run).

This toolpath will also be modified to apply Collision status to the green , clampingbolts from a mm distance.

16 8ight mouse click on the Toolpath /!0"R1 Rgh! and select !ettings to openthe Model #rea Clearance dialog.

17 elect the Re c#cle option to enable editing to occur.

18 #n the main page of the Model #rea Clearance dialog, select the Component

Thickness dialog .

19 #n the dialog use !mart !election to ac uire the data stored on the %e"el ClampingBolts 2 to one of the colour coded rows.

20 et the row with (achining (ode ! Ignore .





21 elect one of the other colour coded rows and use !mart !election to ac uirethe data stored on the %e"el ClampingBolts $ .

22 et the row with (achining (ode ! Collision with a Thickness ! (+, andthen select #pply .

The parts of the model ac uired to a row will be shaded in the samecolour.

23 #ccept the Component Thickness dialog and then Calculate the toolpath .

The updated toolpath ( /!0"R1 Rgh! ) now runs straight through the 2 Axis clamping bolt area and clears the 20#1is clamping bolts by a full mm.





e now re uire a copy of the Toolpath ( /!0"R1 Rgh! ) that locally machines theremainder of the component in the clamping bolt area along the 5-* is.

24 8ight mouse click on the Toolpath /!0"R1 Rgh! and select !ettings to openthe Model #rea Clearance dialog.

25 elect the (ake a Cop# option and in the Model #rea Clearance dialogrename it as /!0"R1 Rgh* .

$s the new toolpath is a direct copy, the Component "hickness settings will be exactly the same as in /!0"R! Rgh! .

26 #n the main page tick the Rest machining bo and then open the Rest page ofthe dialog.

27 #n the above dialog, insert the reference Toolpath ! D*3TR40Rgh* and fill inthe other values e actly as shown.

28 #n the main page of the Model #rea Clearance dialog, select the Component

Thickness dialog .

29 wap over the settings between the e isting rows (as shown below).

30 #ccept the Component Thickness dialog and then Calculate the toolpath .





The updated Rest Roughing , toolpath ( /!0"R1 Rgh* ) now runs straight throughthe $ Axis clamping bolts.

31 #cti"ate the Toolpath BN!3 'in! and then select !ettings from the localmenu to open the !teep and !hallo$ Finishing dialog.

32 elect the Re c#cle option to enable editing to occur.

33 #n the main page of the !teep and !hallo$ Finishing dialog, select the

Component Thickness dialog .

34 #n the Clone pull down select the Toolpath /!0"R1 Rgh! and the click on the

Copy Thickness Data icon.

35 #ccept the Component Thickness dialog and then Calculate the toolpath.





36 The updated toolpath ( BN!3 'in! ) now runs straight through the 2 Axis clamping bolt area and clears the 20#1is clamping bolts by a full mm.

The ne t stage is to create a copy of the above toolpath ( BN!3 'in! ) that locallymachines the remaining areas within the two 5-* is clamping bolts.

37 8ight mouse click on the Toolpath BN!3 'in! and select !ettings to open the !teep and !hallo$ Finishing dialog.

38 elect the (ake a Cop# option and in the Model #rea Clearance dialogrename it as BN!3 'in* .

$s the new toolpath is a direct copy, the Component "hickness all of thecurrent settings will be exactly the same as in BN!3 'in! . In this case there uired Component "hickness settings can be cloned from the "oolpath/!0"R1 Rgh* .

39 #n the main page of the !teep and !hallo$ Finishing dialog, select the

Component Thickness dialog .

40 #n the Clone pull down select the Toolpath /!0"R1 Rgh* and the click on the

Copy Thickness Data icon.

41 #ccept the Component Thickness dialog.

42 #n the !teep and !hallo$ Finishing dialog select the Block page and lockboth the Min value (-39) and Ma1 value ( ). ;eep the Block page open.

43 #n the Po$erMI%% explorer , right mouse click on the %e"el namedClampingBolts $ and from the local menu click on !elect #ll .





44 &ack in the Block dialog enter an 51pansion of *, and Calculate .

45 4nlock the Ma1 value and manually input the value 0(3 .

46 "inally select Calculate at the bottom of the main !teep and !hallo$Finishing dialog to create the new toolpath BN!3 'in* .

47 Cancel the !teep and !hallo$ Finishing dialog.

48 !a"e the Project (but do not close it).





Exercise

1 #cti"ate the e isting Constant Finishing toolpath /8"R! 'in! .

2 elect !ettings and Recycle on the above toolpath.

3 /se the Component Thickness options to Ignore the surfaces on %e"el ClampingBolts 2 (purple), and Machine with a 6mm thickness around thesurfaces on %e"el ClampingBolts $ (green).

4 Calculate the changes to toolpath /8"R! 'in! .

5 elect !ettings and Make a Copy for the toolpath /8"R! 'in! .

6 8ename the copy as D/TR*0Fin( .





7 /se the Component Thickness options to Ignore the surfaces on %e"el ClampingBolts $ (green), and Machine with a 6mm thickness around thesurfaces on %e"el ClampingBolts 2 (purple).

8 6odify the 7 dimensions of the Block to keep the Constant Finishing /8"R! 'in* inside the area already machined with /8"R! 'in! .

9 Calculate the toolpath /8"R! 'in* .

10 #n the Po$erMI%% e1plorer re-order the Toolpaths to keep them grouped forthe same pair of clamping 5olts .

11 !a"e the Project to update 80








PowerMILL 2015 17. Stock Models


IntroductionA Stock Model provides both a visual and physical record of the remaining materialafter such entities as the material block and selected toolpaths have beenconsidered.

Stock Model Rest Roughing1 Select File > Delete All and Tools > Reset Forms .

2 Select File > Open Project :

......\PowerMILL_Data\Projects\StockModel_1

3 Select OK in the PowerMILL Warning dialog.

4 Select File - Sa e Project As :

......\ COURSEWORK\PowerMILL-Projects\StockModelExample

5 In the PowerMILL explorer select Stock Models > !reate Stock Model .

An empty Stock Model entity appears in the PowerMILL explorer and anassociated Stock Model settings dialog appears in the graphics area.

17. Stock Models



17. Stock Models PowerMILL 2015


The default settings for triangulation of the Stock Model are displayed. In this casewe will modify the settings to create a more accurate Triangle Mesh for the StockModel . nce the Stock Model is physically created then these inherent settingscannot be retrospectively altered.

6 !odify the values in the Stock Model settings to be e"actly as shown above andthen Accept the dialog.

The displayed settings in the Stock Model will change accordingly.

7 #ight mouse click on the toolpath D"#t$%R&'%a( and from the local menuselect Add to > Stock Model .

The toolpat) and associated *lock are included in the Stock Model tree but atthis stage are not calculated.

8 In the PowerMILL explorer $ Stock Models area$ right mouse click on

and from the local menu select !alc+late .





The Stock Model will display the visual effect of toolpath D("t$%R&'%a( as apurple wireframe mesh.

9 #ight-click on Stock Model - ( and from the local menu$ select DrawingOptions $ and then tick both$ S)aded and S)ow Rest Material .

10 %rom the ,iewing toolbar$ undraw the model &both S)aded and Wire-rame '.

The Stock Model is now displayed as shown with the component model andapplied toolpath both taken into account.

This represents the remaining material outside the component form after thetaking into account the toolpath D"#t$%R&'%a( .

If Block is made active in the Stock Model tree then this is the stage of themachining process that will be displayed.





11 %rom the Strateg. Selector $ Finis)ing options select the O--set FlatFinis)ing strategy and enter data in the ( pages e"actly as shown below.

a )ote: Add approac)es -rom o+tside is un-ticked to enable fullyindependent Leads to be applied.

b Allow tool o+tside -lats is un-ticked to limit the toolpath e"actly to the /0 dimensions of the *lock .

c The Rest Mac)ining bo" & Rest machining to Stock Model ' is ticked toprevent the already finished$ upper flat areas from being included in thetoolpath.

d *y ticking this option the Rest page will become available for selection in thelocal browser.

12 In the above dialogue select the Stock Model as ( .





13 In the main toolbar$ Leads and Links options set the Lead in options e"actlyas shown below.

14 Then set the Lead o+t options e"actly as shown below.

15 Accept the Leads and Links dialog.

16 !alc+late the O--set Flat finishing strategy and then !lose the dialog.





The latest Toolpath - D20t2-Flats-a1 is automatically added as areference item in the Stock Model list but not as a physical entity.

17 In the PowerMILL explorer $ right-click over the Toolpat) - D20t3-F !TS-a1 and in the local menu select Add to > Stock Model .

18 In the PowerMILL explorer $ right-click on the Stock Model named ( and inthe local menu select !alc+late .

After the calculation$ the Stock Model will be displayed again only this time withthe O--set Flats Finis)ing included.

19 Acti ate the toolpat) D20t3-R"#-a1 and in the local menu select Settings1 to open the Model Area !learance dialog.





20 Select !reate a new toolpat) 2ased on t)is one and input new datainto the dialog e"actly as shown on the following page.

a Input the Toolpat) name as D10t1-R"#-a1

21 Activate the D(#t( tool.

22 Set the St$le as O--set model .

23 Tick the Rest mac)ining bo".

24 Select the Rest page and in Rest Machining use Stock Model + ( .





25 Select !alc+late on the Model Area !learance dialog to machine within thelimits of the specified Stock Model .

26 ,lose the Model Area !learance dialog.

27 The latest Toolpat) 3 D(#t(%R&'%a( is automatically added as a referenceitem in the Stock Model list but not as a physical entity.

28 In the PowerMILL explorer use the left mouse button to drag the Toolpat) D10t1-R"#-a1 to the bottom of the list.

29 In the PowerMILL explorer $ right-click over the Toolpat) + D10t1-R"#-a1

and in the local menu select Add to > Stock Model .30 In the PowerMILL explorer $ right-click on the Stock Model named ( and in

the local menu select !alc+late .

The Stock Model is now displayed as shown with the latest toolpath removed.





)ow that the bulk of the material is removed$ the main component form is nowready to be Finish machined.

31 n-draw the Stock Model .

32 Select and *lank all e"cept the following surfaces:

33 sing the left mouse button$ drag a bo" across the model above to select alldisplayed s+r-aces .

34 Acti ate the tool *45 .

35 In the PowerMILL explorer $ right-click on *o+ndaries and in the local menu$select the Selected S+r-ace option.

36 nter data e"actly as shown above and then Appl. to create the *o+ndar. .

37 ,heck that both *o+ndar. ( and the *45 tool are both Acti e .





38 Select the Toolpat) Strategies and open the Finis)ing page.

39 Select the Steep and S)allow Finis)ing option and enter data into the dialoge"actly as shown below:

40 Select the Limit page and enter data e"actly as shown in the following image:

41 Select !alc+late to create the Toolpat) and then !lose the dialog.





The Toolpath B%&-F'%-a1 has been limited to be inside the Boundar$ .

42 In the PowerMILL explorer $ right-click the toolpat) B%&-F'%-a1 and in thelocal menu select Add to > Stock Model .

43 In the PowerMILL explorer right-click on Stock Model + ( and select!alc+late to update.

The remaining Stock Model is displayed as shown above.





Stock Model Rest BoundaryThe Finis)ing strategies do not have a direct Rest Machining option that relatesto the Stock Model .

It is however possible to create a Stock Model Rest *o+ndar. to define the areaswith material left on. This can then be used to limit a finishing strategy such thatonly the remaining stock is removed.

1 In the PowerMILL explorer $ right-click on *o+ndaries and in the local menuselect Stock Model Rest .

2 nter data e"actly as shown in the above image and Appl. and then !ancel .

Boundar$ segments will only be created where the B%( tool is able toaccess the model form.

The Stock Model Rest *o+ndar. identifies the area of the remaining StockModel .





3 Select the Toolpat) Strategies and select the Finis)ing tab in the dialog.

4 ,heck that the new *o+ndar. B%(-StockModelRest and the *46 tool areboth Acti e .

5 Select the $D O--set Finis)ing strategy and enter data e"actly as shownbelow:

6 Select the Limit page and enter data e"actly as shown in the following image:

7 Select !alc+late to create the toolpath and then !lose the dialog.

8 In the Leads and Links options Appl. &/ st ,hoice' ead in)out as S+r-ace4ormal Arc with !ngle 7# and Radius $ .





9 In the PowerMILL explorer $ right-click the toolpat) B%(-F'%-a1 and in thelocal menu select Add to > Stock Model .

10 In the PowerMILL explorer $ right-click on the Stock Model and select!alc+late to update.

The Stock Model displayed with Sho* Rest Material set will havevisually disappeared apart from perhaps, a few tiny, insignificant patches.

If a previous toolpath in the Stock Model tree is selected then the statusof the material at that point will be displayed.

11 In the PowerMILL explorer , Stock Model % ( tree$ Acti ate the toolpathnamed D"#t$%R&'%a( .







Stock Model starting from a complex block.

If a casting is to be machined then it is not possible to directly add the comple"shape to a Stock Model . It is however possible to import a Triangle model of theoriginal casting as the initial *lock and then use it as the first entity in a StockModel . The Stock Model can then be used as the referenced entity in an intialRest Ro+g)ing strategy.

n import the *lock must use the option$ +oordinate S$stem as &lo2alTrans-orm & "ported Triangle models do not support Workplanes '.

1 Select File > Delete All and Tools > Reset Forms .

2 Select File > Open Project :

......\PowerMILL_Data\Projects\StockModelCasting_Start

3 Select OK in the PowerMILL Warning dialog.

4 Select File - Sa e Project As :

......\ COURSEWORK\PowerMILL-Projects\StockModelCasting

5 pen the *lock form and set +oordinate S$stem to &lo2al Trans-orm .

6 Select De-ined 2. + Triangles $ select and browse to the triangle model:-

C:\Training_Data\PowerMILL_Data\Triangles\StockModel-Casting.dmt





7 pen the Rapid Mo e 'eig)ts form and select !alc+late .

8 Acti ate the tool D"8TR$ .

9 ,reate a new Stock Model .

10 #ight mouse click on the new Stock Model and from the local menu selectSettings .

11 dit the dialogue with above values and Accept .12 #ight mouse click on the new Stock Model and from the local menu select

Appl. *lock .

The comple" *lock is added as the first entity in the Stock Model .

13 #ight mouse click on the new Stock Model and from the local menu select!alc+late .

14 #ight mouse click on the new Stock Model and from the local menu selectDrawing Options and tick both S)aded and S)ow Rest Material .





The model form is visually removed from the Stock Model .

Exercise:15 !alc+late a *lock of T$pe % !.linder and De,ined $ % Model .

16 ,reate a Model Rest Area !learance + O--set Model strategy with theD"8TR$ tool$ using the Stock Model as the reference item.

The Area !learance - Rest strategy is created within the defined volume of theStock Model .



PowerMILL 2015 18. Macros & User Menu


IntroductionThere are various ways in which the user can customise PowerMILL . This chapterlooks at the creation of:

Macros

User Menus

Home AreaThe usual method to enable the User Menu to be recognised by PowerMILL is toset up and use a home area in Windows . This can be located to any convenientarea on the hard disk. In the following example the home area is:-

C:

To check if a Home area already exists on a computer;

1 Open File Explorer .

In the local explorer right-click on This PC and select Properties to open theSystem dialog.

18. Macros & User Menu



18. Macros & User Menu PowerMILL 2015


Alternatively, at the lower left corner of the screen, right mouse click on

Start and from the local menu select System .

2 In the System dialog select the A !ance system settin"s option and then inthe System Properties dialog select En!ironment #aria$les .

3 If the home area is not already defined as shown below select New…

4 In the User Variables dialog enter home in the Variable name field and C:% inthe Value field.

5 !lick &' .

You must have Admin rights to create a New User Variable .

6 If it does not already exist create a folder named pmill( in the re"uired home area # C:%pmill( $.

If the pmuser.mac , user_menu and any other macro s are being storedin this folder, then PowerMILL will have immediate access through thedefault Macro search paths.





Macros% Macro is a text file which contains a se"uence of commands to drivePowerMILL operations. These can be created by recording each command or bytyping in the commands directly. Macros #which have a )mac extension$ can thenbe run from the PowerMILL explorer or from a user defined menu .

&hen PowerMILL starts up it will attempt to identify and run the initialisationmacro #if it exists'$ called pmuser)mac . (y adding customised PowerMILL commands to the initialisation macro the user can set up their own default settingsand parameters.

)or immediate use a pmuser)mac can be placed in the pmill( folder directlybelow the users Home area. The pmill( directory is also a convenient location forstoring other user-defined macros ideally arranged in suitable sub-folders. This willbe covered later.

Creating a pmuser macroMacros are created in PowerMILL by recording the operations as they occur. Onlyflags or parameters that are physically changed will be recorded into the macro;therefore to record a value that is already set it must be re-entered or a flag re-switched. )or example if the finishing tolerance is currently set to *.+mm and it isre"uired that the macro stores the same value then it must be re-entered over theexisting copy in the form during recording.

1 ,elect File *elete All .

2 To start recording right-click on Macros in the PowerMILL explorer and select+ecor .

3 ,ave pmuser)mac by first clicking on the existing folder displayed in ,ave in.

4 Then in the resultant dialog browse to C:\pmill2 and at the bottom of the dialogenter the file name pmuser before clicking Sa!e .





The Macro icon changes to red while recording is in progress

.

The pmuser)mac automatically runs whenever PowerMILL starts up therebyproviding the user with custom default settings. It can also be run at any timeduring a session to reinstate the initialisation settings without having to restartPowerMILL .

All required data or options must be set or selected if they are to beincluded in a macro !ven if it is necessary to overwrite or switch them offfirst".

5 )rom the Main pull-down menus select Tools &ptions .

6 ,elect Tools Fee s an Spee s change the Fee +ate Plun"e Factor to,)( tick the Auto Loa Fee +ate box and Accept the dialog.

7 Open the Lea s an Lin-s dialog and input Short.Lon" Threshol as / bothS ort and Lon! as S-im and "efault as Incremental .

8 Accept the Lea s an Lin-s dialog.





9 In the PowerMILL explorer right-click on 0C Pro"rams and selectPre1erences .

10 On the 0C Pre1erences dialog &utput page select the Machine &ption File ashei 2,,)opt .

11 ven if already set select:

Use Project - On Tool Value - Tip

Automatic Tool Alignment - On

Connection Moves - Move, Rotate

12 ,elect the Toolpath page and even if already set select:-

Tool Change - On New Tool

Tool Numbering - As Specified

Tool Change Position - After Connection

Cutter Compensation : Length - Off

Radius - None

13 ,elect Apply followed by Accept .

It is important to remember to Accept and not to Apply forms that areopened while creating an Initialisation Macro , the only e#ception being thecreation of NC Program Preferences An initialisation file is for pre$settingforms but at this stage without e#ecuting the commands".

14 ,elect Stop from the local Macros menu to stop the recording process.

15 ,elect the plus #/$ sign next to Macros in the PowerMILL explorer to open thetree.

16 0ight-click pmuser then select E it .





This is a standard 3or pa document that can be edited with new values andthen saved.

To try this out you will need to exit and re-open PowerMILL .

17 ,elect File Exit and restart PowerMILL to check that the settings from

pmuser)mac have been activated.

Other Typical Macro Applications%part from tailoring PowerMILL by the creation of an initialisation macro otheruseful applications include macros for un-draw draw and resetting Lea s anLin-s locating and inserting tooling Templates setting 0C Pre1erences regularlyused machining se"uences or settings and input of preview commands not yetavailable on the 12I. 3ote the pmuser macro can be run through the browser at anytime during a PowerMILL session to restore your settings.

Creating NC Preference macros1 )rom the PowerMILL explorer record a macro called Fanuc4m5pre1s and

save it in:-

C:\pmill2\NCpreferences\...

2 In the 0C Pro"rams Pre1erences &utput tab select the Machine &ptionFile as 1anuc4m)opt .

3 Input the remaining settings exactly as set earlier for the Hei 2,, in the pmusermacro.

4 ,top the Macro recording process.





!ven if already set it is essential to re$specify settings if they are to berecorded into the macro.

% macro file # Fanuc4m5pre1s)mac $ is now created that sets up 0C Pre1erences for a post-processor option file and the command lines are shown below.

Exercise5 !reate two more independent 0C Pre1erence macros for the 4ied5** and 6a7ak

option #2se the filenames h2,,5pre1s)mac and ma6a-5pre1s)mac respectivelyfor the macros$ and save them to:

C:\pmill2\NCpreferences\...





User MenuIn PowerMILL it is possible to create a user menu enabling the user to furtherstreamline and customi7e the command structure. To access the user menu rightmouse click within an empty area of the PowerMILL explorer .

1 0ight-click in an empty area of the PowerMILL explorer to access the currentuser5menu #if it exists$.

This menu is created from a text file called user8menu. It must be in thedirectory pmill( in the Home area of the computer for the individual user andsaved as a text file #not a word 9ocument$ and with no extension. If available itis easier to obtain a copy of an existing user8menu and modify it as re"uired.

% user menu can be setup to provide easy access to existing PowerMILLcomman s 6acros and Templates.

2 oad the in-active user5menu file #which is in the pmill( folder$ into 3or pa .

(elow are instructions for the user5menu command line input #these exist inthe sample file$.

% command line will be added to the above user8menu to run the h2,,5pre1s macro.

I "heid400" 1 "macro C:\pmill2\ncpreferences\h400_prefs"

3 %dd the above command line to run the h2,,5pre1s macro directly from theuser5menu .

This line locates and runs the file h2,,5pre1s)mac created earlier in thischapter. It needs to include the correct drive and path where the macro islocated. %ll lettering must be in the correct upper or lower case and include theinverted commas and hyphens.

% more complete version of a typical user5menu is as shown below:









PowerMILL 2015 19. Tutorials

Copyright © Declaim Ltd 19 - 1

Y-Branch1 Select File > Delete All and Tools > Reset Forms

2 Import the Model :-

….\PowerMILL_Data\Models\Y-BranchDuct.dgk

3 Save Project As :

….\COURSEWORK\PowerMILL_Projects\Y-Branch-MC

4 Create the following Tools :-

Dia 16 with a 3 Tip Radius named D16TR3

Dia 12 End Mill named EM12

Dia 12 Ball Nose named BN12

Dia 5 Ball Nose named BN

5 Create an Active N! Pro"ram .

Newly processed Toolpaths are automatically added to an Active NC Program .

19. Tutorials



19. Tutorials PowerMILL 2015


6 Activate the existing #or$pla%e 1 , then sing the defa lt settings !alc&late as ita!le Bloc$ , and Rapid Move 'ei"(ts .

7 Create s ita!le Bo&%daries " Selected Surface # to limit the Finishing Toolpaths "$ote:- %or the BN tool select all of the end recess s rfaces, incl ding the &erticalfaces, and Tic$ the !ox mar'ed Top in the Bo&%dar) dialog e#.

8 Create a 3 Model Area !leara%ce Toolpath sing the Tool D16TR3 .

9 Create an *++set Flat Fi%is(i%" Toolpath on the !ase of the (-form sing theTool EM12 .

10 Activate the Tool BN12 .

11 Create a !o%sta%t , Fi%is(i%" Toolpath "limited to the 3D (-form# sing !oth a)in "*.*1# and )ax "*.5# stepdo-% com!ined with a s ita!le !&sp (ei"(t "*.*3#with the Mac(i%e do-% to +lats !ox tic!ed .

12 Activate the Tool BN .

13 Create a s ita!le Steep a%d S(allo- Fi%is(i%" Toolpath "limited to the 3 endrecesses# sing the same Constant Z !&sp (ei"(t +Stepdo-% settings as ininstr ction 11 a!o&e, and a 3D Offset Stepover of *.2.

14 erform a f ll .ie-MI// sim&latio% on the Active N! Pro"ram .

Save the Project .





Corner Bowl

1 Select File > Delete All and Tools > Reset Forms

2 *pe% the "read onl # Project :-

….\PowerMILL_Data\Projects\CnrBwl-Start

3 Save Project As :….\COURSEWORK\PowerMILL_Projects\CornerBowl-Example

he Project contains/ a Model , 2 #or$pla%es , 0 Tools "incl ding a Form Tool along with the Patter% sed to create it#, Toolpat(s that f ll machine the

nderside " 1#, and an N!0Pro"ram named "P#$CnrB%l$All .

Setup4 Activate the #or$pla%e named M!0Dat&m0*P2 .

5 Create a new N! Pro"ram named *P20!%rB-l0All .

The New NC Program will be Active on creation. Newly processed Toolpaths are automatically added to an Active NC Program .

6 sing the defa lt settings, De+i%ed ) Bo& and T)pe Model , !alc&late a Bloc$ ,change the Ma , &al e to and loc! it !efore selecting Accept .

7 4n the Rapid Move 'ei"(ts dialog enter the #or$pla%e MC$ atum$"P' and!alc&late !efore selecting Accept .





Area Clearance – Tool D25TR31 Activate the Tool D2 TR3 .

2 %rom the Strate") Selector , o en the 3 Area !leara%ce strateg dialog andselect a Model Area !leara%ce strateg .

3 nter the Toolpath name *P20D2 TR30R4'1 .

4 4n the /imit age ens re that no Bo&%dar) is Active and then select (imit tool

centre to )loc! edge .

5 4n the Model area cleara%ce age, se St*le *++set model , with T(ic$%ess5 , Stepover , Stepdo-% 2 .

6 4n the *++set age, tic' Spiral .

7 4n the Step c&tti%" age, tic' Step !&tti%" and in t Step$up 2 , etectmaterial thic!er than , and E&pand area )* .

8 4n the %sa+e se"me%t removal age, tic' Remove segments smaller thanthreshold , with Threshold 57 , and n-tic' "nl* remove segments fromenclosed areas .

9 4n the Flat mac(i%i%" age, set Machine flats to /evel .

10 4n the Approac( age, tic' Add approaches from outside .

11 4n the main /eads a%d /i%$s dialog set:-

/ead i%8o&t # st choice set .ertical arc with istance 1 , Angle 7 , Radius 9 .

/ead i% ' nd choice select Ramp , and in the Ramp optio%s dialog set Follo% !ircle , Ma& +ig angle : , Circle iameter ,T -. 56 .

12 Accept the /eads a%d /i%$s dialog.13 Select !alc&late in the main Area !leara%ce dialog to create the Toolpat( .

14 !lose the Area !leara%ce dialog.

The toolpath is automatically added to the Active NC Program list.





Finish Machining – Tool BN16

1 Activate the Tool BN16 .

2 4n the Po-erMI// e&plorer select Bo&%daries 7 !reate Bo&%dar) 7 S(allo- .

3 nter data exactl as shown a!o&e, and n-tic' the !ox Allo% )oundaries to )e private in the S(allo- Bo&%dar) dialog !efore selecting Appl) .

4 Select and Delete all exce t the 2 innermost Bo&%dar) segments.





5 8ight mo se clic' on the new Boundar* Flat0BN16 and from the local menselect !&rve Editor .

6 4n the !&rve editor select the o ter Boundar* se"me%t and a l an *++set of2 .

7 hen select the inner Boundar* se"me%t and a l an *++set of 06 .

8 Select the 4ree% tic' at the far right of the !&rve Editor , tool!ar to acce t andret rn the changes !ac' to Po-erMI// .

9 %rom the Strate") Selector , o en the Fi%is(i%" dialog and select a Steep a%dS(allo- Fi%is(i%" strateg .

10 4n the S(allo- Fi%is(i%" dialog enter the Toolpath name *P20BN160FIN1 .

11 4n the /imit age, select the Boundar* Flat0BN16 with Trimming set to ;eepi%side .

12 4n the Steep a%d S(allo- +i%is(i%" age enter data exactl as shown !elow.





13 4n the main /eads a%d /i%$s dialog select /ead i%8o&t #st choice set .erticalarc with Dista%ce , A%"le 7 , Radi&s 9 .

14 Accept the /eads a%d /i%$s dialog.15 Select !alc&late in the main Steep a%d S(allo- +i%is(i%" dialog to create the

Toolpat( .

16 !lose the Steep a%d s(allo- +i%is(i%" dialog.





Finish Machining – Tool EM301 ns re that no Bo&%dar) is Active .

2 Activate the Tool EM3 .

3 %rom the Strate") Selector , o en the Fi%is(i%" strateg dialog and select an*++set Flat Fi%is(i%" strateg .

4 4n the *++set Flat Fi%is(i%" dialog enter Toolpath name *P20EM3 0FlatFIN1 .

5 4n the /imit age, select (imit tool centre to )loc! edge .

6 4n the "ffset flat finishing age, enter data exactl as shown !elow "$ote thetic! )o& settings9#.

7 4n the main /eads a%d /i%$s dialog select /ead i%8o&t #st choice set .erticalarc with Dista%ce 1 , A%"le 7 , Radi&s 12 .

8 Accept the /eads a%d /i%$s dialog.

9 Select !alc&late in the main *++set +lat +i%is(i%" dialog to create the Toolpat( .

10 !lose the *++set Flat Fi%is(i%" dialog.





Finish Machining – Tool D16TR3

1 Activate the Tool D16TR3 .

2 Select the upper edge of the S&r+ace Model 3D form 5

3 4n the Po-erMI// e&plorer select, Bo&%daries < !reate Bo&%dar) < serDe+i%ed .





4 4n the a!o&e ser de+i%ed Bo&%dar) dialog un$tic! the !ox Allo- o&%daries

to e private !efore selecting the I%sert Model o tion .

5 8ename the Bo&%dar) as *P20Form0TopEd"e !efore selecting Accept to closethe dialog.

6 Select and Delete the inner Bo&%dar) segment "as shown a!o&e#.

7 %rom the Strate") Selector , o en the Fi%is(i%" dialog and select a !o%sta%t ,Fi%is(i%" strateg .

8 4n the !o%sta%t , %inishing dialog enter the Toolpat( name *P20D16TR30FIN1 .





9 4n the (imit age select the Boundar* Form0TopEd"e with Trimming set to;eep *&tside .

10 4n the (imit age , /imits :-

ic' the Mi%im&m !ox and se the pic!ing o tion totra and insert the &al e 09 "left mo se clic' within the to of the !ase

s rface#. ic' the Ma im&m !ox and insert the &al e 0=7 "this is 6mm a!o&e the to of

the !ase s rface#.

11 4n the Constant / finishing age, enter data exactl as shown !elow "$ote thetic' !ox settings9#.

12 4n the main /eads a%d /i%$s dialog:-

4n /ead i% #st choice set S&r+ace %ormal arc with Dista%ce , A%"le 7 ,Radi&s 9 .

4n /ead o&t #st choice set .ertical arc with Dista%ce , A%"le 7 , Radi&s 9 .


14 Select !alc&late in the main !o%sta%t , +i%is(i%" dialog to create the Toolpat( .

15 !lose the !o%sta%t , +i%is(i%" dialog.





Finish Machining – Tool EM16

1 8e-o en the *P20D16TR30FIN1 toolpat( dialog and select Create a ne%

toolpath )ased on this one .

2 8ename the new toolpat( as *P20EM160FIN1 .3 Activate the Tool EM16 .

4 4n the /imit age, , /imits section, date the Ma im&m &al e to 092 "this isa rox. 3mm a!o&e the to of the !ase s rface#.

5 4n the Constant / finishing age, Stepdo-% section, enter the data exactl asshown !elow.

6 Select !alc&late in the main !o%sta%t , +i%is(i%" dialog to create the Toolpat( .





Finish Machining – Tool FormTool-1

he * Degree angle on to of the ste near the !ottom of the 3D form will !emachined with a Form Tool . he rofile for the tool tip was created from aPatter% which in t rn was constr cted sing the !&rve Editor o tions.

he Patter% m st !e created in the >ve ? and @ ; adrant, relati&e to theTra%s+orm "<lo!al Dat m# for it to !e &alid when sed in Form Tool creationo tions. nce the Form Tool has !een created it will no longer !e de endent on thePatter% .

The above Tool and original Pattern already exists in the start upPro0ect .





1 Select a 1ie% do%n / and n-draw all items exce t the existing Patter% FormTool$# .

2 ,oom into the lower area of the Patter% and from the mai% tool!ar select the

Meas&rer .

3 =ith the Meas&re ta! selected, clic' on the *pe% t(e positio% i%p&t o tion .

4 4n the Positio% dialog select the Bet-ee% ta!

5 n the Patter% in the gra hics area, left clic' on !e* point 1 followed ! !e* point 2 "shown a!o&e left#.

6 )a'e a note of the dis la ed E%d poi%t &al es =5 and 25 1=277 .

$ext a new Patter% segment will !e created along the to , inner edge of the *Degree chamfer "corres onding to !e* point 2 a!o&e#. he a!o&e &al es will !e

sed to offset " =5 # and mo&e " ,025 1=277 # the new Patter% se"me%t to ro&idea ath for the form tool centre " !e* point 1 #.





7 Select all of the s&r+aces that form the to face of the ste near the !ottom of the3D form.

8 4n the Po-erMI// e&plorer right mo se clic' on Patter%s and from the localmen select !reate Patter% .

9 Rename the new Patter% as *P20!(am+er: De" .

10 8ight mo se clic' on the new Patter% and from the local men select 2nsert 0Model " Pattern segments will !e created along the o en edges of the selectedmodel #.

11 Select and Delete the o ter Pattern segment "as shown a!o&e#.

12 8ight mo se clic' on the Patter% and from the local men select !&rve Editor .

13 Select the Patter% segment.

14 4n the Curve Editor tool!ar select *++set item "2D 8o nd#

15 4n t a Dista%ce &al e of =5 and ress ret rn to acce t the action.

16 Select the Patter% segment.

17 4n the Curve Editor tool!ar select Move item .

18 4n the Data 4n t !ox !elow the main gra hics area enter and ret rn the relative (? mo&e &al es 025 1=277 .

19 Select the green tic! to acce t the changes and ret rn the Patter% toPo-erMI// .

20 8ight clic' on the attern, segment and from the local men select 4nstr ment todis la the direction arrow.

21 4f the arrow is ointing along the c t direction "anticloc'wise if &iewed froma!o&e# select Edit - Reverse Selected .

he Patter% is now s ita!l ositioned for se as a tool centre , drive c&rve to !esed in either a 2D !&rve Pro+ile or Patter% Fi%is(i% g strateg .





22 ns re that no Bo&%dar) is Active .

23 Activate the ool FormTool01 .

24 %rom the Strate") Selector , o en the 25 D Area !leara%ce strateg dialog andselect the 2D !&rve Pro+ile strateg .

25 4n the 2D !&rve Pro+ile dialog enter the Toolpat( name as:-*P20FormTool10!(am+er .

26 Set the Positio% o tion to The centre of the tool follo%s the pattern .

27 Select the Pic$ t(e lo-est , 'ei"(t o tion and sna at an oint along thedri&e c r&e, attern segment.

The snapped / height value is inserted into the (o%er limit box.





28 4n the main /eads a%d /i%$s dialog select /ead i%8o&t st choice set'ori o%tal arc with istance , Angle 7 , Radius 12 .


30 Select !alc&late in the main *++set +lat +i%is(i%" dialog to create the Toolpat( .

he %orm tool is acc ratel aligned to the angle across the to of the ste .

31 !lose the 2D !&rve Pro+ile dialog.

Hole Feature – DrillingDrilli%" strategies can onl !e erformed on 'ole Feat&res and not directl on thecom onent Model .

To ensure that the ole Features are created vertical relative to theactive / a&is the Bloc! must first be deleted.

1 %rom the mai% tool!ar select the Bloc$ dialog and clic' on the )lue cross todelete the c rrent Bloc$ definition.

2 Select the whole of the com onent model .

3 4n the Po-erMI// e&plorer , right mo se clic' on Feat&re Sets and from thelocal men select !reate 'oles .





4 nter the data into the Feat&re dialog exactl as shown a!o&e !efore selectingAppl) .

he Feat&re Set contains a total of 12 defined 'ole Feat&res .

!ost of the ole detail has been dealt with in "P# so the only remainingFeatures that re"uire machining from this side are the # Counterbores.

5 Re%ame the new Feat&re Set as *P20'oles .

6 Activate the tool ath *P20D16TR30FIN1 to reinstate the Bloc$ and acti&at e theTool D16TR3 .





7 %rom the Strate") Selector , o en the Drilli%" strateg dialog and select theDrilli%" strateg .

8 Select C*cle t*pe 'elical and in t remaining data into the Drilli%" dialogexactl as shown a!o&e and then clic' on the Select ta!.

9 4n the Diameter !ox select 225 and clic' on to add these holes to theSelectio% Filter !ox.

10 !lose the Feat&re Selectio% dialog and select !alc&late in the main Drilli%" strateg dialog.





11 )a'e a !op) of the last Drilli%" Toolpat( named *P20EM160!Bores and thistime se the Tool EM16 and C*cle T*pe - Pro+ile on !oth of the co nter!oreFeat&res .

12 4n t data into the Drilli%" dialog exactl as shown a!o&e and !alc&late .




13 erform .ie-MI// sim lations for !oth *P1 and *P2 .

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Powermill Full 2015-0