Lesson 1 Page 1 / 7

1
Introduction
PowerMILL CNC Machining () *+,- . / Toolpath
4*,+5 6* 76 *+ Import *9 :, ; () *9 95 <, = = 4>9? 9 +
. @ 5 IGES, STL, Triangle, OLE F, *9 Surface F, Solid = PowerSHAPE

1.1 PowerMILL Environment

1. 9* PowerMILL * -9N9- 4,N, PowerMILL

Pull Down #$ % &' ( PowerMILL .$ /0% &' 1 2$ . /0 34

5. .6 . $7 # .6 .8 ' 1 ./ '. 96 & . / 6 ' .6 .96 % '$
 Lesson 1 Page 2 / 7

%1 $&'8:8 PowerMILL / 6 96 % 1 1 Function ? cursor % %

&'% 1 &' $ $71? A2( . $'. $( % 1

&' B C1 & ( 0&' $'. $($ B C 8:/? ( '. 3 .$

$% 1 8 % 1 3 $ '. %
View along the X-axis
View along the -Y axis
View along the Z-axis
View along the -X axis
View along the Y-axis
View along the-Z axis

Isometric View 1
Isometric View 2
Isometric View 3
Isometric View 4

View Resize to fit

Zoom In
Zoom Out
Zoom window

Last View
Refresh

Draft angle
Minimum Radius
Multi coloured Shade
Shade
Wire
 Lesson 1 Page 3 / 7

1.2 Mouse Buttons

:59. OP ;, ? < : :5 ,, 4 , = < + OP ALT, CTRL
F, Shift () =.4*,R- + * :5,4 <
1. Mouse Button 1 : Picking and Selecting

34 5 . /0 ' 8:8 $ $/6 96 D :2 5

& Wireframe, Surface Solid $ . 8:8 $ $
96 D

2. Mouse button 2: Dynamics

43 $ /0 '8: C Zooming, Panning Rotating

Zooming in out: $ 34 CTRL 1 % 1 2$&' 43 $ /0
$ C &? $ Zoom in out :2
Pan around the model: $ 43 Shift 1 % 1 2$ /0 34 $
/0 6 :2 9 &2S& &' %
Rotate mode: Drag /0&' 34 $ % (D 6 :2 3 ( tracker ball (
6 . /0 tracker ball $ .%
Zoom window: $ 34 CTRL Shift 1 % Drag /0 $$ (/' '. 1 (1 3 /6 &'
9 $ zoom 6. &'&? $ zoom WC &'$ $7
View Spinning: $ 3 BC .6 96 .$ $ /0 43 $ $%
3 % .6 96 1 8 $ 3 .6$(1 8 $ $ /0 969 $? 16
Spin View On
Pull Down [ 9F, Tools Options
View 6;, View N9- Option Spin View
On

3. Mouse button 3: Special Menus

43 '% #$1 2$ &? 8 1? / 96 D $7 / 92 6 #

1 2$&' Screen 1? / &' $'. $( screen $ $7 96# 1 2$&' /
1? / &' $'. $( / $ $7
 Lesson 1 Page 4 / 7

1.3
:6,+5 N< O^=.4* *9 ,+[5 96
1. 9F, File Examples

The open examples form

appears with pre-set
options to enable you to
quickly find the example
models. The folder icon
with eg on is the main
area where the examples
are stored.

2. 9F, 4,N, eg

3. 9F, phone.dgk 96 9F, Open

The phone model is shown in wireframe looking down the Z-axis,

but you can only see part of the model, as it is too big for the
current view. To show the whole model the resize model to fit the
screen can be used.

4. 9F, 4,N, resize to fit

The model is shown on the screen in full.

 Lesson 1 Page 5 / 7

5. 9F, 4,N, ISO 1

You can now see the entire model quite

clearly in an isometric wireframe view.
To see it shaded you need to select the
shaded wire option.

6. 9F, 4,N, Shade Model

This displays the shading on top of the

wire. To remove the wire view and show
the model as shaded only, then click on
the pressed in wire button.

7. 9F, 4,N, Wire Model

By pressing the wire icon again, the

wireframe is hidden showing the model
only in shaded.

8. 9F, 4,N, Shade 9. 9F, 4,N, Wire View

9. *9, 9F, 4,N, View ,F i
 Lesson 1 Page 6 / 7

1.3 PowerMILL Panes

* ( + F,;, =,@ jNF, PowerMILL Panes

/2 6 ' ' .: 80 $ $ $ &? 13\ .

PowerMILL Panes $( 96 D % 8 $]\ &'
/^ $]\0 9 _ :6 Toolpaths, Patterns, Feature
Sets, Work plane, Groups Macros.

Pane &'/ Pane &' / .$ 96 D &' $ :6 # 13\ $ Workplane $ Pane

&' 2
$7 .$ Workplane & &' ' / 8

/2 &' .68 .$ #$ $% :6 '. $(8 Normal explorer .1 6 13\/ # $

Workplane & .8: 34 Shift /0 43 5 . 8: 43 Ctrl 8 $ $ % 6 $ .$ 8
.$ 1 . . .$ 96 D ( .$ &2 .8: 34 Delete

/6 Pane &'/ 8:/? ( OLE (Object Linking Embedding) Pane &'/'8:/? (%h 0 HTML
/6 Pane &' 8:/? ( Help

1. 9F, File Delete All

 Lesson 1 Page 7 / 7

1.4 PowerMill Help

PowerMILL On-Line Help [ ^?l5 [ Help
1. 9F, Help Release notes

Release notes =./[ Load ; HTML Pane 9.;,N6 * /[ ;* : //[ N9- jF, ; [5
;,N6 ,F +6;, 4*
, = < + Dynamic Help () =. *+ N9- 4,N, N F, +? O ;6 F, Pane
N F, +? =. Cursor 9+ N F, +? 9.4 565 NO^=.6 46 * Form =.
n help Form ;)< @ + Pane N F, +? * ( + F,;, =,@ j

2. 9F, Help Whatos New

$7 Whatjs New guide A2( . 6 '/2 8 6&' C2 92 8 Version ' .6 %
3. N9- 4,N, PowerMill Pane
 Lesson 2 Page 1 / 7

2
Machining Set Up
Tool Path
1. Load & '( PowerMILL ( Loading a model into PowerMILL )
2. 5 6 & '( 7 7 8 ( Viewing the model )
3. 7 ' Block ( Material block definition )
4. 7 ' Cutting Tool ( Cutting tool definition )
5. 7 ' D E(8FG HG 5 ( Feed rate and Spindle Speed Settings )
6. 7 ' 8 8 F(N Cutting Tool ( Rapid Move Heights )
7. 7 ' E7 S Cutting Tool ( Tool Start Point )
2.1 Loading a model into PowerMILL
1. (N File Examples

A variety of different types of Model can

be loaded into PowerMILL and can
easily be discriminated on the form
using the filter Files of type to widen or
narrow the choice.

2. V' W(XYN Chamber.tri

The model will be displayed in the PowerMILL

graphics area.

2.2 Viewing the Model

E G 8 7H & '(E H ' 8 7H 6 7 8
1. (N isometric View

This model has sloping sides that join the flat base.
 Lesson 2 Page 2 / 7

2.3 Define the Block

Block FH N 7 ' ' PowerMILL Y 7 5 7 ' 5 F(N Cutting Tool
5 N ' G Z6'S5 E H GS[ N 7 ' 5 F(N Cutting
Tool
1. F(S F Block
Block Form !"
# $ ! %! X , Y !" Z *+,- * . / /-
Block 0 1 ,- $21 3 Calculate
*+,-%4 / /- 5 * "5 6-4 5 4 7 -, $21 Expansion
$ 6- ,-/6 65 * "!" "-? ! @A0 1- 6-
,-/6 6 0? 1

2. F(S 6\ Calculate
3. F(S 6\ Accept

Block * . Wireframe A E * 7 1- @A
$ *1 ? * . %4 @F ,-5 ! $ 1 4F@A Opacity

2.4 Define Cutting Tools

7 ' Tool 8 8 ^ F _ (_ 5 X Tool _ ' ( ` ab
1. F(S (_ c bN 8 7 F Y Tool de

Create a Ball Nosed

Tool

N G Cursor G5 F 8 d 5 (H f E ' F [S5 Ze Y S' Tool f

 Lesson 2 Page 3 / 7

2. (N F End Mill
End Mill Tool Form
M /- Tool 0 1@A A* ,- Diameter #
% 6 %/- Tool # 5 6-4 5 4 7 A * . 5
*@ /- Diameter * " AE
* "A6 ! " 0 1 1-
4 * . A 1 A E4 2,-/- Tool $ 1 - "1-
4F"4 P !" / /- Tool 4E *2 14 bn 6
Tool !FF Ball Nosed @A A Diameter 14

3. D F Diameter 10 FG G Tool 8 d e &' & S 5 50

4. Y Name YN em10
5. (N Accept

Tool -6#F -U +!" * . %4

-4 @A Explorer
444

$ - 1- * "A6 ! " @A0 1 0 !"1%

? @V Exploer *2 E 0 1- ! # Tool
"7 @A "- 0W A* ",- * ,- "7 * X 3 /% @A2,-/- Tool
* # *",- Active * . $21 ,-0 $21 Tool AE
* ",- Edit */1 0 # Tool Definition Form *+,-! 10/ @A
 Lesson 2 Page 4 / 7

6. 7 ' Tool e 7 e E55 Ballnosed ' Diameter 12 . YN bn12

Tool $ bn12 @A Exploer !" * . Tool @A Active -6#

4 * * ,- 6 >
@A Tool Definition Form @A %4 /1- Cutting Data A Parameter
6@A* A6%/1- 4F Tool % @4E -4 -a !" % * ?% -F@A
* ?F0%1 4F Tool 4E 1%6

2.5 Speed and feed rate settings

FG HG 5E(8 D 7 '
1. F(S F Feed Rates

Freed Rate Form /E a- % * ?% -F

!" -4 a- @A 1- AE $21@ Tool Path @A # 1
/E ,-$21 3 Load From Active Tool $ % * %? -F
!" -4 -a Tool Difinition Form

2. (N Accept
2.6 Rapid move heights
FG _ ( 'a E GE Z Z_ 7 ' &' Tool F(N 'G FG HG _ N S
'&' Y 5 S '
Safe Z
Start Z

Rapid

Plunge

Cutting
 Lesson 2 Page 5 / 7

Safe Z ,- % # @A Tool 0 * ,-* ",- @A-- 27E %1 6 % * ?% # Start Z ,- % # @A Tool 0 * ,-

* ",- @A*/1 27E %1 6 % * ?% # - * ",- @A" 0 7 27E %1 6 % * ?% Plung Feed Rate
1. F(S F Rapid Move Heights
2. (N 6\ reset to Safe Height
3. (N Accept
* ,- Rapid Move Type * . Absolute @ 4E @A Tool
* ",- @A*/1 ,--- * ",- @A 1%6 % * ?% # 0 @A Safe
Z * ,- 1- * ",- @A*/1 *+,- 7 $ 24E -0 * ",- @A
1%6 % * ?% # 0 @A Start Z 4E * ",- @A 1%6 % * ?%
Plunge Feed *+,- 7
* ,- Rapid Move Type * . Plunge * ,- Tool * ,- 1-
* ",- @A*/1 *+,- 7 $ 24E -0 * ",- @A 1%6 % * ?% #
0 @A 6 Start Z $ 2- Incremental * . 6
Bottom 4E * ",- @A 1%6 % * ?% Plunge Feed *+,- 7
* -, Rapid Move Type * . Skim @ 4E @A Tool * ",- @A
*/1 ,--- * ",- @A 1%6 % * ?% # 0 @A Safe Z $ 2- Incremental * . 6 @A
Bottom * ,- 1- * ",- @A*/1 *+,- 7 $ 24E -0 * ",- @A 1%6 % * ?% # 0 @A Start Z $ 2-
Incremental * . 6 @A Bottom 4E * ",- @A 1%6 % * ?% Plunge Feed *+,- 7
2.7 Tool Start Point
FN E7 ( 'a 7 5 Tool 8 F(N Ze 7 N 7( 8 ( Tool e _ 5Y 'S
FN
1. (N F Tool Start Point

The tool Start point form appears, displaying the

values of the tool home position.

2. 7 'F Co-ordinate X 50 Y 50 Z 50
3. (N Accept 7 'F Start Point 7 7 5 Tool

n8 7 'F S f H S ( E(G PowerMILL

b 8 Tool Path
 Lesson 2 Page 6 / 7

2.8 Tool Path

F 7 8 7 ' bN FG5F6 FG (8 'E(8 N G S 8 S7 e Tool
Path F b S X G Tolerance E(8 Thickness F6n Z 7 'F '
Area Clearance E(8 Finishing `e 8 ( GZe (8 ' a 7(

Tolerance %F %
" *-A6
/- * 1 @ * 7 /- Tool
!"1%
@A0 1 A # $ "1* A6 4F
5 * " 1-6*+A6 $

Thickness ,- % * ,E-
% * 7 @A* 7 0 5 * "
1-6*+A6 $

Tool Path Z_ e 85 6 G'G _( E ' G Tool Path Z_ e ' Y

GS[ 'S F Tolerance E(8 Thickness ' Block `e _( 7( Z Ze '
(N Toolpath Explorer
2.9 Projects
Project FN ' F Y 7 55 e F _( (Machining Data) Z_ G
PowerMILL Explorer `e _( G Tool Path, Tool, Workplanes E(8 S N f G 5
GS[ 'S Tool E(8 Project Z H5 r Z 8 Active S f n8 Save
'G bN 7 FG N'7 6 ' 6' FG Save & '( G Project F Y 75
Project Z Y '&' Pull Down _ (N File Save Project
 Lesson 2 Page 7 / 7

7 N File Save Project Ass 7 5 Project YN 7 6' 8 FX7( Y Project FN

F f 7 'G Y7 ' 8 Re-Machining ( ` ) 5YS
'S 5 G 7 N 7 '
 3
Measuring Models
!" # $ %
% !" &% ' ( $ % ) Tool ( - $ !"
3.1 Linear Measurements
. / !" % - XYZ ( # $ # - ( - ( )
- ( ( Tool -3 $# 4
1. !7 48 9 powerdrill.tri
2. - # !" ISO View Zoom G ) - -H &!

Snap ( !) # $ % &' $ ( $)* + ,- Snap Filter

Pull Down -* 9 Tools Snap Filter ) #<- + ,- ( =9 )# $ % ! $)* ( , = =
! -
1. Pull Down & Tools Snap Filter Anywhere ( - !" Off )

Off Anywhere C $ ( DE $ ) * -# $ % ,9 *
-F-( & ) &' ! C( - + ,- , Anywhere
#<- On Sketching Boundaries
2. % 4% Measure Model

$# L Model measurement Form

OP Form -F 2 RS - &- =9$& -

2. - ( Line / X&
3. # # (

9 & ,9 E 9

$ ,C- & - P -T From #9 -=#9

9 - F = -F Anchor Point =9$

Co-ordinate $# LTPF- - XYZ Z &+ , -F 10
) - + ,- Area Clearance T Tool Path $ \ (
1 . & &* -=- = - Z ( Z Height ) 11 .
4. Zoom - -H G ) &!

$ ,C- $ $ $T
E , T- T Tool
 5. 4% Measure )
6. $ ( % &!

# /

7. $ ( - ^

# /

&- $# LTPF- $, F & =9$ 9$ ! &- -F $)* =& ( - Form

= ,C- - *# = ,C- - % E $ $, ( # $ 21 OP -F $)* -+ (# - 9
T- ,_ & T Tool $ - + - - ' -F
&+ , &- $ + 3 \ -& - , 9

8. Zoom - -H G ) &!
 a T \' $)* E , a ,_ & T Ball Nose $
9. - ( Circle Measurement Form
10. # Start Point , End Point Middle Point 4! % &!

*# 9 $# L\ - F 3 *#

Measurement Form $# L 9$ T 9 *#
a T 9 # $ 5 . -F- Tool Ball Nose
$ Diameter 10 . P $ , & + - - ' -F
 Lesson 4 Page 1 / 4

4
Workplanes and Models
PowerMILL !" " #$ " "# World Co-ordinate System
23"4 "56 ##$7 ! $8 8 94 5 " #3" :6 ; # < " 94 !" " ! $8
6 2 ;>656#$ ?:
1. B B 7 B! !"56 $8
2. 8 " Workplane ! B! !"56 $8 56B4 94 Workplane !
4.1 Bringing Models in to PowerMILL
6;>6 B PowerMILL
1. 8!" E! B "# PowerSHAPE B 7 : PowerMILL
PowerSHAPE
2. 56 Pull Down File Import Model
3. 8M NO ; 56: ;! Models PowerMILL Explorer ; Import
Model

4.2 Moving, Rotating, Scaling and Mirroring Models

8 56#$ : B B N 5 6 9 QR$ " 9 B! / B B 7 B 8M NO
; 56? " PowerMILL Explorer $ Edit
1. Import ? cowling.dgk $ ISO View

World Co-ordinates
! "# $ % $ & '( )! * +
)(+& " ,'& -)(+& " . ()/ !& 0 +%1!
2 +& ,)#2'34 (Material Block)

2. ;#8 4 " B 8M O ; 56 Models PowerMILL Explorer ;

Properties

PowerMILL '& +4 ) +&? ' /

+& ! $" +4. ? ' -, #( " %( %? ' $
) X +60 Y+50 Z +25 2 '( ! &G( % +&
& +%1! 0 0 0 (World Co-ordinate Origin)
 Lesson 4 Page 2 / 4

3. 8M NO ; 56 ? cowling 56 Explorer Edit Move X

4. [ :! 60 Move X Form

5. B 49 :! 56 [ B : 5656 : " B 86 6B; 9"# 9_ #$ : 567

6. 5 B B 7 ; Y 50 . $ ; Z 25 .
7. c Block Form $ NO Calculate

?'% "%( %? ' $ " "# $ %

)/ !& +&World Origin %4 ,4? ' '(
. "" - " '( %( % , $%,& 2 ' ! &G( % +&
Block

8. 8 N 4 3" B 7 : 56 8M NO ; 56
Explorer $ Edit Rotate > X
9. [ :! 180 Degrees Form 9"
10. : 5656 : " B 86 B6 ;

? ' 2 "+4 X $ 180 +&L

! Block %,&M& *+ '3 #( )(+& " (
Block . !
)(+& / " "( & N- . !

11. 8 B! / B B7 : 56 8M ON ; 56 Explorer $ Edit Scale > X

12. [ :! 2 "9

? ' % %++ $ 2 ! ) X
 Lesson 4 Page 3 / 4

13. : 56 8M NO ; 56 Explorer $ Edit Scale > All Axis $ 8!:! 9

B B 0.5

? ' & 0.5 ! . 2

14. 8 5 6 9 QR$ " 9 ( Mirror ) 7 23";>6 k $5 ?! 6B; 49 ;>6 56E!

15. :NR 8 k#8_ : BB $ N ; 5k Save B: 8M NO ; 56 Models
Explorer ; Export model l$ 9_ :NR 3_ !:NR "5
: BB $ N 2_ 6
4.3 Workplanes
Workplane : $ 4 !"23":NR8 56#$ : B B $ N 7 B 56B4 94 World
Co-ordinate System " ?" "5 Active !
8 " Workplane 5 7 B: 8M56: ;! Workplane #$ m B! B 9"

1. Create Workplane
*+ Workplane #1 "( & N- M"*+& % + $" Q N- ( M/ ! Workplane . Explorer
*+M 3 M"*+& % + ! Workplane 1 '(#1 "( & N-
Workplane . ! #1 "( & N- '% ,4 Workplane / ,& Active +%1! ! ' !
+!+ GN&M2V "#),-&W*+. ! '(. X % ,& " ( Workplane "# " /
'( PowerMILL Explorer
2. : 8M NO ; 56: ;! Workplane 1 ; Activate
Workplane ' . Y! N- '& '& ! $Z Workplane Active GN& %M !
)!+ - $ , )#2 2 W 3' )(+&+( &+3 &)/ ! & Workplane -Workplane "##1
M *+ %( % ! ?'% "M 3 [$2\ M/ ! Workplane 1 ( *+ Edit Move by >
 Lesson 4 Page 4 / 4

X ( $` + M! )( +& " & $ / W! '% , / ", 4 " M * + %( %. +* ?'% "

M *+ %( % 2 / . ( "# $ % )/ !& +& Workplane $. )/ !& )(+& " '(
" % )! & a . " M *+ %( % "# Copy Measuring Tool "*+ Block Definition "*+
$`+ ?'%)"& '( )! / '( f%& M *+ %( % '(M",& ! ,-
3. File Delete All
4. c 7n M? Handset.tri # Examples

5. : BB Z 5! 9_ B o BM " Workplane B!5#N6 8"8N "

6. 8 " Material Block # Calculate $8 " Tool 44 End Mill Diameter 12 .
7. Reset 56 Rapid Move Heights $ Tool Start Point B!56 Block Center
8. 8 " Workplane $5 Active
9. 6B ? < Datum $o BM 7;56#N 3" " " Block B ? $B$# Tool Start Point
Form

M2 V , & ) ! V Workplane
M * + Tool Material Block
M *+ ) $'( % GN& $Z "*+&$ )3',& ,-
)(+& / " Calculate Material Block . !
 Lesson 5 Page 1 / 15

5
Area Clearance
PowerMILL ! Area Clearance ()* +,-./0 1 22)
* )34 ! Block 3 )34 2 7/ * 8./0 ! * 8! . * ./0 8 9*!,- !
) ! * 8)*!:/ + Arae Clearance ,- 7/( . ;!8 Tool ( Offset Area Filter
. Rest Roughing +8 3 (
8 Tool Path ( Area Clearance 2;+ )! 8 +
1. 8 Z Heights 2. 7/( . 3. * )* 8 M
5.1
1. ./N :O9P powerdrill.dgk

12. 9 + / - ! :/ * ./0
Core (9-
Cavity ;!8 Power Drill Casing

2. 8 Block 1 Calculate
3. 8 Tool ( Tip Radius 2 Diameter 40 (9-2 Y2 /9 6 22.
4. )+8 ! Tool * tr40x6
5. .9! :! ! Area Clearance

Area Clearance Form Form

!" # $%&' ($& )* Tool ,- ! * Tool Path
 Lesson 5 Page 2 / 15

6. ;!8 Form .9! :! ! Rapid Move Heights

Rapid Move Height Form 9 Option Rapid Move Type # (-<) Skim
Tool -* 9 ? 9 $( )< ? @9 < )*,AB- CD 9,EB*() F% (Slice)
# F"B(-<) ( I Skim Tool ( -<9) 9F ?D* ? Absolute M Safe Z (!?(%-
*

7. .9! Reset to safe Heights

8. Rapid Move Type .9! Skim
9. .9! :! ! Start Point
10. Start Point Form .9! Reset to Block Centre

Z Heights
Z Heights <) ? )* B Z )*CD AB * P ,AB- CD )* Tool Path 9 ( &$ % B Z
Height D A)*" )"Q- )* Tool, Tolerance ,- Thickness $D* D A)* C B 9( I &* % B Z
Height ! " # $ -D % F$ - ?,EE ,AB! DEAD%)?B * C B Flat ,- Stepdown ( I
AD% $ B Z Height $ 9F"BA)* C! " #-E &*T$? (-<) B Z Height 9A)* -E Area
Clearance Form ,-%(-<) ( <9)* " ? E $!,$*
Option Flat " ?#*@< 9 E )*T"($-T$? ! * Z Height 9A , B* 9"@< 9 E D
Option Step Down ! * Z Height $ E !$ )* Block #*@< -B *!$ )* Block ( I CD P
,AB- CD " ? ( B DE ? Step Down ? (% CD !$ ?) " ? 9,A AB *)) F )?QB DE % "!Q* )*
Block ,AB# A)* ,AB- CD " ? ( B D (-<) Maintain Constant Stepdown

11. ;!8 Area Clearance Form .9! :! ! Z Heights

Z Heights Form
 Lesson 5 Page 3 / 15

12. *!8 Defined by .9! ./0 Flat (9 .9! Calaulate

13. *!8 Defined by .9! ./0 Stepdown (9 * * 10
14. .9! Calculate (9-.9! Close

Z Heights ( I !( ?%( I CD
P $ E )*Block -*" A "
, %, Z ? 10 "". ,-
$DE 9"@< E

Tool
" ($& )?QB 3 ,EE 9 C D$ ? E <)
1. Raster <) ($& ,EE Zig-Zag ,AB- CD )* Z Heights
2. Profile <) ($& )E* ,AB- CD )* Z Heights
3. Offset <) ($& )E* -D ] D )) " <)( F (A^"@< 9 ,AB- CD )* Z Heights
AD%)?B * (-<) ($& ,EE Offset T$?" B Stepover 25 "". $ B Tolerance ( B ED 0.1 ,- B
Thickness ( B ED 0.5 (`<9) ( ^E- ()?$
15. .)2 * )* 8 M Area Clearance Form 8 7/
 Lesson 5 Page 4 / 15

16. *!8 Final Profile Pass 9 :2* 2. !8 2 37

17. .9! Option Area Filter 2 2 * Tool ,-:2*.; :/ . b 2c+ ! * 1.1 . * ;!8
. d* Y7 P 9 8;!8 Tool
18. ;! Lead In Move *!8 Type .9! ( Ramp (9- Option Max Zig Angle
. * 5
19. * . 9! * . 2! 8 7/
20. .9! Apply (9-.9! Accept
Tool Path #Q ! *T$?)DAT "DA&( ^EF% Explorer ( I %DA# 9 C* )?QB (Activated Entity)

21. 9 . !8 2 + * Tool Path ,-( 8 . f ;!8 Tool Path 37 8;g+ 2 b

;!8 Area Clearance ,-( 8 9 hbP 8 7/ 9 . !8 2 + * Tools ,-( 83g8
Tool 8:

22. 9 .2 P/4i2; 9 hbP * Area Clearance jg8.2 7 *! ,-/ k;g+

23. .9! Animate (9-.9! Speed 3 )!8 ,- 4 ( 8d9 /4i2 Esc
24. . 9 9 :! ! Area Clearance .c! ,-:2* Active Tool Path
25. . 9 9 :! ! Area Clearance ! +8.c! ,- Active Tool Path
 Lesson 5 Page 5 / 15

Tool
ViewMILL ! " #,!$* ($& )* Tool ,EE 3 "&A&F$f9* ! " #A % !)E % "#Q A)*
B) * &* ViewMILL " -Q E g( I )*AD%()*,- )?QBE &(% $ E

26. .9! :! ! ViewMILL

Simulation Toolbar

26. .9! ISO View

27. .9! :! ! ViewMILL Toggle

( I h" 9!-DEF " Shade Block

28. .9! :! ! Shaded Tool

( ^ Tool )?QB 9A , B*AB * P F$CD$( ,AB ,!$*`-

C -*
# Tool Path "(! * % "

29. .9! :! ! Start/Restart

30.

( ^ ( -<9) 9 )* Tool ( -<9) 9F ?D*A , B*AB * P Tool

Path
%" D*( ^ ( <) )*%D!$#Q $D *F &
( ^ F$%B ("<9) C Area Filter -"$ E % F"B#Q D$
 Lesson 5 Page 6 / 15

Block 9#Q D$,-% A)*#Q Save (@<9) F C D A) )* Rest Roughing AB)F

31. .9! :! ! Save Block

32. Save ./0 :O9P ! C:\Temp\Rest_Block.dmt

33. .9! :! ! ViewMill Toggle .c! 9 :/ 7* Graphics ;!8 PowerMILL

Rest Roughing using Reference Toolpath and Complex Block

Option ! " #! * Rest Roughing Toolpath T$? C Reference Toolpath B%" DE
Complex
Block 9F$ Ssave () F%

34. ./N Area Clearance Form

35. Active Toolpath 1
36. Active Tool tr20x5
37. 8 Block , Triangles 1 :O9P C:\Temp\Rest_Block.dmt
38. ./9 * Stepover ./0 15 (9- Area Filter ./0 None
39. ;! Reference 9 :! ! Insert the name of the active toolpath
40. .9! Apply (9- Accept

Toolpath #Q ! * # ( ,!$* ( ^ (i@

Toolpath( ( ^ Toolpath -D ] (9 I
D$(i@ E *!B% (Rest Material) )* Tool
9" $A " 9( (-<)
 Lesson 5 Page 7 / 15

Generating drilled holes for Lead-in moves Example

! DEAD%)?B *AB)F " ( (@<9) Tool ! " #( -<9) -9 *F * F$)?B * -)$jD?
( CT"($- Powerdrill ) D* 9* PowerMILL C$) !%B 9" $( B D D* "$ ( Qf9* C
ED
Area Clearance Toolpath
1. , .2 7 File .9! Delete All Yes
2. , .2 7 Tools .9! Reset Form
3. ./N :O9P powerdrill.dgk .9! Draw Draw All
4. .9! Block Calculate
5. 8 Tool ( End Mill ; Diameter 12 22. 2 ! * em12
6. ./N Area Clearance Form
7. 8 5 Z Heights .9! ( Number
8. ;! Lead In Moves *!8 Type .9! Drill

9. 9 Approach Outside ./0 Off

10. .9! Apply (9- Accept
" 2 Toolpath #Q ! * <) Raster Toolpath "C<9)%B 1 ,- Drilling
Toolpath "C<9)%B 1_holes

11. Active Toolpath 2 ! * 1_holes

( ^ Tool ( -<9) 9F ( 9 Q D*! "

 Lesson 5 Page 8 / 15

Editing the Holes

# Q 9( F"B)?QB A , B* 9A)* ( ! " #? ? <)-E &*F$ ("<9) Q#Q ? ? A , B* "B )?QB
j ? CD 9- 9!$ )*!B% (9 I Cavity

1. .9! 2422!8./0 2!8982 ) 2( ( Z

2. Area Clearance Form .9! Edit Move Holes From Picked Input To Digitised Output

? ?A , B * )* Q -& 9 Q 9
A)* ? ?$%?(" !g h " f ? Q
( I !,$*,!$*#* Q D Active (
# F"BA)* Active -& f ) )
(-<9) F ?D*A , B* 9A)* ,-% -&
) D* 9* Q ( -9? A , B* (! ^
,-% $ Enter

3. 7:/ 8) ( *8 /9 97 Y + 7)!* 7 . f,(9 Enter

4. .9! Apply (9- Accept
5. Active Toolpath ! 2_holes

Toolpath ! D E ( Q "B C
A , B* "B
,- Area Clearance Toolpath ^ #Q
! * " "B ( " !" DE Q(
"B
 Lesson 5 Page 9 / 15

Ramping Between Levels

Option Ramp Level Moves Tool ! " #( -<9) 9-*!QBC& * $%?)*l 9- $()?* ( !" #C
Tool (j Non-Plunging Tools F$ * F%%B ("<9) Tool " ( -<9) 9-*!QBC& * $%?)*l -9 $()?* %B *CD
)* Z Heights (Ramping) $ Ramp Move Type ( I Skim ,- B Safe Z ,- Start Z ( I 1.0 (@<9) (%-
* B )? 9!$

6. ./N Area Clearance Form .9! :! ! Rapid Heights

7. *!8 Rapid Move Type .9! Skim

8. .9! Accept
9. Area Clearance Form ;! Lead in Moves *!8 Type .9! Ramp

10. 9 /4i2 Option

Ramp Option Form ( ^ f9* ! " # $

-D ] )*
Ramp 9 A)* F$

11. Max Angle 2 * . * 10 (9 .9! Accept

"" Zig <)""()?* 9 Tool C ( -<9) 9( !QBC& * "" Zag )< "" 9 C 9 % "? % )*
Ramp Length F"B@) 9 Tool ( -<9) 9#*C& * ( -<9) 9-* *D D
 Lesson 5 Page 10 / 15

Tool

Ramp Length

Zig angle

Zag angle

B Ramp Length $( I Tool Diameter Units (TDU) AD%)?B *(CB # Tool " B Diameter 10 "".
,- B Ramp Length " B 2 TDU f9* " B ( B DE 20 "". A " A& Ramp Length % " B " %B
Diameter )* Tool
(@<9) - (-9?* 9 Tool C$ ( -* C& *

Zag Angle
# B Ramp Length #Q $ PowerMILL !B B Zag Angle ( B 9 F$f9*A " A& " B ( B DE
Zig Angle
It is the maximum Zig and Zag angles that are specified rather than absolute angles.
This is because the angles may have to flex in order to maintain the ramp length, which
will remain constant. Angles are always reduced (and never increased) as necessary to fit a
whole number of Zig Zag moves into the length specified.

12. Area Clearance .9! Apply (9- Accept

Zoom F 9 " " ( ^

( -<9) 9,EE Ramping ,!$*
( ^ ( I ! (*&

Profiling Area Clearance

($& )* Tool ( I (! )E Q C& * ! " # 9 ! * ,AB- CD (@<9) $D ( <) 9( -<) 9( &$ $D
D* B) f9* Option AB * P )* Profile ! " # C* F$ DE Q ,EE ($& ,EE Raster ? (% Cut Direction
9A)* C DE Q ,EE ($& ,EE Profile ( B D
When
%B * * T$?($& D$,EE Raster " $ ($& ,EE Profile F$!9,EE <)
1. None F"B" ($& ,EE profile
 Lesson 5 Page 11 / 15

2. Before ($& ,EE Profile B) ,-%($& ,EE Raster

3. During ($& ,EE Raster `!" ED ,EE Profile
4. After ($& ,EE Raster B) ,-%($& ,EE Profile
Cutter Direction $ l& * ($& )* Tool "%&' $$D*
1. Any $ Tool ! " #($& F$ 2 l& *
2. Climb $ Tool ($& ,EE &l *($?% <) Down Cut
3. Conventional $ Tool ($& ,EE &l *($?% <) Up Cut
Profile Outside # $( I On ($& ,EE Profile ($& )E Q Block $%?
Final Profiling Pass Option C! DE ! * *($& ,EE Profile )E!$ ? )EC& * (@<9)-$ ! ) )*
Tool
Specified Stepover <=< < >? @>A BCD Tool ( D$* )E, ("<9)($& ,EE Raster <) B Specificed Stepover
, 9 ( I B Dl" )* Tool ( <9)* )?QB DE % "! " # )* Tool ( -<9) 9( D$C& *
Offset Area Clearance Strategy ! DE ($& Q ,,E B Stepover <) ? %B *,AB- ,#% 9( &$ Offset #
$ B Stepover " %B B Diameter )* Tool PowerMILL DE B Stepover T$?)DAT "DA&T$? F"B?)"
"( <)C& * 9)?QB %B *,#%( -<))?QB
Offset Direction &l * Offset $F$$D*
1. Auto $T$?)DAT "DA&f9*) ( I * ) ( * <) * )) * ) )?QB DE%B ( I D$
Core <) Cavity
2. Inside Out $ &l * * )) * )
3. Outside In $ &l * * )( *
Smoothing Enabled # $( I On (! *($& E &(% 9( I "" #Q DE ( I !B% T *( " DE* D$,EE High
Speed
Machine Smallest First # $( I On D$ D$ 9 ? Offset 9 )? 9!$ B) (@<9) p)* D F"B Tool (!? ?
Maximum Smoothing Allowance $( I % )* B Stepover (CB 40 % " ?#* DE(! * 9( I ""
( I !B% T * B Dl" )*!B% T * F"B( & 40 % )* B Stepover
5.2 Offsetting
1. ./N :O9P handle.tri (9 .9! Block (9 Calculate
2. Reset Rapid Heights (9- Tool Start Point
3. 8 Tool ( End Mill 2 Diameter 10 22. 2 ! * em10
 Lesson 5 Page 12 / 15

4. 8 Model Plane Z 0 1 9 .2 P/4i2; * Model Explorer .9! Plane From

Block

5. /u! * 0 98 Form (9-.9! . !8 2 37 .; .c! !2

T"($-"@< 9A , B* Z
0
" $( B Block

6. ./N Area Clearance Form (9-.9! Offset Strategy

7. Cut Direction ./0 Climb (9- * Stepover ./0 4 * Tolerance ./0 0.05 (9-
Thickness ./0 0
8. 8 Z Heights 1 Flat ( ,-2 + . )
9. .9! Apply (9- Accept

,- 8 Toolpath 1 Option All Offset .

, 8+ Block (9- Model ;!8 Tool 2,
+8 ! 4
 Lesson 5 Page 13 / 15

10. ./N Area Clearance Form (9- 9 /4i2 Options

11. *!8 Type .9! Model

12. .9! Accept

13. Area Clearance Form .9! Apply (9- Accept

%&' Offset ( I F A " Q B * )*T"($-

(@?*)?B *($?% f9* CB%? Tool D$* $%?
, * 9!"9 (!") (l]C& * ( &$ )?B *
!"9 (!")(CB ($?% D ,- D ] l& *($& D$
( I Down Cut ,- -$ % D$,EE(A^"
Tool )? 9!$ ,AB ^ ? )*
Tool " % D* 9" %&' ( " ! DE
D$ Core

Race Line Smoothing

Option ( " ! DE* D$,EE High Speed (@ CB%? DE(! *($& )* Tool 9( I ""
- ?( I !B% T * ,- DE B Stepover " B F"B * 9
1. ./N Area Clearance Form (9-.9! Option Offset
2. 9 Smoothing Enabled ./0 On (9-./9 * Smoothing Allowance ./0 25 %
 Lesson 5 Page 14 / 15

3. .9! Accept (9- 8 Toolpath

( &$Toolpath 9" % "( ?E" %B

4. Draw Toolpath 2 .c!./ . Toolpath 3

( ^ Toolpath D*!)* -D ] 9F"B,!$*

(! * ( )) )* Tool ,- ( ^ % ",A AB *
)* Toolpath *!)*
D
,AB Toolpath D*!)*?D*)?QjB ? Tolerance
! DE Toolpath ,EE Race Line Smoothing CB%?
Tool ($& $%? % "( ^%!"9 (!") * D$* F$
( ^% %B ,- ( <9)* Tool D$* $%?, * 9!"9 (!") *
-$ ! ) )* Tool ,- j @`&%$
HIBJD>K B Area Clearance
AB)F ( I )"Q-( 9?% ED Option AB * P 9")?QB Area Clearance Form f9*! " # F$T$? C !D9* Help

Cutter Directions LM BNB Tool ! " # $( I Climb (Down Cut), Conventional (Up Cut)
<) Any (2 &l *)
Pocket Machine LM J IPHA QRBCI< IPH
Auto Angle HMD A AS Auto Angle PowerMILL (-<) "" )*(! *($& 9$ 9!$ ,AB- Option 9( I
Area, Pocket, Model <) Level $D*
1. Area PowerMILL $Q@< 9T$? %" D* "$,- $ B "" (9 " !"
 Lesson 5 Page 15 / 15

2. Pocket $"" (9 " !" )*,AB- Pocket

3. Model $"" (9 " !" DE Q B * )*T"($-
4. Level $"" (9 " !" )*,AB- CD

Manual Angle $"" )*(! *($& $%?AD%()*T$?"" 0 )*l <)"" 9)?QB 9, X

Join Up Range U SMD H Raster CB%* 9 $ ?F
Infinite Range B BJW H R<@ SMD HX? >= J B A R > = Tool " % )? 9!$
Finite Range (! *($& #Q (C<9)"AB)( $%? D # ? B *F"B( & B Finite Range
Remove Unnecessary Raster Spans D$,EE Profile ,- Raster 9 C Tool 9" $ sB "E *!B% 9"
D$f (!?(%- Option CB%?, ts $D* -B %
Minimise Full Width Cuts -$ D$,EE(A^" "$-*( " DE* D$%D!$ 9" % ", ^*
Maintain Constant Stepover R<B A J $D $%? B Stepover 9!"9 (!")
Z Heights " 5 %&' ! * Z Heights
1. Number ,EB*( I ? 9( B D ( I % A" 9 $
2. Stepdown ,EB*( I ? 9( B D ( I ? *A " 9 $
3. Value ! * Z Height 9*CD 9 ? 9 $
4. Flat ! * Z Height 9 ? 9"@< 9 E
5. Intermediate (@&9" Z Height %B * Z Height 9")?Q,B -%
6. Appending Z Heights C B Z Height Area Clearance Toolpath 9 Save () F%,-%
Lead in Moves %&' 9 Tool ( -<9) 9( C& * (Block)
1. Plunge Tool ( -<9) 9-* , %$&9* $( &9"A -*F ?D*C& *
2. Ramp Tool ( -<9) 9-* , %()?* $( &9"A -*F ?D*C& *
3. Drill Tool ( -<9) 9-* , %$&9* $( &9"A -*F ?D*C& * 9A , B* 9" ( () F%
Approach outside Tool ( -<9) 9( C& * $ ) )* Block ,AB Option CF"BF$ DE Block 9
$ Q <)Fu-g (j Triangle
 Lesson 6 Page 1 / 2

6
Complex Blocks
Block Defined By "! Block Form &'" !()*! +, Block
- ./0 ,!1
1. Min / Max limits +, block 5 6, 7 "5! +8!" ! 1- 9/ Min , Max >0 1- 3 @ , X, Y , Z
2. Picture +, Block 0 E- F G 2 ).) 5 ,6 3 .) )
3. Triangle +, H Model !" !0 7/
4. Boundary +, H Boundary !" (
!"#$%& 6.1 Picture
1. Delete All @8M5 N Model Owheel_segment.tri U H OExamples2U
2. 5 N Block Form

3. + !" Defined By 5 6, Picture

4. 58Y0 090, Open
5. 58Y0 \8] wheel_segment.pic
6. 58Y0 Calculate
Block
7. Toolpath H Area Clearance
8. Simulate Toolpath !"

!"#$%& 6.2 Triangles

()*!,!1 + -d(-. )d !" ! 7 / &-d&0,5 /, ,+8/05 6,., &'" HM +, ( 5 8@dd 3D
Triangle
1. Delete All @8M5 N \8] Door_Pattern.dgk

!"

2. 5 N Block Form +, !" Defined By 5 6, Triangles

 Lesson 6 Page 2 / 2

3. 58Y0 090, Open

4. 58Y0 \8] Y"0 Door_Pattern.dmt

Block # $ % # &'
# $ ( " ) % *
# $ % +%!,-

5. Tool @dd Tipped Radius >, Diameter 40 . @8M ! -E ! "! 8 5 .

6. 58Y0 Reset the Rapid Move Heights
7. +, + Rapid Move Type 5 6, Skim !" ! Safe Z @8M Start Z 5 / d- 1.0
8. 58Y0 Tool Start Point @8M58Y0 Reset to Block Center
9. 5 N Area Clearance Form @8M 0j ,9/ ./ k - 7

$ !$ . / 0 " Toolpath * Offset $ Stepover 25 .

10. Z Heights +, @dd Flat @8M 9! / Stepdown 15 .

11. 58Y0 Apply
12. Viewmill @ 5 ),>0 Tool
13. Save the Project Y"0 Door_Pattern_Example , C:\ Temp
At this stage only the Roughing toolpath has been applied to the component. Finishing
strategies may be applied later in the course once they have been covered. Open the project then and
try out some of the different strategies whilst seeing the results in Viewmill.
Blocks can also be defined by a boundary in a similar way to pictures. The use of
boundaries is covered later.
 Lesson 7 Page 1 / 1

7
Finish Machining Form
Toolpath Finishing Form & ' ( ) '* +

, & Finishing Option ,. & Option ) / , 0 Strategy 456 7 Option ) / 7 7

) Option 86 & 9 ) / Form : 7 ,. ; . ( ) / 86 ) ) '*) 7 Option + /
Apply Tolerance Thickness %& '()% * + , -. &/ )0
Finishing Form 4) 56 0 Thickness 67 8 * % - ) Toolpath 4 ) , -) 0 : )
;) 0 ) & 4 +- 0 - Thickness 67 8 , -) < =;> ) ;)'() * 48) 6 ?
) %4

Option , 0 Startegy 7 < *= >7 ' +

1. Downward projection of a pattern (Raster, Radial, Spiral, Pattern)
2. 3d Offset
3. Constant Z (Constant Z, Optimised Constant Z)
4. Corner (Pencil, MultiPencil, Stitch Corner, Along Corner, Automatic Corner)
5. Projection (Point Projection, Line Projection, Plane Projection)
6. Profile
7. Rotary
They will not necessarily appear in the same order as they are located on the form.
 Lesson 8 Page 1 / 13

8
Raster, Radial, Spiral and Pattern Strategies
Downward Projection of a Pattern ! " 4 $ %&'() Raster, Radial, Spiral 0 Pattern
1) 23&% 4 0 Finishing
PowerMILL ;2< Toolpath >&? 2 Project 0 23&% 1) Tool >"3& @ "0 0 Z
;B C24 2;2< 3&% 1) Tool 0 Raster, Radial 0 Spiral ;2< >&? 2DE) ' Finishing Form
0 ; " 2 &GH 4IJKL&< 23 () Preview ) ! ;2< Tool path 1 " &< ? 2 &DNO" Apply ; 2
;2< Toolpath 0 Pattern @<) B 2;2< 3;< 3@2?"L < ) 0 < >D20 2" B 2 Project 3;< 4
>"3& 3I(!);2< 3DR Toolpath @)LD
4 ST 1) Toolpath 4 4 0 3"(!) " @ "0 0 Z 3DR &4 2GD

Raster Radial

Spiral
Pattern
 Lesson 8 Page 2 / 13

8.1 Raster Machining

1. Finishing Form 3 () Raster Strategy

Toolpath
!
Option !%!&
'

Stepover

() * + ) ,) -& * () )( ./% Cusp Height 67 8 9 Stepover

8 * Cusp Height % ) .&= Tolerance 8 * & Cusp Height () % ? * ()) ?@)
(A) &. * + &B @) Tool
Start Corner 8 * & 8 * B% @) Toolpath %.% &%.%* 7 ? C @ %() 8
Preview ) Toolpath
Angle 8 * &%.% &B &@) Toolpath -& F F X

Raster Angle = 0

Raster Angle = 30
 Lesson 8 Page 3 / 13

Perpendicular Pass Toolpath @7A % ) .&* 7 % BC &B A H F Toolpath .& )

Style:
1. One Way Tool &B &! CB & A %()% &B + *% Tool @7A )
2. One Way Grouped Tool &B &! BC & % & *% &B &
@ % + * 7 ! ) + * 7 ) .&
3. Two Way &B &! 2 BC %()% BC Tool @7A )
4. Two Way Joined &B &! 2 BC %()% BC Tool &B ) () !
Arc Radius Option $<;B C24 Style Two Way Joined 3I(!) B C & C< 2%3 T !3DR "N"3&% 3DR ; >'<
"24Z"@ " ! B C &

8.2 Raster Example

1. ! Pull Down 3" 3G () File Delete All
2. ! Pull Down 3" G3 () Tools Reset Form
3. 3D^&L_ K chamber.igs Example
4. 3D^& Block Form 3 () Calculate 0 ;2< Tool Ball Nose !" Diameter 12 "$(!) bn12

-% & Tool N * *O
Toolpath FF Raster +? @7A %
Q() & BA A

5. 3 () Rapid Move Heights Form 0 3 () Reset to Safe heights

6. 3 () Tool Start Point Form 0 3 () Reset to Block Center
7. 3D^& Finishing Form 0 3 )( Raster Strategy
8. DE) ' Tolerence 3 4 0.1 0 Thickness 3 4 0 3 () Accept

Tolerance F 0.1 !&SB ) @

* F
8 * FSB )& A 8 * & ' 0.01
Thickness F 0 !& & %
@ & B= Tolerance
8* &
 Lesson 8 Page 4 / 13

9. B C &' Stepover 3 4 2 "".

10. 3 )( Style Two Way Joined 0 3 () Arc Radius 0.5

The two way joined style means

the tool moves along one edge,
and curves around to the next
stepover and moves down the
other way. This leaves the tool
in contact with the model, with
no tool lifts

11. 3 () Apply 0 3 () Accept

Toolpath +? @7A ? !% & -% &

Q() * *O Toolpath ) &

12. 0;& 23&% 1) Tool

' ()*+, 8.1 Raster Exercise

;2< Toolpath 0 Raster $< Tool bn12 B C &' Tolerance 3 4 0.01 0 ' Thickness 3 4
0.01
B C &' Raster Angle 3 4 90 $< Style 0 Two Way Jouned 0 B C &' Arc radius 3 4 0 0 3 )(
Perpendicular 0 0;& 23&% 1) Tool

Toolpath &B ' %.% 90 ) C )

Toolpath ) .&* 7 &B A H F Toolpath .&
&B @) Tool + '
 Lesson 8 Page 5 / 13

8.3 Radial Machining

1. Finishing Form 3 () Radial Strategy

Toolpath
!
Option !%!&
'

Center Point
8 * & &. C? V @) &B FF Radial % B &. C? V A ) ? 0 0 0 67 A % + 8 * &!&
-& S? ) ,) ) @ ! * () 8 * &-& )( Reset to Block Center 67 ' .& 7 @) Block
Start and End Radius 8 * &@ &@) Toolpath CB @) &B +

First pass
outwards First pass
inwards

Start End rad

rad
End rad Start
rad
 Lesson 8 Page 6 / 13

Start Angle and End Angle

1. 8 * & @) % Toolpath
2. 8 * & BC @) Toolpath * &B % @O%* () @O% YB

Start angle (120) > end angle (0) Toolpath &B BC % @O% YB
Start angle (0) < end angle (120) - Toolpath &B BC @O% YB

Tool travels anti-clockwise Tool travels clockwise

End angle
= 120
Start
angle = 120
Start angle = 0 End angle = 0

Stepover ()%.% ) ? * + )) % .& Center Point

Join Up Toolpath % + 8 * & * ' FF &B CB & * () &B 2 CB @7A ) ? F 8 * & Jion Up
67 *S & ?

Ends of passes linked Ends of passes unlinked

Join Up flag set Join Up flag unset

8.4 Radial Example

1. 3D^& Finish Form 3 () Radial Strategy
2. B C & C<' Tolerance 3 4 0.1 0 ' Thickness 3 4 0
3. DE) ' Start Angle 3DR -60 0 End Angle 3DR 240
 Lesson 8 Page 7 / 13

4. DE) ' Start Radius 3DR 10 0 End Radius 3DR 47

5. 3 )( Join Up 0 B C &' Step Over 3DR 2 ) Z

%.% \60 O ()%.% 300 ) C * Toolpath

B% C% F 10 %%. 8
* B& ?

6. 3 () "N"") 3DR "N" !") " 0 Z 3 () Preview

@) Toolpath ' & ?

7. 3 () "N"") 3DR ISO 1 &DNO" Apply

Toolpath +? @7A & ?

8. 0;& 23&% 1) Tool

 Lesson 8 Page 8 / 13

' ()*+, 8.2 Radial Exercises

;2< Toolpath 0 Radial $< Tool bn12 B C &' Tolerance 3 4 0.01 0 ' Thickness
3 4 0.5
B C &' Center Point )?G ! X 6.5 Y 26 ' Start Angle 3 4 0 0 End Angle 3 4 360 ' Start Radius
3 4 0 0 End Radius 3 4 12 0 Stepover 3 4 1 ) Z 0 < 0;& 3&% 1) Tool

Toolpath +? Q(A O ^

8.5 Spiral Machining

1. Finishing Form 3 () Sprial Strategy
 Lesson 8 Page 9 / 13

Center Point
8 * & &. C? V @) &B FF Sprial % B &. C? V A ) ? 0 0 0 67 A % + 8 * &!&
-& S? ) ,) ) @ ! * () 8 * &-& () Reset to Block Center 67 ' .& 7 @) Block
Start and End Radius
8 * &@ &@) Toolpath BC &B @) Tool -& Tool &B BC @& * () ))
& ) + End Radius % Start Radius Tool &B )) & ) + + Start Radius % End
Radius Tool &B @ &

Start radius

End radius

End radius > Start radius Start radius > End radius
(tool moves outwards) (tool moves inwards)

Stepover
() * C%@) &B )F

pitch

Direction
BC &B F .%-& () Option Clockwise * () Anticlockwise

8.6 Sprial Example

1. 3D^& Finish Form 3 () Sprial Strategy B C & C<' Tolerance 3 4 0.1 0 ' Thickness 3 4 0
2. B C &' Center Point )?G ! X 10 Y 26 ' Start Radius 3 4 9 0 End Radius 3 4 0 '
Direction B C &3DR Clockwise

Toolpath FF Spiral ' Toolpath &B ) ) )(

 Lesson 8 Page 10 / 13

3. 3 () "N"") 0 ") " @ "0 0 Z 0 < 3 () Preview

& * *O Toolpath FF Sprial B&@7A * () BA

4. 3 () "N"") 0 ISO1 0 < 3 () Apply

*O Toolpath FF Sprial +? @7A

5. 0;& 3&% 1) Tool

' ()*+, 8.3 Sprial Exercise

;2< Toolpath 0 Sprial $< Tool bn12 B C &' Tolerance 3 4 0.01 0 ' Thickness 3 4
0.5
B C &' Center Point )?G ! X 0 Y 0 ' Start Radius 3 4 0 0 End Radius 3 4 75 0 < 0;& 3&%
1) Tool

@ &@) Sprial *a B ! %() F F -% &

%() Tool &B +7 @)F@) -% & @7A ()
% &B -% & )!
 Lesson 8 Page 11 / 13

8.7 Pattern Machining

%J $<3 ' %' 2 Project 3;< !HG< $<;2< 1 >"3& 3I(!) B C<3 %& Toolpath %J 3C" ;B C24 2
4&3DR
@4 )4 S2C2() $< 4 Tool !" 4 ST !L"3DR " @2r

1. Finishing Form 3 () Pattern Strategy

Pattern Toolpath Bb A +? OF! Explorer Pattern

Drop Pattern When Machining
+ ) A+? () Pattern +? Project % % Z Q() ToolpathF -% & =
C%@) Tool Thickness 8 * & + ) A!%+? () Toolpath +? Project Pattern
% % Z F -% & -& !%% 8 7 +7 C%@) Tool Thickness 8 * &
 Lesson 8 Page 12 / 13

8.8 Pattern Examples

1. ! Pull Down 3" 3G () File Delete All
2. ! Pull Down 3" G3 () Tools Reset Form
3. 3D^&L_ K swheel.dmt Examples
4. 3 () Block Form 3 () Calculate ;2< Tool 0 Ball Nose $(!) bn2
5. 3 () Rapid Move Heights 3 () Reset to Safe Heights
6. 3 () Tool Start Point Form 0 3 () Reset to Block Center
7. 3D^& Finishing Form 0 3 () Pattern Srategy DE) ' Tolerance 3 4 0.1 0 Thickness 3 4
s0.5

8. &3" ;KDNO"1 !L)') Pattern Explorer 0 < 3 () Toolbar

When Toolbar is selected off the Pattern menu it loads

a new toolbar into PowerMILL. The toolbar contains
icons to create an empty pattern and load different
types of entities into that empty pattern

The toolbar can be removed from the screen by

clicking the small x at the right.

9. 3 () L)') Create Pattern

10. 3 )( L)') Insert File into Active Pattern
11. 3 )( L_ K Engrave.dgk

!f V+? () @)%? +? Load

@ % Pattern
 Lesson 8 Page 13 / 13

12. 3 () Open
13. Finishing Form 3 () Pattern C" ?3 1 1

Once patterns are generated, the required

pattern can be picked off the list. The dropped
pattern will give the toolpath.

14. 3 () Apply

The engraved pattern is

shown clearly, with the
Pattern de-activated.
The pattern could be
used again on another
model, if required.

15. &3" ;KDO"N 1 !L)') Pattern Explorer 0 < 3 () Deactivate

16. 0;& 3&% 1) Tool

' ()*+, 8.4 Pattern Exercise

1. ! Explorer &3" ;KDNO"1 !'B Model 0 < 3 () Delete All
2. 3D^&L_ K phone.dgk Examples
3. B 2 Reset Block , Rapid Z Move 0 Tool Start Point
4. ;2< Toolpath 0 Pattern >&? $<' @ t !")?G

Toolpath FF &B% % + F
-% & & O!&+ Toolpath B&SB&
8 * % + () !&-&
Option % ? B& & % V ./%
@

5. 0;& 3&% 1) Tool

 Lesson 9 Page 1 / 8

9
3D Offset and Constant Z
9.1 3D Offset Machining
Toolpath Offset Tool !" # $ % &'!" )( * (
+" ,& &
1. () Finishing Form #5 3D Offset Strategy

Toolpath
!
Option !%!&
'

Spiral ( Tool &) * * +* ,, Sprial /& &) & * 0 1& 0* /% &

Max Number 2 0* offset % 6&
Use Pattern 1 0* Pattern % ' ,, Offset
 Lesson 9 Page 2 / 8

9.2 3D Offset Example

1. () Pull Down = #5 File Delete All
2. () Pull Down = #5 Tools Reset Form
3. A B#C cowling.dgk

(8 /% & % 1 9 ' :) , :)
/
(% %) & &) ,, 3D Offset

4. A Block Form #5 Calculate

5. K Reset Rapid Move Heights O#% Tool Start Point
6. Tool Ball Nose () ( Diameter 12 (,5) "* bn12
7. () Finishing Form #5 3D Offset Strategy
8. K $ U$+* Stepover * &' 1 O#% Direction Climb

9. #5 Apply

Toolpath =1 0>9 %+* & &) 0*

Tool
(8 Tool &) & * 0* /% & 0
!
0 /% & 0>9 %+* )9 6& &) 0*
9
 Lesson 9 Page 3 / 8

10. O Tool
11. #5 )( Option Spiral O#" Toolpath U$ *

Option Sprial & 0* Tool

12. O Tool

) *+,-. 9.1 3D Offset Exercise

1. #' # X O#% A B#C chamber.tri Y examples
2. #5 [)( 5X #* # O#% )( = )( # #5 Delete Selected
3. A Block Form #5 Calculate
4. K Reset Rapid Move Heights O#% Tool Start Point
5. Toolpath O'' 3D Offset () (+* Stepover 2 .

6. O Tool
 Lesson 9 Page 4 / 8

9.3 Constant Z Machining

Y% Toopath ,&X \ # O "O Z ( % % %$"* ,&X * &'+* Stepdown
$ % &'!" () (+" ,&
1. () Finishing Form #5 Constant Z Strategy

Toolpath
!
Option !%!&
'

Corner Correction 2 (, ) ? % )@ 0* Toolpath ' Arcfitted ( / ) , Sharpened

(%6% ( %), ( +* None (!% )
Stepdown ( ( 9 0>9 * 1 , Cusp Height
Direction 2 ( & )@ &) 0* Tool Climb (Down Cut), Conventional (Up Cut) ( +* Any
Pocket machining 2 ( & ( &) & ( 6% ( 8 *
Boundary Trimming 2 ( & ( & Toolpath , 9) & Boundary K> & )9 * ' &
(Inside) ( +*& * (Outside) 0* Boundary
 Lesson 9 Page 5 / 8

O'' Constant Z Y% * $ % &'!" () (+" ,& $ 5 !" '

0? :) 0* /% & % % *
Stepover % 0>9 !%% Stepover

, :) ,

9.4 Constant Z Example

1. () Pull Down = #5 File Delete All
2. () Pull Down = #5 Tools Reset Form
3. A B#C camera.ttr Y Examples

/% & &1 (%+* *,&

Wireframe
2 Shade P+* (8 /% & *
& 0>9
(8 ' /% & %,1 ?Q

4. A Block Form #5 Calculate K Reset Rapid Move Heights O#% Tool Start Point
5. Tool Ball Nose () ( Diameter 10 (,5) "* bn10 )( Finishing Form #5 Constant Z Strategy
6. K $ U$+* Stepdown * &' 1 O#% Corner Correction #5 Sharpened O#% Boundary
Trimming #5 Keep Inside

2 ( & (8 Stepdown !% * 1
%%.
2 ( & (, ) ? % )@ 0* Toopath
' %6% ( % P+* (% Tool !& +* 0 =>
, ) ? ' %6%T /% & * )
 Lesson 9 Page 6 / 8

7. #5 Apply

(8 = :) ) % % * Stepover 0* Tool )
%%

8. O Tool

) *+,-. 9.2 Constant Z Exercise

1. Toolpath () a O$# K $ &' # chamer.tri
2. O#" Toolpath () a + () ( &b ( *" + 0.2 ( ' ( ' Toopath &X Zoom
= c[ %' "d $
(8 % 0* Toopath 9 * * &
Toolpath
%%6%/ (% 2 ( , & ,, Highspeed
 Lesson 9 Page 7 / 8

9.4 Optimised Constant Z Machining

Y% Toopath .U,"e( ! & %$"* Constant Z O#% 3D Offset f ' "d )!( " +( "
,& Y%U, O'' Constant Z &X Y%U, O'' 3D Offset
1. () Finishing Form #5 Optimised Constant Z Strategy

Toolpath
!
Option !%!&
'

Stepdown ( ( 9 0>9 * 1 , Cusp Height

Direction 2 ( & @) &) 0* Tool Climb (Down Cut), Conventional (Up Cut) ( +* Any
Closed Offsets 2 ( Offset )& & * 0 % ( &
 Lesson 9 Page 8 / 8

9.4 Optimised Constant Z Example

1. #' # X O#% A B#C camera.ttr
2. A Block Form #5 Calculate
3. K Reset Rapid Move Heights O#% Tool Start Point
4. () Finishing Form #5 Optimised Constant Z Strategy
5. #5 Direction O'' Climb O#% #5 Closed Offsets

' &) & * 0(& )@ &

,,
Down Cut

6. #5 Apply

(8 &) 0* Tool &)

& Stepover
%2 %*

7. O Tool

) *+,-. 9.3 Optimised Constant Z Exercise

Toolpath U$ * * #5 Closed Offset O#" ( ' ( '+" O *
 Lesson 10 Page 1 / 10

10
Corner Machining
Corner Machining !"!! # $%& 5 # Pencil, Multi Pencil, Stitch
Corner, Automatic Corner 012 Along Corner 34 # 51& 6720 & 0 $ $8 9!
!"!: ;6 (Pencil) 012 6 >& 51 7 Tool !@ :5A& & (Rest Milling)
10.1 Pencil Machining
> D Toolpath 0 $ $8 9! !"!: ;6
1. Finishing Form 1 Pencil Strategy

Toolpath
!
Option !%!&
'

( )%* +* %,* Tool ,* ( - . % % (Steep) 3 ,* * (Shallow) ,*

5 3 & 6* Threshold Angle %,* 5 3 & * Output ' Shallow %= 5 3 Toolpath >?
( - . =- %%)%6* % * Threshold Angle 6 % %,* 5 3 & * Output ' Steep
%= 5 3 Toolpath >? ( - . =- %%)%6* % % Threshold Angle > 5 3 &
' Both Toolpath >? ) A * B 6* %
 Lesson 10 Page 2 / 10

10.2 Pencil Machining Example

1. Pull Down ! % 1 File Delete All
2. Pull Down ! % 1 Tools Reset Form
3. N 8O1P cowling.dgk
4. N Block Form 1 Calculate
5. U Reset Rapid Move Heights 012 Tool Start Point
6. > D Tool Ball Nose ! Diameter 12 !; & bn12
7. Finishing Form 1 Pencil Strategy
8. 1 !"!! ISO2
9. U 5 :5D & Threshold Angle 30 a

,* Output ' Both Toolpath C (- . (

10. 1 Apply

& &- 6* Tool 3D Tool ,* ! ( - .

%)%6* % - 6* Threshold Angle ( 30 * B )
 Lesson 10 Page 3 / 10

11. 0> @ Tool 01D 1$ ; Toolpath pencilboth

12. 1$ 7 Both Shallow
13. 1 Apply b > D Toolpath @46 ! :5!&

Toolpath >? ( - . %)%6* % !% -

6* Threshold Angle ( 30 * B )

14. 0> @ Tool

# $%&'( 10.1 Pencil Machining Exercise
1. > D Toolpath 0 Steep Pencil :;D Tool 0 Ball Nose ! Diameter 16 !!. c $:;D &
Threshold Angle10 a

Toolpath >? ( - . %)%6* % -

6* Threshold Angle (30 * B )

2. 0> @ Tool 01D Save Project 8 D: C:\temp !; & train-corner

10.3 MultiPencil Machining
> D Toolpath 0 51 $ $ 8 9 ! !"!: ;6
1. Finishing Form 1 MultiPencil Strategy

Toolpath
! Option !%!& '
 Lesson 10 Page 4 / 10

MultiPencil
' &- G. & ( Pencil ,* &- ! %( - . ' %)% -C J &- 3
,* * & ,C* 3 ,* Tool &! * 3 C %6 & 3K G. 6* Toopath
&- & & * 6 ?( - . 6* ' %)% & (( C* Rest Milling
5 3 ( 6* Threshold Angle C 3= & ( Toolpath (( Pencil
N J& & ( - . % ,C* 3 ,* Tool 3K & C MultiPencil ' Toolpath -&
3 J,C % ,C* 3 *, Tool 3K (Reference Tool) &- &P& Tool ,* (Active Tool)

10.4 MultiPencil Example

1. Finishing Form 1 MultiPencil Strategy
2. > D Tool Ball Nose ! Diameter 5 !; & bn5
3. 5 @D Reference 1 Tool ; bn12

' Toolpath (( MultiPencil

P& * *- Tool %6 & 3K

4. 1 Apply

Toolpath >? 6RC

 Lesson 10 Page 5 / 10

5. 0> @ Tool 012 1$ ; Toolpath mutiboth

6. 1$ Both Steep
7. 1 Apply

Steep Reference Toolpath >? 6RC

8. 0> @ Tool 1$ ; Toolpath multisteep

# $%&'( 10.2 MultiPencil Machining Exercise
1. > D Toolpath 0 MultiPencil :;D Tool 0 Ball Nose ! Diameter 4 !!.
2. 1 Output 0 Both U 5 & Overlap 3 !!. :;D Tool bn12 Reference Tool

5 3 & 3% Overlap 5 3% %,* &

!%% ,C* &) 3 ,*

3. 0> @ Tool 01D Save Project 8 D: C:\temp !; & train-corner

10.5 Stitch Corner Machining

> D Toolpath 0 96 i 8 ! 8 9 ! !"!: ;6
1. Finishing Form 1 Stitch Corner Strategy
 Lesson 10 Page 6 / 10

Toolpath
! Option !%!& '

Stitch Corner
' &- G. C S ! % ! %( - . ' %)% -C J,C % ,C* 3 ,* &
6* Tool &! * 3 C %6 & 3K
5 3 ( 6* Threshold Angle C 3= & ( Toolpath (( Pencil
10.6 Stitch Corner Example
1. Finishing Form 1 Stitch Corner Strategy
2. 1 :;D Tool bn5 U 5 Output Both 012 Direction Any U 5 & Overlap 0
3. 1 Apply
4. ! >P "j!@ Toolpath 1 Edit ZigZag b 1$ 7 a $ 2
a

%,* Tool ( &- > 6RC ! Safe Z

UR ( )% *, 6RC 6* Tool 5 !&P& 5 3 &
6* Option A Leads and Links Form

!* * Leads and Links * ? Main Toolbar Finishing Form

* C ,* main Toolbar
 Lesson 10 Page 7 / 10

5. N Leads and Links Form 7 Main Toolbar n & 9 ! % 01D 1 Apply

!& Toolpath % - [-N J

6. 0> @ Tool
# $%&'( 10.3 Stitch Corner Exercise
1. > D Toolpath 0 Stitch Corner U 5 & Overlap 3 !!. 01D 0> @ Tool
10.6 Along Corner Machining
> D Toolpath 0 @ 8 !8 9! !"!: ;6
1. Finishing Form 1 Along Corner Strategy

Toolpath !
Option !%!&
'
 Lesson 10 Page 8 / 10

Along Corner
' &- G. &- 6 ! % ! %( - . ' %)% -C J,C % ,C* 3 ,*
&6* Tool &! * 3 C %6 & 3K
G. 6* Toopath &- & & * 6 (? - .& 5 3 ( 6* Threshold Angle
C 3= & ( Toolpath (( Pencil
10.7 Along Corner Example
1. Finishing Form 1 Along Corner Strategy
2. 1 :;D Tool bn5 U 5 & Cusp & 0.05 U 5 & Overlap 0
3. 1 Apply

Toolpath >? 6RC

4. 0> @ Tool

# $%&'( 10.4 Along Corner Exercise

1. > D Toolpath 0 Along Corner Climb Milling 01D 0> @ Tool
 Lesson 10 Page 9 / 10

10.7 Automatic Corner Machining

> D Toolpath 0 o>! 25 & Stitch Corner 012 Along Corner
1. Finishing Form 1 Automatic Corner Strategy

Toolpath !
Option !%!&
'

Autometic Corner
' Toolpath ((= % 3 (( Stitch Corner (( along Corner 6RC * ? ( Threshold Angle
> 6* %)%6* % % Threshold Angle -& Toolpath (( Stitch Corner 6 %>
6* %)%6* % * Threshold Angle -& Toolpath (( along Corner 5 3 ( 6*
Threshold Angle C 3= & ( Toolpath (( Pencil
 Lesson 10 Page 10 / 10

10.8 Automatic Corner Example

1. Finishing Form 1 Automatic Corner Strategy
2. U 5 Direction 0 Any 01D 1 Apply

Toolpath >? 6RC G.

= % 3 Stich Corner ( %,*
6* %)%6* % %
Threshold Angle ) Along Corner (
%,* 6* %)%6* % *
Threshold Angle ) J,* *+
,* 6* Tool (Plunge Down )
%,* % % %

3. 0> @ Tool

# $%&'( 10.5 Automatic Corner Exercise

1. > D Toolpath 0 Autometic Corner ! & Threshold Angle & 20 a 01D 0>
@ Tool
 Lesson 11 Page 1 / 8

11
Projection Machining
Projection Machining Toolpath ! " # Project $ % &'( )$ )$ *
#'+ , -.( /. 0& !1 #,234. "%% Undercut ) , 8 * - Tool )
"%% 5 Axis
,#'+ "= => 3 #'+ Point Projection , Line Projection "$1 Plane Projection
Point projection

Line projection

Plane projection

Projection Machining , - .
/ - / 0 .1 Point Projection , - 23 4 0 .1 Line
Projection , - / 0 .1 Plane Projection , - /7 8 /
Finishing Form < Project 8 = / Outward ( / ) / 8 Inward
( / ) 4= E F Core - Cavity
3 F 8 .1 - Azimuth / 8
Elevation
Azimuth Angle - / Z < , L

E. =/ M Chamber M
F / / Z
 Lesson 11 Page 2 / 8

Elevation Angle
- 4= 2. 8 XY

E. /= M Chamber M
2.F / / X
11.1 Point Projection Example
1. Delete All "$1 Reset Forms
2. 83I 2J$K Projfin_model.dgk

This model has areas on it that lend

itself to the projection machining
technique.

3. 83I Block Form 8$ Calculate

4. Tool Ball Nose , Diameter 12 ,& #> bn12
5. T Reset Rapid Move Heights "$1 Tool Start Point
6. Finishing Form 8$ Point Projection Strategy

F /. Q
Toolpath 8 . 2. Option
2 2 Q8 .1
 Lesson 11 Page 3 / 8

7. 3[ > 100 0 27 T ) % Origin Point

8. T ) _' 83` Outwards
9. T ) Style 83` Radial
10. T ) > Stepover 83` 3 8$ Join Up
11. 8$ Preview

T-= 8 Project 8/ ,
E</ < Project

12. 8$ Apply

Toolpath 80E T-= =

13. " 8 ' - Tool "$#83$* & Toolpath 83` lineproj-bn12

14. Finishing Form 83$* Style 83` Circular "$#8$ Apply

Toolpath / Circular 80E 4=

15. " 8 ' - Tool 83$* & Toolpath 83` circproj-bn12

16. Finishing Form 83$* Style 83` Spiral "$#8$ Apply
 Lesson 11 Page 4 / 8

11.2 Line Projection Example

1. Finishing Form 8$ Line Projection Strategy

F /. Q
Toolpath 8 . 2. Option
2 2 Q8 .1

2. T ) % Location 3[ > 95 0 0
3. T ) % Direction 8$ Outwards "$1 T ) Style 83` Circular
4. T ) %,e, Azimuth 3[ Start 8 > % g180 "$1 End 8 > % 80
5. T ) % Height 3[ Start 8 > % 65 "$1 End 8 > % 80
6. T ) 0) Stepover 83` 1 "$18$ Join Up "$18$ Preview

T-= 8 Project 8/ ,
E</ < Project
/

7. 8$ Apply
 Lesson 11 Page 5 / 8

Tool 8 - 2. 2.U
.1 / Up Cut l down Cut

8. " 8 ' - Tool

9. 2,>8$ Join Up 8$ Oneway "$# Toolpath 0),>

Toolpath =4 8 4= - =
/F 8Q= .1 <

11.3 Plane Projection Example

1. Finishing Form 8$ Plane Projection Strategy

F /. Q
Toolpath 8 . 2. Option
2 2 Q8 .1

T- F . Slider
.X E < Y -
 Lesson 11 Page 6 / 8

2. T ) % Anchor Point 3[ > 195 -30 57

3. 3 % > ,e, Azimuth 83` 90
4. 3 % > ,e, Elevation 83` 90
5. T ) % Direction 8$ Outwards "$1 T ) Style 83` Across
6. T ) % Height 3[ Start 8 > % 35 "$1 End 8 > % 0
7. T ) % Width 3[ Start 8 > % 0 "$1 End 8 > % 60
8. 8$ Join Up
9. T ) 0) Stepover 83` 1 "$18$ Join Up
10. "$18$ Preview

T-= 8 Project 8/ ,
E</ < Project
/

11. 8$ Apply

Tool 8 Stepover
= Z Q
-

12. 2,>8$ Join Up 8$ Oneway "$#8$ Apply

Tool 8 <
 Lesson 11 Page 7 / 8

11.4 Undercut Machining

4= 0& Tool "%% Disc Type ( "% $ *! ) 0 % '8#l 83` Undercut #'+ -
Projection Finishing ( 3 "%% , 4 T , 3 1*e =K0&2
1. Pull Down 8, m8$ File Delete All
2. Pull Down 8, m8$ Tools Reset Form
3. 83I 2J$K heatsink.tri ! Examples
4. 83I Block Form 8$ Calculate
5. T Reset Rapid Move Heights "$1 Tool Start Point
6. Tool "%% Tipped Disc , Diameter 75 , Tip Radius 1 ,,. ) 4 ,,.

7. 3[ > => n m3"$#8$ Apply

8. " 8 ' - Tool

9. 83I Finishing Form -.( , ( ) . 2,>8$ Join Up "$18$ One Way

10. 8$ Apply
 Lesson 11 Page 8 / 8

8 , Tool 8 - Q Q=
F /2 Tool

11. 83I Lead and Links Form 3[ > => n m3

Lead In 1st Choice

Horizontal Arc -Radius 2.0 - Angle 90

Lead Out 1st Choice

Horizontal Arc - Radius 2.0 -Angle 90

Extensions
Straight - Inward 75.0 - Outward 75.0

12. 8$ Apply

+Toolpath !14m " 2-o * =o ,='

 Lesson 12 Page 1 / 4

12
Profile Machining
Profile Machining Toolpath !""# $ "%&# '( !)*'+,- # * - .# $ #/0
"# 012 2' 0 " 43 !)*.+(, "%&# ' #56 47'8!"" Triangle 4&*4
12.1
1. Finishing Form #' Profile Strategy

2. #5A 47'8 profile_model.dgk

3. #5A Block Form #' Calculate !'+#' 4 Lock Block Block .+J Lock
4. L Reset Rapid Move Heights !'+ Tool Start Point
5. Tool End Mill & Diameter 6 &, 1* em6
6. #' T$1 5U (,5VW& Shift L 2 "#' !'+0 #'$ #' (,5VW& Ctrl
7. L Shade %&# '
 Lesson 12 Page 2 / 4

8. 21Z Depth L 2 * Bottom #56 0

9. 21Z Offsetting #' Inside Edge !'+ L 2 * Clearance #56 0
10. ,* Surface Limiting #' Remove
11. L 2 Direction #56 Climb !'1#' Apply

Toolpath ! " Surface )*+,-., /0

12. L 2 * Surface Limiting #56 Rise
13. 21Z Depth L 2 * Top #56 25 !'1#' Apply
 Lesson 12 Page 3 / 4

14. 21Z Depth L 2 * Top #56 10 !'1#' Apply

15. #' T$1 U5(,5VW& Shift L 2 "#' !'+0 #'$ #' (,5VW& Ctrl
16. L Shade %&# '

17. 21Z Depth L 2 * Top #56 15 L 2 * Bottom #56 0

18. #' Multiple Cuts
19. L 2 * Step Down #56 5
20. 21Z Offsetting #' Outside Edge !'+ L 2 * Clearance #56 1
21. ,* Surface Limiting #' Remove
22. !'1#' Apply

Toolpath 12 3 4 5 "6 7. )*+ 8 7. Top Bottom ! "-* " 8. 1

--. 3 6 =. 3
 Lesson 12 Page 4 / 4

!"# 12.1
Toolpath !""(2# $ ",$- #/0 "# 01 + "T$1 " 10 * Offset #56 0 bc
Toolpath 4
#56 U5
 Lesson 13 Page 1 / 5

13
Four Axis Rotary Machining
Four Axis Rotary Machining !" # $#% &' X ')* Tool -*. ! /0 12 32 .
13.1
1. Finishing Form .) Rotary Strategy

X Limits X Block
Technique 9!: . ! Circular, Spiral Line
Direction !"! Climb (Down Cut), Conventional (Up Cut) any
Stepover -. Circular / Spiral 0 1 2 2 2/ 234 Line
4 5 02 "
Y Offset 0 1 !.6 /6 7 Y 9 Tool 0/6 !.6 ; <
 Lesson 13 Page 2 / 5

Angular Limits 4 = !.6 = /2 Circular / Line 5 = !.6 1<2 2

Start Angle / End Angle = ;. !"! H I 6 7 !" X+
z
S tart an g le

E n d an gle

13.2 Circular Rotary Machining

. ! . ! '&& Circular <#. )-*$#% )&/0 )&# .# &'32)* & Tool -*. ) /03 #' 9'
X . 2 & *1* = $ > 2 Stepover
1. Pull Down .# .D ) File Delete All
2. Pull Down .# D.) Tools Reset Form
3. .0G /H)I Rotary_bottle.dgk

4. .0G Block Form .) Calculate

5. = Reset Rapid Move Heights ')* Tool Start Point = $ .0R X0 Y0 Z40
 Lesson 13 Page 3 / 5

6. W X Tool Ball Nose # Diameter 10 # 92 bn10

7. Finishing Form .) Rotary Strategy .) Technique '&& Circular = $ \$X 2 Stepover . 2 & 5
8. $9>X X Limits .) Reset To Block Limits = $ Direction .) Climb
9. .) Apply

10. 'W . ! > Tool H 2 Tool !"! !.6 5 Down Cut / 1 != 0 ; !.6 . /.61
K Tool 7 X 3; 3= 1 Block K 4 Direction 5 Conventional
Tool !"! !.6 5 Up Cut / K 4 Direction 5 Any Tool !"! !.6 5
Down Cut / Up Cut 3/ 7
11. = $ Direction .) Any ')X9 .) Apply
12. 'W . ! > Tool W . 3 .0)1 '0) 1 Tool 0 0= Q 1 4 02 Leads and Links

13.3 Line Rotary Machining

. ! . ! '&& Line Tool -*. ! /0- W% *1*\ ' 9' X ')X9 !" -*$#% /0. 2 ` =$ >
2 Stepover Tool -*1 )&# 3= '$ 2 . !#3X ')X9. ! \ 'a932 /0
1. \ X 2 Parameter . 2 . 19 &39 12 ')X9 .) . ! .0R Line
2. W= $ & Angular Limits = $ Start Angle . 2 & 90 ` End Angle . 2 & -90 `
3. .0G Leads and Links Form = $ Z Heights .0R Skim # *1* 20 ##. ')* Links " $# .) Tool Axis
4. .) Apply ')*'W . ! > Tool
 Lesson 13 Page 4 / 5

5. .0)1 Direction .0R Any

6. .) Apply ')*'W . ! > Tool

13.4 Spiral Rotary Machining

. ! . ! '&& Sprial !" -*$#% &' X /0 12 32 . \ >d* Tool -*. ! /0- W%
*1*\ ' 9' X
1. \ X 2 Parameter . 2 . 19 &39 12 ')X9 .) . ! .0R Spiral
2. .0)1 Direction .0R Climb
3. .) Apply ')*'W . ! > Tool
Lesson 13 Page 5 / 5
 Lesson 14 Page 1 / 20

14
Boundaries
Boundary ! "#$ %& ' ( ) Finishing
Toolpath & ' Toolpath 3 Raster 3 3D Offset ! : Boundary ; < '=< !'=( > Toolpath
3 Constant Z % !A B> ' & $ $B Option Boundary
Toolpath 3 Finishing 3 Plung Area Clearance ! ::F %& ' ( ) Active Boundary
3 Boundary ' ! : ' " ; ; < H ; $ Project 3 ! H ; "# Explorer
$ Boundary ' ! 10 (N ' Sketch, Block, Rest Material, Shallow, Silhouette, File,
Pattern, Toolpath, Model 3 Selected Surfaces
Boundary ! ::F 3 < $B Explorer Boundary Toolbar
14.1
1. "# Explorer ! V WX! "#Y& > Boundaries

All the boundary options available are

displayed.

2. Create Boundary 3 User Defined

User Defined Boundary Form Accept

#$ % & ' Boundary ($ 1
*+ *,*,$ User Defined Boundary Form Option
*+'%,$ . Pattern, Toolpath, Model / 0 Sketch 10# & 2
*3 '

3. Accept
4. "# Explorer ! V WX! "#Y& > Boundary 3 Toolbar

Boundary Toolbar 10 *,$7& 8 '9& : '1 ; # < Tool Selector Toolbar

5. Y ( "#B> "#! Y # ! ! # !B % H Option => ^ "#$B Boundary
 Lesson 14 Page 2 / 20

9$' Option *+'< . user defined, silhouette, shallow, selected surfaces, rest block

6. !# Option :F Option => ^ "# Toolbar % ` !"&

7. Option 3=> ' Y

Save boundary

Insert Boundary File

Insert Boundary

Insert Pattern
Insert Toolpath

Insert Model

Sketch Boundary
Edits the Boundary
Clears the Boundary

Delete the Boundary

8. Y& '# Insert Boundary % & Boundary > # ! ! ' Boundary "# & ' $B F>;

($ Boundary <2 : 1 >? % & ' @ PowerMILL Explorer /H8:+'I282,

Boundary J7 1 K8 10% & ' 1 Option @7 Option < $'@ User Defined Form
9. !# Y ( ! V WX! "#B# Boundary % e! F > ' F

Boundary % 2 > 3 < 7@<& Active < Inactive I7&

*M . +'*,$% 2 > Boundary 2 @<28 10 ($ :?8*$, Explorer
,$: ($ @<2810(8K:@<&'8 :@ & ' J'>'@ ; :< '+

14.2 Sketch Boundary

 Lesson 14 Page 3 / 20

Option % & %W `# $B > => ^ Boundary < $B Sketch Tool < %W % :F &
< Y ( ! V WX!f g Y> XYZ A> Form (N % & > "# $ !>! ! ' Boundary
"#! F>3
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset Form
3. ;k V cowling.dgk
4. Block Form Calculate
5. "& Reset Rapid Move Heights 3 Tool Start Point
6. Tool Ball Nose "#! Diameter 8 !B# > bn8

7. "# Boundary Toolbar ;Y Sketch

10 Boundary Sketcher Form

Definition 3 < 7K8 .8 *,$ P & 2 Q .8
Absolute < Increment +R1M7*,$/ &K
Projection 3 < 7K8 Sketched Boundary 10>?
S 1. 'R 0 R XY-Plane < 'R Current
View Plane

Add Point #J$21M7@<28 & I @ Boundary *,$@(&' :?8

Delete Last Point R1M7%M7*& :*,$% & '

Delete Last Segment R1M7*+'<27 '%8K *,$I7&% & '

Close Segment *3 @<&%8K ' Boundary Q K' Y7

8. !W!! ! = !3 3 Z
9. "# Pull Down ! F Tools Snapping ;!> Model 3 !'# $% > Anywhere 3

Snap Filter . %J$'*,$ 2 %Z% 2 > . $ *,$ & I >'I7&

 Lesson 14 Page 4 / 20

10. "& Sketch < $B ! V WX!f

/H8 01M710 <[ Q %, 3 'J S7:2, %& %, K ($ 2H8

0<K8 '1M7

11. Accept
12. Finishing Form 3 Optimised Constant Z
13. Boundary ! 1

>& @(& Option Boundary / &K Toolpath 10>? 13 7+

R J K\
7&K: Boundary ,

14. Apply

10 <[ K8 Toolpath>? 13 +7R J K\7&K: Boundary ,

" #$%&' 14.1

Toolpath 3 Raster < $B Sketched Boundary
 Lesson 14 Page 5 / 20

14.3 Block Boundary

Block Boundary n ="#! "> ' F Block "#! =' o ' XY
1. Y ( ! V WX! "#Y& > Boundaries "# Explorer 3 Create Boundary Block

2. ; Y Block
3. # Y> X Max Value n 0 $ Block Form
4. Accept $ Block Form
5. Apply 3 Accept "# Block Boundary Form
6. Toolpath 3 3D Offset Finishing

Toolpath 10 J7 @ R H ' Block

*8 +

" #$%&' 14.2 Toolpath 3 Raster < $B Block Boundary

14.4 Rest Material Boundary
Rest Material Boundary n ="# ( % ( )"#! % ' Tool "#!
$ q> > (Reference Tool)
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset Form
3. ;k V restmill.dgk

S2 7 ,2,2M2*,$ Tool @<]8 & I I28>'

 Lesson 14 Page 6 / 20

4. Block Form Calculate 3 Block ; = !3 3 X 10 !!.

5. Tool Ball Nose "#! Diameter 16 !B# > bn16 Raster Finishing 3 & (
' $ 3 45 t & Y> Stepover n 1 Y> Tolerance "> ' 0.01 3 Thickness
"> ' 0
6. Accept "# Finishing Form
7. Y ( ! V WX! "#Y& > Boundaries "# Explorer 3 Create Boundary Rest

10 Rest Boundary Form

8. Y ( $ B> Reference Tool 3 bn16

9. Tool Ball Nose "#! Diameter 6 !!. B# bn6

10. Y ( $ B> Tool 3 bn6

11. Apply
12. Accept

Boundary 10>? % & ' Q R H '

# *,$*$,
Tool bn16 & I28>'

13. "& Active Tool bn6

 Lesson 14 Page 7 / 20

14. Toolpath 3 Raster Finishing ( ' $ 3 45 t !Y> Stepover 1 !!.3

Two Way

" #$%&' 14.3 Toolpath 3 Raster < $B Rest Boundary

14.5 Shallow Boundary
Shallow Boundary n ="# ( % ( )"#! t Y !B' >F > Y> "# &
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset Form
3. ;k V cowling.dgk
4. Block Form Calculate
5. "& Reset Rapid Move Heights 3 Tool Start Point
6. Tool Ball Nose "#! Diameter 16 !B# > bn16
7. Y ( ! V WX! "#Y& > Boundaries "# Explorer 3 Create Boundary Shallow

10 Shallow Boundary Form .M\H& ' 3 < 7 '` '.K 2(+

8. Shallow Boundary & ' ` "#"#! t Y !B' > 0 : 40 t

9. Apply
 Lesson 14 Page 8 / 20

10 7J
R H
%3 < +R
# *,$*,$2,
'`
'
.K 2(+
0<K8 '
0 >' 40
'`
10. Accept
11. Toolpath 3 Constant Z $BY> Steodown 0.5 !!. 3 Bounadry Trimming n
Keep Outside

Toolpath >? % & ' Boundary @

R J K\*,$2, '` '.K 2(+ 2 K8 40
'`

12. Toolpath 3 Raster Finishing 3 # !W! Upper Angle n 45 t Steodown 0.5 !!.
13. Style n Two Way Joined < $B Shallow Boundary

Toolpath >? % & ' ; :@ Boundary

 Lesson 14 Page 9 / 20

" #$%&' 14.4

1. Shallow Boundary ! $ !>"#! t Y !B' F> > 03 5 t
2. Toolpath 3 Raster Finish< $B Boundary 3 $B Tool End Mill "#! Diameter 10 !!.
14.6 Silhouette Boundary
Silhouette Boundary n ="# ( % Project <! ! = !3 3 Z < !
B B Y> 't! Tool
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset Form
3. ;k V mouse.tri
4. Block Form Calculate 3 $ 3 X 3 Y 10 !!.
5. "& Reset Rapid Move Heights 3 Tool Start Point
6. Tool Ball Nose "#! Diameter 10 !B# > bn10
7. Y ( ! V XW! "#Y& > Boundaries "# Explorer 3 Create Boundary Silhouette

10 Silhouette Boundary Form

14. Apply

10 J7 R H 1 Offset R 'S2 7 *,$

Project '@ 0 R XY 7&K: 0:0*,$ *8 +R 0:0 '
+`2, Tool
R H 10>?, % & '@<& :?8*,$ 0:0.K 2 *,$%M7 '
Block
K2 +R +`2, ' : Tool
 Lesson 14 Page 10 / 20

14.7 File Boundary

File Boundary n ="# ( % & !F => ^ ="# Y ! 3 "# H
; $ ;k V ' ! $B
1. % Boundary Toolbar ; Y Save
2. Save Boundary $ B# sillbound1 $ Directory C:\Temp
3. Boundary "' ! "(
4. Y ( ! V WX! "#Y& > Boundaries "# Explorer 3 Create Boundary User Defined
5. "# User Defined Form ; Y Insert Boundary File

6. ;k V C:\temp \ sillbound1.dgk

R H*,$ [RIK&10
 Lesson 14 Page 11 / 20

14.7 Pattern Boundary

Pattern !Y !Y Y ' Boundary 3=> Pattern ;!> ! : & $B$ %& ' ( ) Toolpath ; 3=>
Pattern "# n ! : & ! "& n Boundary ;
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset Form
3. ;k V chainsaw.ige
4. Block Form Calculate
5. Tool Ball Nose "#! Diameter 10
6. ! V WX! "#Y& > Pattern "# Explorer 3 Toolbar
7. ; Y Create Pattern
8. ( )"# n A( <! "> ' 3 "& Shade

The shaded icon shades the whole

model or the selected surfaces.

9. ;Y Insert Model into Active Pattern

Pattern 10>? % & '

10. # B# Pattern n topsurface

11. ! V !XW "#Y& > Boundary "# Explorer 3 Create Boundary User Defined

When using this form, the item needs to be

named and selected. By pressing the icon it
will turn the particular item into a boundary.
 Lesson 14 Page 12 / 20

12. "# User Defined Form Pattern B# topsurface

13. Pattern "# F> % z `< # # !Y
14. ; Y Insert Pattern

10 Boundary %, K
14.8 Toolpath Boundary
Boundary ! ::F % Toolpath "# n ;
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset Form
3. ;k V Predrill.dgk
4. Block Form Calculate
5. User Defined Boundary 3 ; Y Sketch
6. !W!! ! = !3 3 Z 3 "& Sketch ' F

@ Sketch .K *3 @ 2M22 '*,$2 ' 'I H 2/ K/ Z

7. Tool End Mill "#! Diameter 6 !B# > em6

8. Constant Z Finishing & Y> Stepdown n 1 !!.3 Boundary Trimming Keep Inside
9. Apply

Toolpath >? % & ' @ < M2

10. # B# Toolpath n conz-em6

 Lesson 14 Page 13 / 20

11. User Defined Boundary !< Toolpath B# conz-em6

12. ; Y Insert Toolpath / &K Boundary @<2810>? % & ' 2 < :(+
13. Accept
14. ;!>3 $ H <! !W!! = !3 3 }Y
15. Zoom $ H $ ( ) ' F # # !Y Boundary ' F f# B' > W

16. WX! Delete "# Keyboard

17. Tool 3 End Mill "#! Diameter 5 !!.

18. Toolpath 3 Raster Finishing 3 ( 90 t 3 !Y> Stepover 1 !!. $B Style Two Way
Joined

10 J7 Toolpath 7+' ?
 Lesson 14 Page 14 / 20

14.9 Model Boundary

Boundary ! ::F % Surface
1. "# Pull Down ! F File Delete All
2. ;k V Speaker.dgk
3. !W!! ISO 4 3 <! $ ( )"#3 ' F

4. User Defined Boundary

5. ; Y Insert Model

6. Accept

Boundary 10>? % & ' 1 R 'S2 7 *,$

7. Block Form 3 "#B> Defined by Boundary & $ Z Max n 60

 Lesson 14 Page 15 / 20

8. ToolBall Nose "#! Diameter 4 !B# > bn4

9. Reset Rapid Move Heights 3 & $ Tool Start Point >"F # Block Center
10. Toolpath 3 Raster Finishing $BY> Stepover "> ' 1 !!. ( $ 3 90 t 3 Style
n Two Way Joined

14.10 Select Surfaces Boundary

Boundary ! ::F % Surface < $B Surface n =' & 3=>% ! ' ;!>$ Tool
( ( ; ( > #
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset
3. ;k V resmill.dgk
4. Block Form Calculate 3 Offset ; =' 10 !!.
5. ToolBall Nose "#! Diameter 16 !B# > bn16
6. A( "# Shade ' F

The model has to be made up of

surfaces
for this command to work.

7. Boundary Toolbar
8. Option Create a Selected Surfaces Boundary
9. Apply
 Lesson 14 Page 16 / 20

Boundary 10>? % & '

1 R 'gJKS7:102,
+R 0:0I28@<& Tool
7J J I J %8K
$

10. Toolpath 3 3D Offset Finishing & Y> Tolerance "> ' 0.05 3 Thichness "> ' 0 !
Y> Stepover 1 !!.

Toolpath 10>? % & ' 7+' ?

14.11 Offsetting Boundary

Boundary ! ::F Offset $ $ q> H ;
1. "# Pull Down ! F File Delete All
2. "# Pull Down ! F Tools Reset
3. ;k V handset.tri
4. Block Form Calculate
5. ToolBall Nose "#! Diameter 16 !B# > bn16
6. ! V WX! "#Y& > Boundaries "# Explorer Create Boundary Shallow
7. g Y> Upper Angle n 45 t 3 Apply
 Lesson 14 Page 17 / 20

8. Boundary > # ^ $ n =' F

9. ! V WX! "#Y& > Boundary 1 $ Explorer Edit Offset 2D

10. g " 53 Y# ! :F

Boundary 10>? Offset I Q

0:0* ' 5 22. >& H& ' Offset &
2 7& @ H& ' P .8 Q R

>& .M\ Offset Boundary 7& / 0 Offset & 7& @ , . +'7&K: 0:0* '*,$ *8 + Boundary
12, 7I28 *8 7J2I7&

11. Toolpath 3 Raster Finish Y> Stepover 1 !!. ( ' n !W! 90 t $B Style Two
Way Joined
12. Boundary % Selected Surfaces Split Surface
13. Toolpath 3 3D Offset Y> Stepover 1 !!. 3 & Y> Links n On Surface

The resultant toolpaths can be

seen overlapping each other,
which will help eliminate the
tool witness lines created from
previously created toolpaths.
 Lesson 14 Page 18 / 20

14.12 Editing Boundary

Boundary ! ::F 3 ; ; < $B; Y Scissors "# Boundary Toolbar

The Mode option provides various editing functions

as described below.

Delete Point R1M7R Boundary

Move Point To . $ :& :1M7R Boundary I :+' Absolute
XYZ *,$ 3 < 7
Move Point by . $ :& :1M7R BoundaryI :+' Incrementally
XYZ *,$ 3 < 7
Move Segment By =>?@ A B C AD BoundaryI :+' .8 *,$ 3 < 7
Insert Point &'()*+,-&./01234 Boundary @<& :?8 0<K8 '1M7% '1M7*,$
2$ H& ' / &I Boundary @<& 7 2 %Z Mi2 K *,$($ ' Boundary + *,$ Explorer/ &K Edit

Move &5 6)748/08 Boundary I Q 0:0* 'H 2*,$ 3 < 7@

*J`* ' X, Y < Z

Rotate :*,4 Boundary I Q 2M2H 2*,$ 3 < 7 R/ X,Y

< Z

Scale :8 / : : Boundary H 22 H %8K *,$ 3 < 7

Mirror % & ' Boundary @ + l\0H ' + & 2g8 0 R

XY, YZ < ZX

Workplane Transform 8/08 Boundary /H8H3 /< 8'@

Workplane :+' <2 7J2

Points <-= Boundary Editor Form

Arc Fit Selected 2ABC3:/ Boundary 2,.K 2 ,:R2
Spline Selected &2 D)84 Sketched Boundary @<& Q Spline
Polygonize Selected &2 D)84 Boundary Q ? < : < ,$:2
Flatten - This option flattens the boundary making it 2D.
Offset 3D Offset Boundary 7&K: 0:0* '*,$ 3 < 7
Offset 2D Offset Boundary 7&K: 0:0* '*,$ 3 < 7 Q Offset @ # R *8 +
 Lesson 14 Page 19 / 20

Select Duplicates selects all duplicate segments of the boundary and can be used effectively in
conjunction with the Delete Selected option.
14.13 Blanking Surfaces using Boundary
Blanking Plane % $B & ' F3 W!=> ^ <! `# ;!>$ Tool Y # "# ; ! (N 3 (NY
Block CEB Plane !# ! & Block < % "# Z Height "# &
Best Fit CEB Plane < % F> > %W F W 3 %W =#& W Boundary
Projected CEB Plane ' XY Active Workplane < % "#%W F W Boundary
1. <! , Toolpath 3 Boundary "#! F>"( ;
2. ;k V=' > pockets.tri
3. Block Form Calculate
4. Tool 3 End Mill "#! Diameter 12 !!.
5. A( <!

6. User Defined Boundary 3 Model

7. Accept

10 7J Boundary S7:2,%8K [ o % 2%8K :?8

; :@ %8K @<]8

8. > "#$ q>"# W "'

9. # # !Y > "#
10. ! V WX! "#Y& > Models "# Explorer Plane Projected
 Lesson 14 Page 20 / 20

gJK/R o *,$2, ? 8 'H 2 Boundary

10>? % & '

*,$R J K\ Models *,$ Explorer 102,S2 7 J7@<28($ Plane >& H& ' R*J'@<& 7 2 %Z Mi2 K / K& Delete Model

" #$%&' 14.5

;k V mouse.tri 3 Surface `# W!$ W! #
 Lesson 15 page 1 / 16

15
Editing Toolpaths
PowerMILL save # Project
'( Pull Down Options Tools Toolpath

Auto Raise Machining Form Toolpath

! "##!$ # Toolpath %& Load )!*!+
,-." /.+ Auto Load -, -" +2

Auto Load # Toolpath %& 3*-4-5-#$ ! 56

Toolpath "7"89%& Load +-#- ! "#!$

Auto Select Toolpath $ :7". ;< 89%&

! "#!$

23 Toolpath 4 PowerMILL Explorer 74 8 9 :; <= > '( Active Toolpath

Edit 2 A BC 4D 2

Option Transfrom 'G H 8<I: 2J Mirror, Move 2 Rotate Toolpath 4

-5 Transform # 3 )@@3 Mirror, Move

) 9 Rotate.
 Lesson 15 page 2 / 16

15.1 Transfrom ! Mirror Example

-5 Mirror 3 -5 ,-/.+ $ ;$ !5 " +-# " Toolpath 8- B+- C" 2- .5 8- @" "C *- C"!+"
1. '( Pull Down File Delete All
2. '( Pull Down Tools Reset Form
3. R4 Project S wheel_cav
4. R4 V ; wheel_segment.tri
5. Active '( Toolpath 1

Toolpath
D +%& ;5+-
:7"#-
-5 -, ."
Block 8-
Picture
I
wheelsegment.pic
Toolpath "789%& Transfrom -5 Mirror 4 /I+/" -5 + 35: +
6. < 3 >3 Z
7. '( Toolpath Edit Transform
8. '( Transfrom Form Mirror 3 G 4 X , Y 3 Angle # 0

Plane 89); /.+ .K" 8 L-4 C" Plane /I+

/" -5 Mirror 3*- X ) 9 Y /" Form 89
,-." !,-)."* Plane /")"25-@ ) 93*-
Angle 89 ,-." #<# Plane 2 /"
O$ !- K#"-P$ -8- ) " X+

9. Apply
Toolpath /.#* & .# "2*-89/I+ -"D )+ !* D#*# -5!528; @
89 .K" 35 .#- ! /8/" 5 @;) ); /.+ .K"2*-325592

10. 4 :; <= > '( Active Toolpath Verify

 Lesson 15 page 3 / 16

5) 5#89@ 3<R2*- Tool $"I"I$7" -".5 D#*

11. Active Toolpath 1
12. Explorer Animate Fast
89 .K"2*- Tool 89 $"/" $O - Climb Milling ) 9 ,- @/" -5 $"3 8- +-"@" -";&* +-" *-
13. Active Toolpath 1_1 3 >3:4 2 49 Tool
89 .K"2*- Tool 89 $"/" $O - Conventional Milling )!* ,- @/" -5 $"3 8- +-"@" -";&* +-" *-
I*" 2 " "7"8,- C"89!+ ) D+ /.+ O$ - /" -5 $" C"D /" O$ - 2 "
14. 4 :; <= > '( Toolpath 1_1 Edit Reverse Direction
15. 3:4 2 49 Tool
Tool 89 $"/" O$ - Climb Milling
16. 'G 2 Mirror Toolpath 4 Toolpath 4 :>
17. 2> : c'9d' 49 Tool 3 > 2Dc ( J G #

15.2 Transfrom ! Move and Rotate Example

-5 Move 3 -5 -+ !,-)."* Toolpath ;*2" -5 Rotate 3 -5.#<" Toolpath D 5 @8< ,-." @"59"-@ XY
1. '( Pull Down File Delete All
2. R4 V ; handcav.cut
3. Active '( Toolpath handcav_cut_1

3<R;-#-5% Copy Toolpath "7D + -5 Move

4. '( Toolpath Edit Transfrom 3 Type G 4

# Move
5. G 2 H 2 8 '(8 X 160 Y0 Z0
 Lesson 15 page 4 / 16

# Form ,- ,- -" &*89 .K" & O5I7D O$ - ) 959 9 89 Move

D # ,-." Type C" Move 3*- XYZ 89 ,-." $O - ) 959 9 - /"
-5 3 " %+-D#* Delete Original 89 C" -5 Copy Toolpath
%+- Delete Original 89 C" -5 @ Toolpath $# $7 D

6. Apply 94 Toolpath 4D 2

89 $ Toolpath I handcav_cut_1_1 :7" ) 9

Transform Toolpath Form ,- -" &* ,-/.+3<R
;-#-5% Copy Toolpath D +
Toolpath ;-#-5%52# +- +2 "D +%+-/I+ Tool
# "- 2 ") 9/I+ Workplane 2 "

7. Active '( Toolpath S handcav_cut_1_1 3 > 4 =< Ctrl 8 >3 > Toolpath S
handcav_cut_1_1 >H Toolpath S handcav_cut_1
8. Active '( Toolpath S handcav_cut_1_1
9. Edir Transform 3 Type # Rotate
10. f 8 < 60 d 2 c <4 X0 Y0

89 .K" ;+"; ;+"; -2 ); %: 8< .#<") 9#<# .#<"D 3*- X ) 9 Y ,-." 8<
.#<" ) 93*- Angle ,-." #<# .#<"D 5 @8< .#<" 2 /" $O!-# K#"-P$ -8- ) " X+
11. Apply

12. 2> Toolpath handcav_cut_1_1_1 Dc Toolpath handcav_cut_1

 Lesson 15 page 5 / 16

15.3 Limiting
8<I: 2J G D4c29 >I Toolpath 474 HS Plane, Polygon 3 Boundary
Limiting to a Plane
HS Plane H 2 G 4D c29 >I Toolpath Plane '(HSH 2 Limit G 4 # X-Plane, Y-Plane
2 Z-Plane 3 G 3 Plane DC

X Plane Y Plane Z Plane

2 G 4 Plane 74 HS Option Arbitrary 74 2G 4 <4 Origin 3 '9d' Normal Vector

Plane CD 4> 8 XYZ
Limiting to a Polygon
HS Polygon H 2 G 4D c29 >I Toolpath Polygon : 2J Sketch BC 74 HS Mouse 4'G H
: 2J:2 Boundary '(mDcm 4
Limiting to a Boundary
HS Boundary H 2 G 4D c29 >I Toolpath
15.4 Limiting to a Plane
1. '( Pull Down File Delete All
2. '( Pull Down Tools Reset Form
3. R4 V ; radknob.dmt
4. 4R Block Form Calculate
5. :2 Tool Ball Nose '( ( Diameter 6 S bn6
6. :2 Toolpath 3cc Constant Z 4> 8 Tolerance 0.1 Thickness 0 8 Stepdown 1 . G 4
'9d' # Climb 3 Links G 4 # On Surface

7. '( Toolpath Edit Limit Plane

 Lesson 15 page 6 / 16

8. f 8 2 3 D Apply

89 5- ^5& Plane ) 9 & O5); $O - +-" 89 . Toolpath D2+

9. ( Option Save # Inner

10. ( Option Save # Outer Apply

Tollpath 89%& ;5+- :7"#I 2*- 1_1 ) 9%& ! "#!$%+-

save 7 Inner ) 9 Outer 89 $ Toolpath I 1_1 ) 9 1_2

# 3<R Limit Toolpath 89 ,-/.+ Toolpath 8< %&

Limits 8,- C" 89!+ ,-." 3*-/" Lead and Links 4 I #!*
;*2"!*- a
11. ( Links # Lead and Links On Surface 3 Apply
15.5 Limiting to a Polygon
1. '( Pull Down File Delete All
2. '( Pull Down Tools Reset Form
3. R4 V ; D> handle.tri
4. R4 Block Form Calculate 3 2 c >D 15 .
5. :2 Model Plane 74 HS Block '(8 Z 0
6. :2 Tool End Mill '( ( Diameter 10
7. :2 Shallow Boundary '( Upper Angle 0
8. > 2 2'DC : 3 > c:> '( H 3 > 2 '( o '(:<4
9. :2 Toolpath 3cc 3D Offset (8 Stepover ' Dc 1 Spiral 3 Climb
10. < View Z
11. '( Toolpath Edit Limit Limit to Polygon
 Lesson 15 page 7 / 16

12. Sketch 2 Polygon 2c < 2 74 HS :; <= m 4D 2

5& . - . #!+ C"2

13. Inner 3 > Apply

Toolpath H J :2 BC (S > 1_1
%+- Delete Original " Toolpath /.#*%& ;5+- :7" Toolpath /.#*89%& @ $7 D
14. R4 Leads and Links Form
15. '( D> Lead in 3 1st Choice # Ramp
16. Option Add Leads to Short Links '( < m Form
17. =< Ramp Options 3 f 8 H Form 4D 2
18. 3 > Accept
19. Apply 3 Accept '( Leads and Links Form

Toolpath 89 +- -" +2 -5 $")@@ Helical B: 89

# 59 I"6/" -" )@@ High Speed ) 989 "C
Toolpath /I+ -, -")@@ Helical Drilling

15.6 Limiting to a Boundary

11. '( Pull Down File Delete All
12. R4 V ; handset.tri
13. R4 Block Form Calculate
14. :2 Tool Ball Nose '( ( Diameter 10
15. :2 Toolpath 3cc Raster Finishing, Two Way Joined, Stepdown 2 . , < 49 D4 0 d , G 4
Perpendicular Pass
 Lesson 15 page 8 / 16

Toolpath %& ;5+- :7"#- ,- -" @

# 7 .# 3<R!+ -5 Limit
Toolpath
+2 Boundary

16. ( S Toolpath # raster1 3 > Active Toolpath (C

17. Split Surface 3 :2 Boundary Surface (C
18. c Boundary 2 c '9C H 4D 2

19. Active Toolpath '(S raster1

20. Edit Boundary
21. f 8 2 3 > 4 Apply

45-9 Option Save ,-." C" Both -, /.+ Toolpath 2

I< %& ;5+- :7"#-I< )5 3 Toolpath $ :7""
Boundary ) 9 I< ; 3 Toolpath $ :7"L- /"
Boundary

22. 3:4 Toolpath H o 'DC 44D 2

 Lesson 15 page 9 / 16

Option Keep -, /.+3<R;-#-5%;5+- Toopath /.+ L&* - " .5 L- /" Boundary ) 9%+- Delete
Original %& ,-." Toolpath C"!+"e@@89%& @ 7$ D )!*%+- Delete Original D#*%& ,-." Toolpath C"
!+"e@@89 3 &*Toolpath $ :7"" Boundary 89 ,- -"/";*2" C"f$2 5 @ 2*-)!*@5 2R Toolpath
%& Limit 89 ,-/.+ Tool :7" ." Boundary -5 Reorder B: -889 ,-." /.+ Fixed Direction .5 Free
Direction 89;-#-5%I*2 59 9 - /" -5 3 " Tool 52# 7 -5 ,-." Links /.+ C" Onsurface +2
23. Active Toolpath S Raster1_2
24. Edit Reorder Free Direction
25. R4 Form Leads and Links 3 G 4H Links # On Surface
26. Apply 3 Accept

27. Active Toolpath S Raster1_1

28. R4 Form Leads and Links 3 G 4H Links # On Surface
29. Apply 3 Accept

8,-"2" -5 Tool Toolpath 7 ; 89 4 2 -/" -5 ,- -"

 Lesson 15 page 10 / 16

15.7 Edit ! Divide Example

Toolpath : 2JJ 3 # :> 4 S :> '( D4 rs 49 D4 BC 4( > 2 4( > 2
49 2 c 4( >
1. c'DC 43 Reset Form 'DC 4 3 > R4 V ; D> S chamber.tri
2. R4 Block 3 Calculate
3. :2 Tool Ball Nose '( ( Diameter 12 .
4. :2 Toolpath 3cc Raster Finishing G 48 Stepover ' Dc 5 . < H 2 49 D4 0 d
G 4 Perpendicular Pass set 3 G 4 Style # One Way
5. ( S Toolpath # raster

Toolpath 5& ); /.+ .K" D#*); -5 Links

%+-3<R ,- -5); -5 $" Tool 3<R89 .K"2*- Tool 89#
-5 $" :7") 9 $"

/" -5)@* Toolpath )@* 8- $O - -5 $"89)

Toolpath # O$ - /" -5 $" :7" 8-
Toolpath # O$ - /" -5 "$
6. Active Toolpath S raster
7. Edit Divide o Divide Toolpath Form D> Direction 3 f 8 4D
2

Option Subtract 89) Toolpath # O$ - -5 $" :7",

.5 5-@ 8- "
Option Save 89 K@ Toolpath ;*2" -, ." -D2+ Subtract
3 + -, ." /" Subtract
Remainder K@ Toolpath /";*2" D#*/I* ,-." D2+/"
Subtract ;*2" Both 89 K@ -D2+ 7 .# )!*) C";
Toolpath

-5 3 " 89% 2*- C" Flat (5-@) 3 -5 3 " @"47" -, #<# @59"-@ XY D#* $"3*- Flat Angle
3*- Remove Segments smaller than 89) ;*2" # "- K $7 D
8. Apply
 Lesson 15 page 11 / 16

raster_1
(Tool cuts upwards)
Toolpath 2 I< 89%& ;5+-
:7"I raster_1 ) 9
raster_2 45-9 ,-." Save
C" both 5&

raster_2
(Tool cuts down and flat)

45-9 Subtract %& ,-." C" Up "7" Toolpath I< )5 89 C" Toolpath # O$ - -5 "$ :7"
3 Raster_1 ) 9 Toolpath I< .": 89 C" Toolpath # $O - -5 $" ) 9 $"5-@3 raster_2
9. 3:4 2 49 Toolpath raster_1 3 raster_2
@ $O - Toolpath
10. Active Toolpath raster_1 3 > Edit Reverse Direction
11. 3:4 2 49 Tool s H 3 H > Toolpath ( '9d' 49
12. Active Toolpath raster_2 3 G 2> Dc Toolpath raster_1

Toolpath $ 8- -552# " Tooplath

7 ; 89 & .# " @ Toolpath $ :7"/"
357 )5
)!* Toolpath /.#*"789# O$ - -5 $" .5
$"5-@ -* "7"

15.7 Changing the Order of a Toolpath

Tolpath J 3c # :> 3 S D 4> Links G 4Dc 3 :> : 2J
( 3 4 D> S J H 2'G 29 '(:> S9C 74 49 H '9d' BC c
2 : 2J ( H 29 'G '(4 c 3 > 49 H '9d' '( 74 '('9d' H 2 49
Tool ( 3
Option '(HS8 Fixed Direction 3 Free Direction
Fixed Direction 78 9:; <=>7:? Tool 8 > 49
Free Direction Toolpath (2 ' '(:DC '(:<4
2 Reorder Toolpath 'G H 2 S 2 > :> # 4> 2 ' '(:DC '(:<4
 Lesson 15 page 12 / 16

30. c Toolpath '9C 'DC 4

31. ( 8 Block H Min Z # t5 3 Max Z # 25
32. :2 Tool Ball Nose '( ( Diameter 8
33. :2 Shallow Boundary 74 G 4H Upper 3 Lower Angle # 0
34. c Boundary :> '( 4

Delete this segment

:2 3D Offset Finishing Toolpath 4> Stepover 3 .

Toolpath 5$#!+"8- -+ " *- I$7" -" $" :7" -+ @"

# ); -5 $" Tool 89 .K" Tool "$ /" $O!-#
K#"-P$ -

35. 3:4 2 49 Tool

-5 $" -"/" lR9"789 ,-/.+ Tool -" +2 59 932-# : #- 325 $" 8- @" *- #- 2*-
36. Edit Reverse Order
! ""7 ,- @ -5 $" Tool D + "D 3 $"8- @" *- )!* $"/" $O!-# K#"-P$ - .# " $#
15.8 Moving the Start Points
<4 29 Toolpath : 2J D G3 '( 2 4 74 2 G 4 : 2 u :> Toolpath DC
1. Active Toolpath 3 Edit Move Start Point
2. < View Z 3 f 8 4< : 4< '( G 4 # : 2 4D 2
3. 4 <= Enter '( Keyboard
8< 5$#!+" 7 .# 89 "D &*/")"2 ;+"!5 ,-." :7"
 Lesson 15 page 13 / 16

-5 " Start Point .#-9;,-.5@ -5. < -R6/" -58@ : !*- a .5 4 /.+;-#-5% &*/"
!,-)."* # .K"D + *-
15.9 Collision Checking
Collision Checker 2> 4> 4 Dc 2 4 Tool S S9C 2 2 Clearance
2 74 2> : c Toolpath '( Active
Toolpath J 2> : c3 sc> 94 2S BC PowerMILL 3c Toolpath # : :>
:> 32 # :> '( ( 2S :> '(: 8 :> '( ( 2S 3 4J 3 8> > Tool 74 D 7 D 9
s ( ( 2S
1. '( Pull Down File Delete All
2. '( Pull Down Tools Reset Form
3. R4 V ; chainsaw.ige
4. R4 Block Form Calculate
5. :2 Tool End Mill '( ( Diameter 16
6. :2 Toolpath 3cc Area Clearance 4> 8 Z Height '( ( Constant Stepdown 5 . Tolerance 0.1
Thickness 1.0 8 Stepdown 5 .
7. 8 Collision Checker
8. f 8 4D 2 3 > Apply

# !5284@ -5I" PowerMILL 89)"9",- "- .#-9;# Tool 4 . -5I"

 Lesson 15 page 14 / 16

9. OK
59 9 Overhang )"9",-89%& /;* +-D /.#* ! "#!$
10. Accept
Toolpath 89)@* C" 2 ;*2"

;*2" D#* $ -5I"

;*2" $ -5I")!*D +) +D /.#* "3*-32-# -2 Tool

Toolpath 7 ; ;*2"89 5- ^/" Explorer

Toolpath 1_2 ;-#-5%",-D 52# @ 1_1 ) +2 ,- -5!528; @ 357

Clearance 59 9 "+ ;< Tool Holder .5 Shank &*.*- 8- I$7" -"
Overlap 59 9 Toolpath ; ;*2"#-4@ " -5 ,-." /.+#3*- Overlap 4 D#*/.+@5$ 2R Toolpath
7 ; 4@ " $ C"5
Draw Collisions ); ;+" - $ -5I"
Draw Tool Holder / Shank ); /.+ .K" Tool Holder / Shank
Feeds and Speeds

Feed 3 Speed Toolpath : 2J ( 3 474 8 Feed Rate 3>

=< Apply to Active Toolpath
 Lesson 15 page 15 / 16

!528; @3*- Feed rate /I+ PowerMILL Explorer 894@2*-#3*- "D

Safe Z and Start Z Positions
Rapid Z heights ;,-.5@ Safe Z ) 9 Start Z ;,-.5@ Toolpath Active ;-#-5% ") D +
"3*-!*- a ) +2 <o# Apply to Active Toolpath

Editing Tool Datum Position

Datum .5 8< 5$#!+" Toolpath ;-#-5% ) D + I*" 2 "
 Lesson 15 page 16 / 16

15.9 Single Direction to Zig Zag

Toolpath '(:2 H 49 3cc'9d' 4( > : 2J3 H 49 3cc 2 '9d' 4 74 2HS Edit ZigZag
1. '( Pull Down File Delete All
2. '( Pull Down Tools Reset Form
3. R4 V ; handset.tri
4. R4 Block Form Calculate G 4 Min Z ' cD 0 3 Max Z ' Dc 37
5. :2 Tool Ball Nose '( ( Diameter 6
6. :2 Toolpath 3cc Raster Finishing 74 HS Style One Way HS8 Stepdown 3 . < 49 D4 90 d

8- -5 Link - )!* 9;*2"89 .K"2*- Tool $" /" $O - 2

7. 3:4 2 49 Tool 2o>
4 " C" -5 $" /" 2 O$ - < ;*2" Toolpath !+ @ O$ -
8. '( Toolpath Edit ZigZag
)!* 9;*2" Toolpath 89# $O - @D @#-

)#+2*- Tool 89 $" /" lR9 "$ 2 $O - @D @#-)!* -5 Tool #8,-"2"

#- &* 5-;-#-5%) +D D + /.+ -5 Link 3 " @" Surface
9. 8 Leads and Links 3
( Links # On Surfcae 3 >
Apply
89D + Toolpath ); 5&
 Lesson 16 page 1 / 11

16
Leads and Links
PowerMILL Toolpath " # $% #&' Tool " #(
Lead In +, Lead Out (#/ + / ,0#( (#/ Toolpath " #( Links /$%/ 4 "0+ "#&' 56
7 0/8 89/ Leads and Links Form

Lead Out Links

Approach move

Lead In

Retract move

Leads and Links + < / "=( Toolbar 8 /?/ 0 "=(9/ Finishing Form
 Lesson 16 page 2 / 11

Z Heights
Skim Plunge Toolpath ! "#$% Safe Z Start
Z& # '"! () ** +,
Skim distance - Tool " + ## . /* 0 -01 # Z
" '( $ , ."3 - # / * 0 1 ! #$% Skim
Plunge distance ,", + / Tool '(#$ .1 # Z " #8 *
Lead In/Lead out Moves
Lead In % ,"# - Tool " - #$ .1
Lead Out % ,"# - Tool " # # .1
Lead in "* .9 None, Vertical Arc, Horizontal Arc, Horizontal Arc Left, Horizontal Arc
Right, Extended Move, Boxed Ramp
Lead out &'()*+,)-./0-1)2*&34 Lead in 2&-*50 Ramp
Leads Links ! (@ #$ # - Tool ' ! "( +. 9. & 3! & (@ #$ # 3
# Gouge Check Toolpath Leads and Links Form' +" Lead I "J 8 * #. #
'"!/K#+ -01
16.1
1. +? %$ 0 8 +# CD8 E+FG$# "( H mouse.tri
2. CD8 Block Form + Calculate
3. Model Plane < Block Z 0
4. Tool Ball Nose Diameter 8
5. Toolpath ?? Raster Finishing 8#" ( Stepdown 4 . W 9/ 8&/ $8 0 X Two way
Joined
6. Toolpath \8" Limit 8#" Plane \8" ( X ( $? 74 +, Option / _ (G

Toolpath 1 1_1 #8 * * Lead In Lead

out () none

7. 8 FCW` # Toolpath +, + Edit Copy

8. Active Toolpath 1_1_1
 Lesson 16 page 3 / 11

Vertical Arcs
9. Toolpath Leads and Links Form + 0$# Lead In
10. + Vertical Arc $X 5 . W 90 X +# + Apply

Vertiacl Arcs Leads 8 *# - #$ " $#QR () () +! 3$1 " +$"J$+#$%

,# I / - Toopath
Tangent
Angle

Toolpath Radius
Segment
Lead

3 1 # Lead In " Vertical Arc #. -01

3! / - Toolpath

/ 3 # * Lead Out " $#QR ! #$%

Lead In *$ - Edit 8 * ,R+ " Copy
,# ! #8 * Lead In '( Lead Out

11. + 0$# Lead Out

12. + Edit Paste Lead In Lead Out
 Lesson 16 page 4 / 11

13. + Apply

Horizontal Arc
8 *# Leads " $#QR () +! % # #8 * ! $V" "," 8 ! #$% Vertical
Arc .9 1 +8 * $% Toolpath %% Constant Z "# ( ! Z Height I

Tangent
Angle

Toolpath Radius
Segment
Lead

14. C+"/ Lead Out Cg/ None

15. C+"/ Lead In Cg/ Horizontal Arc $X 5 . W 8&/ $8 90 X +# + Apply
 Lesson 16 page 5 / 11

* ! " Horizontal Arc #. -01 3!+8 * $% / "# #. Horizontal Arc Left Z0 ()

J ## # Gouge Check
16. C+"/ Lead In 90 Cg/ Horizontal Arc Left 7 90 (#/\ X& #/ C 5 " +# + Apply

17. C+"/ Lead In Cg/ Horizontal Arc Right 7 90 (#/\ X& #/ C # +# + Apply

<, 04/#( 2 # Toolpath ( &8

(#/\ 6%/ / < \C G #<
k? H/ 6%/

18. ( + Gouge Check +# + Apply

+ ** ! # # Gouge Check () +. +8 $[ (@ #$ '"! * Tool .1

19. + Gouge Check
 Lesson 16 page 6 / 11

Extended Move
9H 7 0 $? k& + / 9/ /# /G 9/ + / 0 \8" $ m$ $? /# + /
8& \8" ,", 9/ + / 909 (9/H( Distance
Lead Out tangential to toolpath

Distance

Distance

Lead In tangential to toolpath

20. C+"/ Lead In Cg/ Extended Move \8"9H ,", 8$ =C

Lead In - 3! / - Toolpath /K# #'- *"! $ K(

Boxed and Straight

Boxed +8 * $% &."# + 3 # -* # () + 3 K!
% ! 1$ # * +! ! Distance +! Straight +8 * $% &."#
+ 3 # -* # 8 ","3 " #8 *
 Lesson 16 page 7 / 11

21. Toolpath \8" Limit 8#" Plane 8#" ( X ( ?$ 12 +, Save Outer

22. C+"/ Lead In Cg/ Boxed +# + Apply

Boxed Leads '"! #. -01 % . R Toolpath % #"# #. -01

23. 7 0 $? Lead in 2nd Choice + Vertical Arc X$ 3 . +, 7 W 90 X
24. Lead out + Extended Move 10
25. + Apply

Ramp
# - - Tool " 3 %% Arc, line Profile
26. 7 0/890 Lead Out Cg/ None
27. + Lead In Cg/ Ramp +# + CW` Ramp Options

28. 7 0/8 ( 9/ Ramp Options 8$ 8 9/ =C +# + Accept

 Lesson 16 page 8 / 11

29. + Accept +, Apply

% . R "# '"! #. # Ramp $ K(

30. 8+ 7 0/8 ( Lead In Cg/ ?? / _ +# C "? "? # G G(

Extensions
# Toolpath #'( Toolpath # 1 $#QR +$"&$ 9b#$% K( ! - .1
*" #$% ! ' .1 #'( # Lead In / Lead Out 3! #$%+! #'( 1
31. Active Toolpath 1_1_1
32. 7 0/890 Lead In Cg/ Horizontal Arc Left $X 5 . W 45 X
33. 7 0/890 Lead Out Cg/ None
34. + 0$# Extensions 7 0/8 ( G _ G =C +# + Apply

35. 7 0/8 ( Extensions +$? Cg/ None

 Lesson 16 page 9 / 11

16.2 Links
# Link 8 *# - Tool - "'(" % .1 "( +. 9. &" #-01 Z0 # Link $1
"* .9 $ 1
Short/Long Threshold Short Links
/ # ( - Toolpath / * 0 '( $ , ."3 - Toolpath / 3! '( #. # !
Short/Long Threshold long Links
Short Links ' #$% Safe Z, Incremental, Skim, On Surface, Stepdown, Straight, Circular Arc, Tool
Axis, Tool Axis Safe Z
Long Links ' #$% Safe Z, Incremental, Skim, Tool Axis Tool Axis Safe Z
Safe Links ' #$% Safe Z, Incremental, Skim, Tool Axis, and Tool Axis Safe Z
1. Active Toolpath H 1_1
2. 7 0/8 Lead In +, Lead Out Cg/ None

Toolpath $ K( + # Link 1$ + %%
Short Link Long Link Z0 #
Link
Tool '( Safe Z

Incremental
3. 7 0/8 Short Cg/ Increment +, Plunge Distance ( ( $? 2

4. + Apply
 Lesson 16 page 10 / 11

/ # ( - Toolpath / * 0 '(
$ , ."3 - Toolpath / 3! '(38 # ! 10
"". Tool #'( Safe Z " +K - "
'( $ , ."3 - / 3! '( "
2 "". * " #$
" Plung Rate

Skim
5. 7 0/890 Option Short Cg/ Skim +, ( Skim Distance Cg/ 6 8$ =C +# + Apply

Short Links ( / - Toolpath Tool

" +K -01 '( # 6 "".
" +K - "'( $ , ."3 - / 3! '(
" 2 "". *
" #$ " Plunge rate

On Surface
6. 7 0/8 Option Short Cg/ On Surface +# + Apply
 Lesson 16 page 11 / 11

Stepdown
Tool () + 3 -01 '(3 " # Z () !* 0 '( $ , "3
.
- / 3! '( " $ .1
Straight
Tool () + 3 '( $ , ."3 - / 3! '(
Circular Arc
Tool () + #( - Toolpath / * 0 '( $ , ."3 - Toolpath / 3! '(
/ Leads Extensions 8 () 3 #8 * * Gouge Check
7. 7 0/8 Option Short Cg/ Circular Arc +# + Apply

Link " #$ QR () +! #. -01

#, / # % . R "#
 Lesson 17 Page 1 / 14

17
Patterns
Patterns 2D 3D Toolpath #$%&' '(
Toolpath Contour +,- ./ (' ( 012
1. 5 6.78 2 9:-; 2< Pattern 9:- Explorer #$2 $
Toolbar

2. $ @ ; Create Pattern #$% Empty Pattern - 1 +,- 0 C1- D< E @.@5

Pattern Active !" !"#

Pattern $% & '( ) * Option !&". )/ 0(

Automatic pattern generator (from existing pattern).

Insert file into active pattern (picture or dgk file).

Insert boundary into active pattern.

Insert active toolpath into active pattern.

Insert model edges into active pattern.

Insert sketch into active pattern.

17.1 Patterns With 3D Offset Machining

1. .F5@G$6D2' &< - speaker.dgk #$% $ 7 ISO3

$ %!A"!B . & 0( " & % *& Surface !&%/ Surface 0D .

% A A &(# )/
 Lesson 17 Page 2 / 14

2. $ Surface P5& (P5& Q.78 + & R% S Surface 9:- $ ./ : $ R Pulldown $ File

Delete Selected $ Surfcae C1- 5.78 Shift #$2 $ Surface & $1 $ 5.78 Ctrl
#$2 $ Surface
3. Tool Ball Nose Diameter 6 9:- : - 2< bn6
4. 5 Block P5& Min/Max Limits #$% 5 Start Point &<9-: Block Center

Pattern 0D $% & /E Toolpath % Sketch

5. $ @; Insert Sketch R Pattern Toolbar

/% G Pattern Sketcher Form B#I0 * *. 0 B !A % Sketch

Boundary . B. Snap Filter ) .) K anywhere

6. 9:- Tools Snap Filter @ < $ Anywhere

7. $ 9:$%R75 P 5$ C- 51 Profile 5' .

". M " & !A B $0D 0D N O

PKD $. )/ Pattern

8. $ Accept
B#I0 0(Q. & $0 B % &
9. Pattern ' <
 Lesson 17 Page 3 / 14

10. $ Surface 5 $< 9< 'd #$2 $ 9:-@ ; Model

11. @ <# 5 P 5$ C- 9:-R%@5 S Pattern @5 '5 R ,d #$2 $ 52& ( :- $:-& 5 6.87 2 9:- Pattern
& $ 2 9:- Explorer #$2 $ Edit Split Selected
12. $ #$%$( (5 ( #$%5 $ #D< (5 $<

13. # 5 S P 5$ C- R%5 Surface

14. $ Surface 9'd 5#$2 Boundary User Defined Model
15. $ 3D Offset R Finishing Form
16. $ Use Pattern #$% .$:-& Stepover ./ 1.5 #$2 $ Apply

Toolpath 0 % Tool /E B PKD

B % & Tool & Links "# & /E On
Surface

17. $ @ ; Leads and Links

18. $ ' 2 Linls #$% 5
Short Links ./ On Surface
 Lesson 17 Page 4 / 14

17.2 Patterns with 3D Offset Machining

Pattern 9:-R% R ( Surface P5& PS-Sketcher #$%&' . '(. 7 # @ Boundary
@552& PS-Sketcher ./ version C1 Qh PowerSHAPE 9:- :;2 Workplanes, Lines, Arcs,
Points #$%Curves #$% Composite Curves '( PowerMILL
1. $ File Delete All #$% Tools Reset Forms
2. .F5@G$6D2' &< - cowling.dgk
3. 5 Block P5& Min/Max Limits Tool Ball Nose Diameter 10 : - 2< bn10
4. Shallow Boundary P5& ;< 9:- : &<#$2
5. @ <# 5 S P 5$ C- R% S Boundary &< '5 R

6. Empty Pattern

7. ( Boundary ./ Pattern P5& $ @ ; Insert Boundary

8. @ < Active Boundary 1
Pattern $% & '( ". /E $ 3D ".$ % /E $ 2D )
9. 5 6.87 2 9:- Pattern 1 9:- Explorer $ Edit Flatten

/ D0 Pattern /E $ 2D PKD &. % P#D $ "%& $.B Q& )/

Pattern 0 $ B&/V $ & $ W'D&

" & ) /E $ B& $ B&
 Lesson 17 Page 5 / 14

10. 5 6.78 2 9:- Pattern 1 Explorer $ Insert PS-Sketcher /E % Load PS-Sketcher

PowerMILL Pattern Load /E .

PS-Sketcher Toolbar D0 . 0D" A N Option A & Option /E $0 $ & *& ) .)

11. $ 7 View Z
12. $ @ ; Line R Toolbar 5 ( #$2 $ @ ; Single Line
13. $ C- D1 < 2< 9'd 4 R755' .

14. $ @ ; Edit Toolbar #$% $ @ ; Interactively Limits Wireframes

#$% $ <2 9:-@ <D 91d @. $ 5' .

B& !(&$ & 0D K$ % %0 A) % * Option Bezier Curve * M 0D . Pattern

 Lesson 17 Page 6 / 14

A%# B^ D0 /E % ! &$.B & Pattern

15. $ @ ; Curve #$% $ Option Bezier Curve

16. 5 .6 78 + & R75P5& $ R759:- &< <2 Pattern 5' .

" & *QB * _ % K M ". & O PKD

#
$ 0D %0 A

17. $ D< - ' @.R ; ( ( 5'( (1d$;$1 9:-R75# C- 1d 75 Curve

18. < 5:&2 ' '( Pattern 2 57

$ # !( &$ &" & A #( &

)/

19. $ 51 9'd 52& 6.78 + &#$2 5.78 Delete 9:- Keyboard

PKD $ . 0( *" & !D B. $ /E AA". KD & ! !& !( '&QB% /E Composite Curve /E AA/V

20. $ @ ; Curve
21. $ Option Composite Curve

/% G Toolbar !&%/

22. $ 9:- 5 S@59:- ( . :- $:-& 5

PS-Sketcher begins to trace around the edge in orange, but will stop if it comes to a choice
of where to go and will highlight the choices with an arrow. The paths will also be highlighted in pink. When the curve has traced all the
way round the segment a blue circle at the start point will appear to confirm this.
 Lesson 17 Page 7 / 14

23. Save . Composite Curve 52&.78 Save

24. Composite Curve '( 9:- $

25. $ .78 Eject C- .F5 Toolbar

26. 9:- Pulldown $ File Close and Return to PowerMILL

/% G QB B. Pattern ) Update B
27. $ Accept

Pattern N /E 2D ".$ % $. !AQK

)/ )

28. 5 6.78 2 9:- Pattern 1 Explorer $ Edit Drop Pattern $. !A )/

N /E $ 3D
29. User Defined Boundary P5& Option Insert Pattern
30. Toolpath #(( Constant Z Finishing P5& ;< 9:- 5@2#$2#D< Boundary Trimming $
Keep Outside
31. 3D Offset Finishing P5& ;< 9:- 5@2#$2#D< Toolpath &< Boundary Toolpath (0
) . $ & Leads and Links
 Lesson 17 Page 8 / 14

17.3 Autometic Patterns Generator

Pattern 9:-R% <@5P5& 'DP 'D1R Pattern
9:- : &< 1 2 Pattern
19. $ File Delete All #$% Tools Reset Forms
20. .F5@G$6D2' &< - phone.dgk
21. Pattern 9:-&' @ < : $ 5 E &<
22. $ <2 5 ( 75 P 5$
23. <2 P 5$9:- $ @.@2 Active Pattern P5& $

@; Insert Model into Active Pattern

24. $ <2 9:- &<$< 75 Pattern

25. $ @ ; Automatic Pattern R%. r Form 5' .

26. .s ;< D< E $ Form 5' .#$2 $ Apply

 Lesson 17 Page 9 / 14

/E % P#D $.B & Pattern )/ Pattern # N B. 0

A &$.B 0D" & A #(&)/

27. Zoom S 5' .

28. $ 2< 9:-D $(#$2 5.78 Delete
Alternatively, the pattern could be copied and then automatic patterns can be
generated on the copy leaving the original intact, if it was required for further work.
29. 5 Block P5& Min/Max Limits
30. Tool Ball Nose Diameter 6
31. $ @ ; Finishing #$2 $ Pattern Strategy
32. 9:- Pattern $ Pattern 1

Pattern
%K *KD & Pattern
Drop Pattern When Machining
Pattern Project &A PKD $% & Toolpath $ %!A Tool D0 Active Q. Thickness 0D
33. '- R2< $ Pattern & $ 1 #$% $ Drop Pattern When Machining
34. $ Apply #$% Accept
 Lesson 17 Page 10 / 14

Pattern 0D A Project &A PKD

$% & Toolpath !&%/ Toolpath 0D N ) . $ &
Leads and Links

35. $( Toolpath 1 R Explorer

36. $ <2 5 ( 9:- ./ 01 ( P 5$#$2 Pattern R P 5$
37. $ $'
38. R .6 78 9:- $ Instrument

e% $ &B. Curve (&! $ & 0 #e &$B !

39. $ Curve 5 ,-
40. 5 6.78 2 $ Edit Reverse Selected Segment
41. $ Curve 9'd
42. $ Autometic Pattern #$% .s ;< D .

43. $ Apply C- Pattern

 Lesson 17 Page 11 / 14

44. Toolpath #(( Finishing P5& Pattern Strategy #$% $ Drop Pattern When Machining
17.4 Trochoidal Patterns Generator
Trochoidal Pattern ./ Option 9:- &<t & Automatic Pattern Maker Form ./ 9; 1; '( '5
#(( High Speed #$% < Slot
21u: :d & , ;7v Tool 9:- : 5 $S 2< < Slot #$%D '5 $' hv%9:- ./ #((C1 Qh
; : 51 #(( Spiral Stepover 9 @ < :.x w - %( &;2
1. $(9'd 5#$2 .F5@G$6 dashboard.dgk

0(QK %/ Slot D0 ! B B#I0 Trochoidal Pattern

2. 5 Block P5& Min/Max Limits

3. Empty Pattern #$% Insert 52&@G$6 trochoidal_pattern.pic
. % ! Slot " & % % $0 . 0 Diameter 8 PKD # *. &B. &
PKD Tool 6 . $ % &)/ K( & ) W'D& % * Feature Set
4. Tool Ball Nose Diameter 6
5. 5 6.78 2 9:-; 2< Feature Sets 9:- Explorer #$% $ Create Feature Set #$%;$1 9:- ; - &
(2 Explorer C- 5 Feature <
6. $ <2 Pattern 52& 6.87 + &#$%$ ( :- $:-& ; (R75.$ &5' .

7. 5 6.78 2 9:-; 2< Feature Set 1 $ Edit Create Feature

 Lesson 17 Page 12 / 14

8. .s ;< D< E Form 5' .

Feature $% & '( !& !( $ % $% & Helical Toolpath )

9. $ @ ; Drilling R%. z Drilling Form 5' .

10. .s ;< D< E D .#$2 $ Apply C- Toolpath

Toolpath 0D # '( # #e B N h# PKD %! i #e & & % ! /E Climb $% &% 8.5 .
PKD Tool 0D N B. $ % &)/) # ! ! i^ Trochoidal Millimg ". )/ Feature Sets ) . 0 %
"%B $ A %* !& (! &$% & . &% ! % B!&
11. Tool End Mill 5 Diameter 6 .
12. @ < Active Pattern 1 ( trochoid_curve) #D<# 5 S ( ;$1 9:-52 @GR% ./ : :&2)
13. Empty Pattern (2)

14. $ Curve Pattern (1) #$% $ @ ; Automatic Pattern Genertion

 Lesson 17 Page 13 / 14

15. .s ;< From D .#$2 $ Apply #$% Accept

QB B & &%. & Solt ) . 0D B & !A & Tool Q. %!e 0$&$M QB% /E Q%'D& D0& &
QB B. & &%. & Slot Q. Stepover O !A % ! B!$ M N&

%!e 0 /E 2.5 Pattern 0 ! i^ !&%/ W'D&%/ AA &

Pattern (&! $ & *& ) *. !

16. .F5 Finishing Form #$% $ Strategy Pattern

 Lesson 17 Page 14 / 14

17. '- R2< Pattern 2 @5 $ #$%@ < $ Drop Pattern When Machining
Toolpath 0D$% & Trochoidal Pattern 0D) . 0 % Drop Pattern When Machining "%B $ A %* B
Leads and Links
Drop Pattern When Machining *"%B $ A %* Toolpath N .k " Pattern ) . 0 %* ".
Toolpath N .A Pattern 0 %* # '(
18. $ Apply #$% Accept

KD & Pattern ) . 0QB D0 B & !A

& Tool
!& !( %$% & Toolpath " & 0 %* *
%!e 0 & Tool B

19. D 2R ( Toolpath 9'd 52& ViewMILL

 Lesson 18 Page 1 / 13

18
2D Machining
2D Machining 2 3 ! " # $%& ' ( () Z ! +) ,
Feature 2, ) & )3 45 Toolpath ':
Feature
2 ;) ) 2 (< )# : Pocket , Slot , Boss # C2 Hole
Area Clearance (2D Machining Strategies)
C! 2 Feature 3 (< ;$2 Area Clearance Strategy ;)45 # H) (HH 2 D )
) ):#+ H, ) ):(HH),2 I 3 (< ) ):I 3
Drilling
45 Feature Created Form (< 4# )< )< + ) H2) 45 Option Drilling ':M:+
3 (HH"C2 Drilling, Boring (< Helical Milling
Features
(H, 22) 6 5 :"C2
1. Pocket "C2#< Tool : ):Q +4 #< , &
2. Boss "C2( , ! & $%& Tool : ): 2H R Boss , &
3. Slot #< ! $ : <3)(< ("H 45 Tool : ):':4 ) : S+ !+ :+
4. Hole "C2 ; ! 2 ) M:+45 , M:+ , "<C!2 !$%& < Q +4 ; , & ) # : ) : ,
)< # C2 Curve
5. Circular Pocket #< ! ; , ) H2) ) # : ) : , )< # C2 Curve
6. Circular Boss ( , ! ; , ) H2)) # : ) : , )< # C2 Curve
"#$%&'() 18.1 Feature Generation
) Drawing !( : : ;
 Lesson 18 Page 2 / 13

1. <H & # :(< Reset Form

2. Y:'Z<[ PM_holes.dgk

3. Feature Set ) Explorer

Feature 1
4. <!+ 5C!2 Feature set Location_plate
5. Feature Set $%& 2)(< & 5C!2 , Hole_recess

6. Active Feature set 5C!2 Location_plate ): [ ` $ (< <C2) Edit Create Feature
 Lesson 18 Page 3 / 13

7. ): ` Shift " ' (< <C2) & ! ! ) 2H 2) ! <C2) #<C2 (< c2 ", ,
R ;

8. <C2) Apply SC!2 Boss Feature ! 5C!2 +) , base-plate_1

9. <C2) )< ! Diameter 18 .
10. c2 ", , R : ; (< & 5C!2 , location_holes

11. <C2) Apply SC!2 location_holes_1 (< location_holes_2

 Lesson 18 Page 4 / 13

12. <C2) )< ! I, i; +[)< 10 .

13. c2 ", , R ; (< & 5C!2 , Fixing_holes (< <C2) Apply (< Close

! Hole Feature % & 24 ) *+ + Fixing_holes_1 Fixing_holes_24

14. Active Feature Set 5C!2 Hole_recess 4 Explorer
15. <C2) Edit Create Feature
16. <C2) )< ! I, i; +[)< 40 . (< Feature Set ;

17. <C2) Apply (< Close

3 + Feature Set 5 +67 689&: ; ! Toolpath % )7 2D Machining
) PowerMILL Explorer ! 2H$2 <; $2 Feature Set M:+< 2+:
 Lesson 18 Page 5 / 13

"#$%&'() 18.2 Area Clearance ( 2D Machining Strategies )

)A Model Feature % ! : Slice % )7 Feature Slice : Area
Clearance * )
1. Active Feature Set 5C!2 Location_Plate ) explorer
2. " k Block (HH Min/Max Limits <!+ Type Feature

3. Tool End Mill I, i; +[)< 14 .

4. Reset Safe Heights (< Tool Start Point Block Center
5. Y: Area Clearance Form (< Z Height ! 20.5

)AE 6 Location_holes *) GA6 9 ;& 0.5 .

6. Y: Z Heights Form (< <C2)'2"2 Slice Generation

7. <C2)# $2 Feature Set (< <C2) Accept

8. 4 Area Clearance Form ) # : Strategy Offset , Cut Direction Climb , Stepover 5
, Thickness 0.5 (< Lead In Move ) # : Ramp ! Option ) # : Zig (< Angle
, )H 5 (< Follow <C2) Profile
 Lesson 18 Page 6 / 13

9. <C2) Apply (< Accept

10. <!+ 5C!2 Toolpath Rough_loc_holes (< :;I< ) Viewmill

11. :Y Area Clearance Form 2)" & <H Z Height ! 20.5 (< 4# , ! + 20.0
12. <!+ Thickness 0 <C2) Apply (< Accept
13. <!+ 5C!2 Toolpath Finish_loc_holes (< :;I< ) Viewmill
"#$%&'() 18.3 Drilling
Drilling Cycle ;) $%& M:+45 Feature ! ' (< Surface # C2 Solid Model 4 ; $2
dgk ;) $ 4 PowerMILL "k ! 45'2"2 Create Feature !: # $2 Drilling Form SC!2
Drilling Feature M:+2 M ; !< ;# C2 )<, R ':

1. Tool (HH Drill $ : 5 .

2. <C2)'2"2 Drill
3. c2 ", , R 4 Form : ;

4. <C2)# $2 Order

5. <C2) Option Shortest Path (< <C2) Apply

+ K& L : & A A & 95 & A Feature
 Lesson 18 Page 7 / 13

6. <C2) Accept (< Y: Form

7. <!+ 5C!2 Toolpath Center_drill (< ( : ) : $2 Tool : + Viewmill

8. Tool (HH Drill $ : 5 . <C2)'2"2 Drill

9. 2c ", , R 4 Form : ;

10. <C2) Accept (< Y: Form

11. <!+ 5C!2 Toolpath Finish_drill (< ( : ) : $2 Tool : + Viewmill
 Lesson 18 Page 8 / 13

"#$%&'() 18.4 Helical Milling

4#"k ! 45 Tool $ : <3)" ;$ :4#o,':M:+ 4 ( () Z ( ," ! 45
Tool ! $ : 60% - 90% $2 I,i; +[)< ; Tool <3)) , " %! # !% $2 ; 2 ) ! )< ;),2
q) & # )H High Speed Milling
1. Active Feature Set 5C!2 Hole_recess ) Explorer ( Active Feature 2 #3 , (< Feature !' ,
Active #3 )
2. Tool End Mill I, i; +[)< 30 .
3. Y: Drilling Form (< c2 ", , R : ;

&"C2 : ! $2 Toolpath

&"C2 + Picth C!2 ) (HH Helical Milling

4. <C2) Apply (< Close

) : K9 *+ Tool 5 & Tool K9 *+

*MN* Climb Milling 89 *+ A)79 QA AM !
Sprial QAN 6R 9

5. <!+ 5C!2 Toolpath Helical_mill_recess (< :;I< ) Viewmill

 Lesson 18 Page 9 / 13

6. Save Project 4 5C!2 C:\Temp\2D_Machining

Try out some of the remaining Drilling options on the 10mm diameter features
created earlier along with the order in which they are drilled.

"#$%&'() 18.5 Car Dashboard Examples

1. <H & & # :(< Y:'Z<[ dash_wire.dgk
 Lesson 18 Page 10 / 13

2. Feature Set 4# , (< <!+ 5C!2 Underside

3. <C2) , ! Outer Wall
4. Boss Feature $2 Outer Wall : ;

5. <C2) , ! Inner Wall Pocket Feature : ;

6. <C2) , ! Lamp Base Boss Feature : ;

7. <C2) , ! Four Lugs Boss Feature : ;

 Lesson 18 Page 11 / 13

Four new Bosses have been created called lugs_1 to lugs_4.

8. <C2) )< ! !
9. Hole Feature : ;

The Feature Set is now completed and is now ready for toolpath generation.
10. :Y Feature Form
11. Tool End Mill $ : 10 .
12. ) # : Block M:+45 Feature Limits ) Lock ", Z (< $+ + Block 4 ( () X (< Y
+ 15 .
 Lesson 18 Page 12 / 13

13. Reset ", Safe Z heights (< ) # :", Tool Start Point Center of the Block
14. 45 Area Clearance ) # : Z Heights !", Stepdown 5 . (< :Y Form

15. <C2)'2"2 Slice Generation (< <C2) !# $2 Feature Set

16. <C2) Accept
17. c2 ", , R ;

18. <C2) Apply (< Accept

19. ( : ) : $2 Tool

20. Tool (HH Twist Drill $ : 4 . + 40 .

21. <C2)'2"2 Drilling
22. <C2) Hole Feature & ! (< ) # :", , R ; (< <C2) Apply
 Lesson 18 Page 13 / 13

23. ( : ) : $2 Tool

The machining is now completed.

 Lesson 19 Page 1 / 5

19
NC Programs
Toolpath ! "#$ #"%&' ' ( )$ * ) $ &'
NC Code / 0 &1 %" CNC !2 0
CNC $3 Tool 0#4#3 "!4 "!5 #" " Toolpath *&1 Tool !2 # "
# 3 " 0# NC Program #3 " )!2 CNC 0 2 $3 Tool 0#4#3 "!4 "!5 Toolpath
*&1 Tool # #3 " *2 " * # 3 " 0#
19.1 Output Area
1. $%*" ' #
2. =#0>$? Project 1 Tapefile1
3. Toolbar * 32# % $ Tools Customise Paths )$( $ NC Program Output

4. $ 0 Folder ( K Select Path Form $ C:\Ncprog )$ =# Form Directory *1 Ncprog !

5Q( " (0 2 Output NC program File 0#
19.2 Setting Preferences
1. * Explorer # T UV * 2 NC Program Preferences
 Lesson 19 Page 2 / 5

2. $ *0 Folder ( K Select Machine option Filename Form

Option File CNC "# $

3. $ heid.opt )$ $ Accept
19.3 Creating the NC Program
1. * Explorer # ? UV * 2 NC Program

2. !" 1 2 Job_646_top )$( $ ' 3 3

3. * Explorer $5 * % '$3 * ' 3 +/- ' 2 NC Program ( '` 2 Job_646_top a

NC program * Active * Toolpath & 20 0#
 Lesson 19 Page 3 / 5

4. $5 * 0 Area Clearance # ? VU a 3* 2 Roughing_16 )$ $ 0 & 20 & NC program *

Active ( Job_646_top ) $5 * % '$3 * ' 3 +/- ' 2 Job_646_top ( '` 2
Roughing_16

5. * Explorer $5 * % '$3 * ' 3 + ' NC Program * ( '` Toolpath *" ' #

* & 2 0 3 $ #"% " 0
6. # ? UV * NC program * Active ( Job_646_top ) )$ $ Write / NC File `%0 & Disk
)$(0 ( 3

Toolpath ( "#)*$ +, - $ )*$ + ./ NC program "# Active 6(7- 6 8 9

7. $ File Example =#0>$?1 Handset.tri
8. Toolpath )%% 3D Offset 4#3&1 Tool 10_B )$( Stepover *2 %" 1
 Lesson 19 Page 4 / 5

Toolpath ./-7* Job_646_top ? @ A +- .-B- Job_646_top / #7 ./ C,# - "

$ Write /E NC File 8-$B ? - $ Write ?7$--$8 6(7 FG .8 A8$ Toolpath -H#
9. / * ()3 Toolpath Q/ ( " & 2 Toolpath Active 32 # ? VU * 2 Toolpath
)$ $ Create Individual NC Programs

10. NC Program &' 2 $5 * % '$3 * ' 3 + ( '` 5 * 32

11. # ? U * NC program * Active ( Job_646_top ) $ Rename )$ $3 1
Job_646_top_mod " # ? U " ' )$ $ Write
 Lesson 19 Page 5 / 5

19.4 Viewing and Editing NC Code

NC Program ( `% 0 & Disk a * ( =# 2 0#4#3&1 Text Editor
*" ) 0 & 2 *! 0#
1. Windows Explorer 0 * C:\NCProg #"% %5$ $5 *1 NC File ( '` NC Code 32&
Wordepad
$" qr( $ 3#" *) #
 Lesson 20 Page 1 / 12

20
Customising PowerMILL
User PowerMILL !"#$ %& ! ' !("
Project Templates
%&)* + , * + -. ! /& ! ' / 0 !$ 1 & Project + . 5 ) 6!7& 68 Template >1 &?
! #$ Insert Template Objects & , 7$ $C " ? %& ) & Template )* + , /.
) D /&$ / > -DE) 6 Template )* + , ,, Conventional )* + , ) D ! ' Mild Steel
Templare $# )* + , ,, High Speed )* + ,!+ N %D, 7N ) -DE) 6! N,1 & template -#$
1. Tools * + .D 7$ Tool Parameter ! 7&$ )* + , ) D+ #$!- #$ /. %
2. Workplane D. / 0 7$ Workplane
3. Levels D. / 0 7$ level
4. NC Preferences * + -. !,#>$ /& Preference )* + , !- #$ *+
#$%&'()* 20.1 Creating a Template
1. , >+ Reset Form > +
2. ) & Tool End Mill 7 16 . 12 . Tool Ball Nose 7 10 . 8 .
3. ) & Workplane /> %#$ . Datum
4. ) & Level %#$ Cavity Core

Level !
"# $ "%& ' () * (
Level Option Acquire Selected ! #%& $
Level 8 ' )9 Core ' Cavity

Level % $ " Level ( )9 off

%$ '"# Machine
5. ! )c Dd 7 -* . NC Programs Explorer ! #$ Create NC Program

6. " "c-* . JB1001-M/C1 Form & ! #$ !- #$ + 6i )!7

7. ! )ck Dd 7 -* . JB1001-M/C1 Explorer & ! #$ Parameters
 Lesson 20 Page 2 / 12

8. $l -. Form / i & ! #$ Accept

9. ) & NC Program $ + . %#$ . JB1001-M/C2
10. * + -. Parameters 1o c Fanuc6m.opt ) /. -DE/&$ & ! #$ Accept

& NC Program # $ Tools, Workplane ' Level

""# !I$ ' Save * ( )9 Template Object

11. Pull Down ! i ! #$ Save Template Objects

12. Save ! ' Template ! N,1 & %#$ My_Template C:\Temp

13. ! #$ File Delete All
 Lesson 20 Page 3 / 12

! # Project Template % ( 8 Insert %& Pull Down #

14. ! #$ Insert template Objects

15. ! #$ My_template.ptf & - Open

O %& ' (! Template )P Template $ (! Tools, Workplane, Level NC

Preferences %&8QR ()
#$%&'()* 20.2 Macros
Macro -#$1o c7&$- (.mac) u8 7&$ i ! ,7> /$ Run -* ) 7$ PowerMILL u8
) 6) & 1 &? , 8 D 5 -* ) + #$" "c-* ) 1 ? / Macro ) 6 Run 1 &? /
Explorer
Macro 6i ) & 78> ? , 8 * -DE/&$ D -. -DE! ) 66i , 8 1 &1 &
>+
1. ! #$ File Delete All
2. ! $!
# , 8 ! )c Dd 7 -* . Macros & ! #$ Record

3. l$ %#$1o c test_1
 Lesson 20 Page 4 / 12

4. ! $# Save
( 8 Macro ' )9 & # ' %I ( ! # %$ & )S !
() ! # $ & #

5. ! v 1o c/ $ . %#$ handset.tri
6. ! #$ View ISO1
7. -* E Block ,, Min/Max * + Tool ! ' ,, Ball Nose 10 .
8. Reset Rapid Move Heights Tool Start Point
9. ! v finishing Form ) & Toolpath ,, raster Tolerance 0.05 , Thickness 0.3 , Stepover
1.0 , Angle 90 , Two Way Joined Arc radius 0.5
10. ! #$ Apply Accept ! %#$ Toolpath ! ' raster-10bn
11. !"#$ + D , 8 ! #$ Stop ! i7$ Macros

12. Run Macros , Toolpath > & ! #$ Macro %#$ test_1 ! #$ Run

Macro "%& ' )P # ' (!(

Option Edit

13. ! $# Macro %#$ test_1 ! $# Edit

File '"# )P Word Pad 8QR " (!8 V
8 ()
 Lesson 20 Page 5 / 12

14. &17 +& Tool 7 +y.78> i & Save File

15. , Toolpath > Run Macro

Toolpath '"# !I$ Tool 12 . 8 Z//\ ( ! 8 %&
'( %& ] O Macro Run
PowerMILL "# Load 'O Macro %& & pmuser.mac _I * (
C:\dcam\product\PowerMILL4XXX\lib\macro (! Macro %& ) &$ 8QR " &8
)9 () %&8QR (d e pmuser.mac Directory %& pmill2 * ( User Home
Area
pmuser.mac ) )9 %& ' %I pmuser.mac % (d e h
16. , > + & Reset Form > +
17. ! #$ Record ! i7$ Macro * + /* + . 1
C:\dcam\product\PowerMILL4xxx\lib\macro & ,!,> - 1 1o c pmuser.mac

18. ! #$ Yes !"#$ * , 8 ) & Tool End Mill 7 10 .

19. ! v Area Clearance Form
20. * + Z Heights ? Stepdown ! . , , 3D Offset Strategy , Cut Direction Climb, Tolerance
0.05, Thickness 0.5, Lead In Moves Ramp Options * + ! ' Max Zig , Angle 3
21. ! #$ Accept
( Accept Form %&"# )P ' Macro !I$ Apply
22. ! #$ Stop ! 7i $ Macro > ! #$ Edit
 Lesson 20 Page 6 / 12

8QR% ( ' ! # PowerMILL & 8 $

23. $$ !7& )i. PowerMILL $ - > / i-. * + Area Clearance 7 7$ Tool %&
#$%&'()* 20.3 Creating Tool Libraries
Macro ) 6 %&)* + ,) & Tool Library ? , 8 Feature 7$ /. Tool , !%. Speed
Feed ! ' /& ! #$-DE * ) & Tool Library - /> %#$ Macro +& - + ! N,1 & !+ )
1. !7& )i. PowerMILL ! /& , 8 Macro %#$ Cutters C:\temp
2. ) & Tool End Mill 7 12 . 60 . + ! 7 1 %#$ 12-endmill
3. ) & Tool End Mill 7 10 . 50 . + ! 7 2 %#$ 10-endmill
4. ) & Tool End Mill 7 8 . 40 . + ! 7 3 %#$ 8-endmill
5. ! #$ Accept
6. Stop , 8 Macro
!R' &$8QR & Macro %& &! # ! Tool %$ _I "%& ' & ( User Menu &
Macro &$ "%& Run ( ! Macro %& Explorer
#$%&'()* 20.4 Creating an NC Output Macro
Macro ) 6 ! N,%#$ NC Program 1 &
1. PowerMILL ! , 8 Macro ? /> %#$ . NC Toolpaths ! N,1 & C:\temp
2. ) & NC Program 78> 3 ? %#$ . Roughing , Semifinish finish
3. Nc Program Preferences ! #$ Heid400.opt ! #$ Form
4. + D , 8
!R' $8& QR & Macro %& & NC program 3 ) ' Postprocessor %& )9 Option File %&O '
8QR Toolpath () ' Macro &$ "%& & ( User Menu % %&%&
#$%&'()* 20.5 Writing Macros form Scratch
! $# PowerMILL Macro ! ' Text File > -DE 8 ) 6 Copy Paste + . Macro
& 1 &

1. ! #$ Tools Echo Commands

2. * + Tool Ball Nose 7 10 . Form
3. ! #$ Accept
PowerMILL " "c7&$- /.$1 >
 Lesson 20 Page 7 / 12

[EDIT TOOL "1" LENGTH 50.0\r]

[RENAME TOOL "1" "10dia-ballnose"\r]
[TOOL ACCEPT\r]

! $-D
# E" "c7&$- !+ . > Macro 7$ -DE-DE) 6 -* . |\r} !" + 68 78>
, + .
#$%&'()* 20.6 User Menu
PowerMILL -DE) 6 ) & User Menu ! ' 7$ -DE!$ 1 & ) 6 Option /. 5
%&! i > +&-DE ! )c dD 7 Explorer "#> .

u8 ! i > 6i ) & ! ' 1o c %#$ . User_menu Wordpad + #$ Notepad /.$ . 1 N/ /&$ ).

1 & Directory %#$ pmill2 Home Area 7$ !- #$ -$ " !/$ c7$ -DE Save ! ' 1o c7&$- ! N,1 &
(1 . %. Word Document) Macro 5 6i ! ! i /&$ ! ,N 1 & !
Home Area * + Windows Explorer C /& My Computer + #$ Control Panel System
Settings /. ) & -DE/&$ Admin Rights

! $)
# & Directory & -DE) 6 ). user_menu Macro 5 /&$ 1 1 &

Macro 7$ Cutter NC Toolpath ) 6 Copy !7& 1 1 & pmill2 > ! #$! /& ?
PowerMILL N ) 6! %&~. Explorer 1 &
 Lesson 20 Page 8 / 12

/ $ . /.$1 >-#$7&$- $ i. user_menu

#$%&'()* 20.7 Setupsheet Utility

Setupsheet Utility -#$ * !$ ) )* + , /. ? ! -u8 ) 6! %& User
Menu Explorer
Setupsheet %& Project ? ! * %& $ i. PowerMILL !"#$) & !$ ) 7&$ i ) 6
). 1 +&~i& * Shop u8 !$ ) ) 6 ) & HTML + #$ Microsoft Excel
1. , > + ! v ? ! -%#$ Tapefile1
2. ! v 1o c/ $ . %#$ handset.tri
3. ! )c Dd 7 Explorer User Menu ! #$ Setupsheet V2.0.01

Setupsheet Utility '"# Load ! ' * Explorer

 Lesson 20 Page 9 / 12

% '"# Load ! () Setupsheet ! Toolpath _I # Explorer ! )

8%& #
4. ! $# 1$-$ Update List of Toolpaths

/. Toolpath 6i load !7& 1 Setup Sheet " &$ & %#$ *

5.

Snapshot "%& '% Toolpath %$ Toolpath ' Toolpath ( ]

Visual Aid ! l#% O # Setupsheet O & % ()
5. ! #$ Toolpath Roughing_16
6. Dd Shift -& 1 & & ! #$ Toolpath Corner_Finish_2
 Lesson 20 Page 10 / 12

' )9 Toolpath %$ O '% " #) ()

7. ! #$ 1$-$ Make Snapshot for Selected Toolpath

8 " )# ) m!I$ %& '

Toolpath ( & " #) (Snap Shot) (

! # & ' & ! Project # 8, h$ , ! )9 )9 Oh

() Setupsheet %& #

8. ! #$ 1$-$ Information

9. ! #$ + 7&$ Programs
10. ! v Block Form 1 .! #$ Draw & ! #$ Accept
11. 1 . ) Toolpath > + ( v 1o )
12. ! #$ 1$-$ Camera
 Lesson 20 Page 11 / 12

8& " )# '!R'%& )9 Wire Frame Shade !I$ #

Preference %& ! Setupsheet $ I ( 8 * Block Tool

13. ! #$ dD Option ! #$ Option Setup sheet

Form &$% 8QR " Setupsheet

' & #) ( Logo ! hq%! 8QR
" ( " * ( #) GIF
JPG

14. ! #$ Accept
15. ! $# 1$-$ Generate Setupsheets Save 1 & %#$ handset_mod.sif C:\temp
16. / i Setupsheet !) N & ? ! $# 1$-$ View Current Setupsheet

Setupsheet %& * "%& ' )P #(

#) HTML ' Toolpath %&
_
' Toolpath ') m
' & ! ' Toolpath !I$
*

&8 %$ &
 Lesson 20 Page 12 / 12

Toolpath Roughing_16 sheet. Toolpath Semi Finish 10

Toolpath Flat Finish 10 Toolpath Wall Finishes 6