PM7006 WhatsNew English

8/10/2019 PM7006 WhatsNew English

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What's New in

PowerMILL 7.0

By Delcam plc

Release Issue 1


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Delcam plc has no control over the use made of the software described inthis manual and cannot accept responsibility for any loss or damagehowsoever caused as a result of using the software. Users are advised thatall the results from the software should be checked by a competent

person, in accordance with good quality control procedures.Information contained in this manual is subject to change without noticeand does not represent a commitment by Delcam plc. The softwaredescribed in this manual is furnished under licence agreement and may beused or copied in accordance with the terms of such licence. No part ofthis manual my be reproduced or transmitted in any form or by anymeans, electronic or mechanical, including photocopying and recording,for any purpose without the express permission of Delcam plc.

Copyright 1996-2006 Delcam plc. All rights reserved.

Acknowledgements

This documentation references a number of registered trademarks andthese are the property of their respective owners. For example, Microsoftand Windows are either registered trademarks or trademarks of

Microsoft Corporation in the United Stated and/or other countries.

PatentsThe Raceline smoothing functionality is subject to patent applications.

Patent pending: GB 2374562 Improvements Relating to MachineTools

Patent granted: US 6,832,876 Machine Tools

Some of the functionality of the ViewMill and Simulation modules of PowerMILL is subject to patent applications.

Patent pending: GB 0504073.8 Surface Finish Prediction

PowerMILL Version: 7.0 Date: 11/07/2006 12:18


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ii Contents What's New in PowerMILL 7.0

Deferred Models ..................................................................................53 Feature Sets ..................................................................................................54

Hole Creation.......................................................................................55 Edit Feature Colour..............................................................................56

Boundary and Pattern Enhancements ..........................................................57 Stock Model Rest Boundary................................................................58 Transform Copy...................................................................................59

Stock Models ...............................................................................................60 Leads and Links ...........................................................................................62 Tool Notes....................................................................................................63 Options .........................................................................................................64

Toolpath Generation 65 Interleaved Constant Z.................................................................................65 Surface Finishing .........................................................................................69

Surface Finishing Example..................................................................70 Surface Projection Finishing........................................................................74

Smoothing............................................................................................75 Parametric Offset Finishing .........................................................................76 Port Machining.............................................................................................80

Port Area Clearance.............................................................................82 Port Plunge Finishing ..........................................................................88

Port Spiral Finishing ............................................................................91 Area Clearance Enhancements ....................................................................93

Spiral Offset Area Clearance ...............................................................93 Multi-Axis Strategies ...................................................................................95

Example of New Multi-Axis Strategy .................................................96 Projection Finishing Enhancements ............................................................97

Point Projection ...................................................................................97 Line Projection.....................................................................................98 Plane Projection ...................................................................................99

Toolpath Editing Enhancements ............................................................... 100 General Toolpath Enhancements .............................................................. 101 Variable Feed Rates .................................................................................. 103 Drilling Enhancements ............................................................................. 104

Compound Holes .............................................................................. 105 Profile................................................................................................ 111 Use Drilling Cycles........................................................................... 112 Gouge Checking ............................................................................... 113 Multi-Axis Drilling........................................................................... 113 Retract Feed Rate.............................................................................. 113 Feed Rate Reduction......................................................................... 115


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What's New in PowerMILL 7.0 Contents iii

Subsidiary Peck ................................................................................ 117 Chamfer ............................................................................................ 118 Drilling Method Enhancements ........................................................ 119

Information Toolbar.................................................................................. 119

Toolpath Verification 120

Toolpath Output 121 Additional Coolant Options ...................................................................... 122 Additional Variables on NC Programs..................................................... 123

User Interface 124

General 125 Folders....................................................................................................... 125 Dynamic Sectioning.................................................................................. 128

Example Using Dynamic Sectioning................................................ 131 Copy and Paste.......................................................................................... 134

Copying Between Entities ................................................................ 134 Copying Data from Information Dialogs ......................................... 135

PowerMILL Licences ............................................................................... 136

Thickness Dialog 137

Select Similar Coloured Items 138

PowerMILL Buttons 140 Main Toolbar Buttons............................................................................... 141

Boundary Toolbar Buttons........................................................................ 143 Boundary Types Buttons .................................................................. 144

Pattern Toolbar Buttons ............................................................................ 145 Simulation Toolbar Buttons...................................................................... 146 Tool Toolbar Buttons................................................................................ 147

Tool Dialog Buttons ......................................................................... 148 Toolpath Toolbar Buttons......................................................................... 150

Reorder Toolpath Buttons................................................................. 151 View Toolbar Buttons............................................................................... 152

Shading Toolbar Buttons .................................................................. 152


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iv Contents What's New in PowerMILL 7.0

ViewMill Toolbar Buttons........................................................................ 154 Block Dialog Buttons................................................................................ 156 Toolpath Strategy Buttons ........................................................................ 157

Drilling Strategies............................................................................. 157

2.5D Area Clearance Strategies........................................................ 157 3D Area Clearance Strategies ........................................................... 158 Finishing Strategies .......................................................................... 158 Ports .................................................................................................. 160 Toolpath Strategy Dialog Buttons .................................................... 160 Sorting Buttons ................................................................................. 161

Transform Dialog Buttons ........................................................................ 162

Index 165


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What's New in PowerMILL 7.0 Introduction 1

PowerMILL 7.0 offers all the original features of PowerMILL 6.0, butwith numerous improvements. The most significant improvements are:

Toolpath PreparationThe interface to Modelling has been improved and is integrated insidePowerMILL. This means that you can use the standard PowerMILLinterface (such as the View Toolbar). There are three types of modellingavailable:

Surface Modelling (on page 12). Wireframe Modelling (on page 13).

Curve Modelling (on page 17).

You can now Edit a Block Graphically (on page 18).

Routing Tools are now supported in PowerMILL. They are defined in asimilar way to Form Tools. You can create a toolpath using a routing tooland then simulate the toolpath to see its effect.

A new Main toolbar button of Point Distribution (on page 26)controls the point distribution of every toolpath.

A new Main Toolbar button of Automatic Verification (on page 30)enables automatic verification of toolpaths on creation.

You can now control the translucency of the Tool Axis Limits (on page33).

Automatic Collision Avoidance (on page 35) is a new 5-Axis optionthat will automatically tilt the tool axis, in a user defined way, to avoidcollisions between the shank / holder of the tool assembly and the model.

Introduction


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2 Introduction What's New in PowerMILL 7.0

There are several enhancements to Setup Sheets (on page 45):

You can control the number of toolpaths shown on each page of thesummary sheet.

You can specify which set of setup sheets you want to generate.

The axis preview graphic (bottom left hand corner) is no longerincluded in the setup sheet snapshot images.

A Project header sheet is now available.

The variable, {project.notes}, has had its meaning changed andnow refers to project level notes rather than NC Program notes.

Several additional variables (see "Additional Variables available onSetup Sheets" on page 48) are now available.

The export pathname is now saved between PowerMILL sessions. Variables can now use either curly brackets { } or percent symbol

and square brackets %[ ].

Word wrapping (the splitting of long words over several lines) oftoolpath names, NC Program names and file names is now thedefault behaviour.

There are a couple of Model enhancements (on page 50):

If a model is deleted and reimported (say for a design change) thecomponent thickness (see "Modifying Models Retains Thickness"on page 50) information is retained.

Less memory is required to machine large models.

A new model type of Reference Model (on page 52) allows youto have a model containing reference surfaces which will NEVER

be considered for machining or collision checking.

Deferred Models (on page 53) are represented in the explorerwith a .

Models containing trimmed surfaces use less memory.

There are several enhancements to Feature Sets (on page 54):

Hole Creation (on page 55) now allows you to select whetheryou create compound holes and holes from partial geometry as wellas Multi-Axis.

Compound Holes have a Component (on page 106) which allowsyou to select the relevant portion.


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A new option of Copy Holes to Pockets converts holes to pockets so that you can machine the holes using Area Clearancestrategies.

The colour of holes can now be either the Model colour or theFeature Set colour.

You can edit Feature Colours.

There are a couple of Boundary and Pattern enhancements (on page57):

There are several changes to Stock Model Rest Boundaries (see "Stock Model Rest Boundary" on page 58).

A new option of Transform Copy (on page 59) is now availableon the Transform Boundary dialog.

Improved quality and faster calculation times for ShallowBoundaries that don't use ball nosed tools.

Automatic collision checking is available for ShallowBoundaries .

When inserting a toolpath into a pattern only selected segmentsare inserted.

There are various enhancements to Stock Models (on page 60):

When you create a Stock Model Rest Boundary (on page 58), PowerMill automatically selects values from the active stock

model.

By default the Stock Model state is NOT locked. This makes iteasier to invalidate the stock model without explicitly unlockingeach state and then invalidating each state.

The representation of stock models in the explorer has changed.

You can now apply new toolpaths to a Stock Model entity so thatits state appears after an output reference in the stock model tree.

The Stock Model Object right click menu has an additional itemof Volume .

The Stock Model Object right click menu has an additional itemof Edit - Make Invalid .

The Leads and Links (on page 62) enhancements include:

The Allow Start Points to be Moved option on the Lead In

and Lead Out tabs of the Leads and Links dialog nowmoves the start point of a closed toolpath segment.


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Smooth Multi-Axis leads and links are now available.

You can now have Tool Notes (on page 63).

The Tools - Options - Tolerance dialog (see "Options" on page 64)has been simplified.

Toolpath GenerationA new finishing strategy of Interleaved Constant Z (on page 65)is available. This creates Constant Z toolpaths in the steep areas of amodel and 3D Offset toolpaths in the shallow areas. This differs fromOptimised Constant Z Finishing as you can specify when to changefrom 3D Offset machining to Constant Z machining, and you canspecify an overlap.

A new finishing strategy of Surface Finishing (on page 69) isnow available. Surface Finishing is similar to Surface ProjectionMachining except there is no projection. Surface Finishing justmachines the selected surface and will not attempt to machine any othersurfaces.

A new algorithm produces better Surface Projection Finishing (on

page 74) toolpaths.A new finishing strategy of Parametric Offset Finishing (on page 76)

is now available. Parametric Offset Toolpath machines between twocurves. This strategy takes the rulings between two curves to generate the

parametric offset toolpath.

A new Port Machining (on page 80) strategy is available on theToolpath Strategies New dialog. There are three types of PortMachining available:

Port Area Clearance (on page 82) .

Port Plunge Finishing (on page 88) .

Port Spiral Finishing (on page 91) .

There are a few Area Clearance enhancements (on page 93):

There is now a Spiral (see "Spiral Offset Area Clearance" on page93) option on the Offset Area Clearance strategy.

Faster creation of offset toolpaths which contain many contours.


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Improved ordering to reduce air time.

All 3-Axis strategies (except Plunge Milling and Drilling) can now beused in 5-Axis (see "Multi-Axis Strategies" on page 95) mode whenusing a ball nosed tool.

The Pattern (see "Projection Finishing Enhancements" on page 97)frame of the Point , Line and Plane Projection Finishing strategydialogs have changed to improve consistency.

Move Start Points (see "Toolpath Editing Enhancements" on page100) has been improved so that it works on more toolpath segments.

There are several General Toolpath enhancements (on page 101).

When a toolpath has Variable Feed Rates (on page 103), you candisplay an information dialog that shows a key to the various colours.

The philosophy of Drilling (see "Drilling Enhancements" on page 104)has changed to be more consistent with the other machining strategies.

There are many Drilling enhancements:

You can now have Compound Holes (on page 105) whichcontain several superimposed holes.


Several enhancements to Profile Drilling (see "Profile" on page111).

Use Drilling Cycles (on page 112) is now available on theDrilling dialog.

Gouge Checking (on page 113) against a model is optional.

PowerMILL knows when a drilling toolpath is Multi-Axis (see"Multi-Axis Drilling" on page 113) and defines the appropriatetoolpath.

There are several new drilling factors: A Retract Feed Rate (on page 113) for Single Peck and

Deep Drilling Cycles .

Feed Rate Reduction (on page 115) allows you to reduce thefeed rate towards the top or bottom of a hole for Single Peck ,Ream and the Boring cycles.

A Subsidiary Peck (on page 117) for Deep DrillingCycles .


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An Overlap Angle (see "Profile" on page 111) LeadDistance and Final Profile Pass for Profile Drilling .

You can now create a Chamfer with a tool larger than the holewithout having to define the hole as a tapered hole.

There are some Drilling Method enhancements (on page 119).

You can now select all diameters and lengths in CompoundHoles (see "Selection by Component" on page 119).

The Information Toolbar (on page 119) always shows the Toleranceand Thickness for the active toolpath.

Toolpath VerificationToolpath Simulation (see "Toolpath Verification" on page 120)

produces more realistic results on Multi-Axis toolpaths.

Toolpath OutputThere are several enhancements to NC Programs (see "Toolpath Output"on page 121):

There are three additional Coolant options (on page 122).

There are two additional Variables on NC Programs (on page123) available on the Output File field

Additional items can be output as a CL records (see "ToolpathOutput" on page 121).

NC Program Commands/ Comments are remembered fromone PowerMILL session to the next. This is the same behaviour asall other NC Program preferences.

Tool Change Positions are remembered from one PowerMILLsession to the next.

NC Program information now contains the name of each toolpathwritten in the NC program and any warning messages appear underthe name of the toolpath with the problem.


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User InterfaceAll the buttons/icons have changed in this release, including the desktopshortcuts:

or

Tables comparing all the other icons in PowerMILL 7.0 and 6.0 areshown in PowerMILL Buttons (on page 140).


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GeneralFolders (on page 125) give you an easy way to organise your data. Youcan create a Folder in any of the explorer entities, but they are probablyof greatest use for organising tools and toolpaths.

Dynamic Sectioning (on page 128) gives you the ability to quicklysection through the current view. This can be particularly useful whenanalysing a portion of a toolpath.

You can Copy and Paste (on page 134) entities between models, patterns and boundaries. This is available from the explorer right clickmenus.

PowerMILL now automatically releases FLEX licences (see"PowerMILL Licences" on page 136) after two hours of inactivity(although this time is configurable by the System Administrator).

There are several changes to the Thickness dialog (on page 137) :

The General tab has been removed.

The Area Clearance, Finishing and Boundary thicknesses can nowonly be edited on the toolpath strategy and boundary dialogs.

The Automatic Collision Checking options are now available onthe new Automatic Verification (on page 30) dialog.

You can now select similar coloured items (on page 138) of the sameentity.


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What's New in PowerMILL 7.0 Toolpath Preparation 9

Interface to ModellingThe interface to Modelling has been improved. The modelling capabilitynow starts inside PowerMILL and you can use the standard PowerMILLinterface (such as the View Toolbar). There are three types of modellingavailable and PowerMILL chooses the most appropriate type dependingon where you access the modelling functionality. PowerMILL ModellingVersion 7.0 is available on the PowerMILL installation CD or the Delcamweb site (accessible from Help - Check for PowerMILL Updates ).

Surface Modelling - previously this functionality was availablefrom PS-Surfacer.

Toolpath Preparation


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10 Toolpath Preparation What's New in PowerMILL 7.0

It is available from the Model Object right click menu.

Wireframe Modelling - previously this functionality wasavailable from PS-Sketcher.

It is available from the Boundary and Pattern toolbars and theCreate Boundary dialogs.

Curve Modelling - this is a new option and is a subset of theWireframe Modelling options.


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It is available from the Boundary and Pattern toolbars and theCreate Boundary dialogs.

Curve Modelling option.

Wireframe Modelling option.


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Surface ModellingClicking on the Surface Modelling option on the Model Object rightclick menu displays PowerMILL's surface modelling functionality.

For information on how to use Surface Modelling refer to the contextsensitive help.

Once you have created what you want, click to accept the changesand return to the PowerMILL main window.


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Wireframe ModellingClicking the Wireframe Modelling button displays PowerMILL'swireframe modelling functionality.

For information on how to use Wireframe Modelling, see the following"Example of User Defined Boundary", or refer to the context sensitivehelp.

Once you have created what you want, click to accept the changesand return to the PowerMILL main window.

Example of User Defined Boundary

This example shows you how to create a boundary on a surface using theModeller.

The example assumes that you have the Modeller installed. Although it is installed as separate program, the Modeller is startedautomatically for you from inside PowerMILL whenever it isneeded. The most appropriate type of modelling is chosen, thechoice depending on where within PowerMILL the Modeller iscalled. The three available types are: Surface Modelling (whichdoes not apply to boundaries), Wireframe Modelling , andCurve Modelling (which is made up of a subset of theWireframe Modelling options).

The example covers both Wireframe Modelling , and CurveModelling .


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1. Start PowerMILL and open Speaker.dgk from the File -Examples menu.

2. Select the surface from which you want to create your boundary.

3. Click the Wireframe Modelling button on the Boundary toolbar.

This action simultaneously creates a new boundary andopens a Wireframe Modelling session within PowerMILL,

following which the selected surface is displayed within thenew session window:

4. To create a boundary on the surface, click the Curve Creation button on the top toolbar of the Modeller.


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5. Click the Composite Curve button on the side toolbar:

The Create Composite Curve toolbar is displayed:

6. Select the surface edge:

7. The Modeller now traverses round the boundary of the surface:

8. Click the button (now highlighted) on the Create Composite

Curve toolbar to save the boundary curve.


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9. Click on the Create Composite Curve toolbar to end theCurve Modelling session.

10. Click the button (now highlighted) on the top toolbar to save

your changes and return to PowerMILL.The boundary curve is displayed in PowerMILL. If you cannot see

it, undraw the wireframe and shaded view using the and buttons.

This boundary can now be used in the same way as any otherboundary to help generate toolpaths.


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Curve ModellingClicking the Curve Modelling button displays PowerMILL's curve

modelling functionality.

For information on how to use Curve Modelling see Example of Userdefined Boundary (on page 13), or refer to the context sensitive help.

Once you have created the relevant curves, click the Save button andthen to accept the changes and return to the PowerMILL mainwindow.


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Block EnhancementsThe Block Enhancements are:

You can modify a block graphically (see below).

the Block - Defined By now has Box as its default option. In previous versions this was called Min/Max Limits .

Edit a Block GraphicallyWhen you select a block it is surrounded by a blue cuboid with doubleheaded arrows on all faces. This is an Instrumented Block .


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Place the mouse over the double arrow at the side of the block. This turnsthe double arrow white. Now clicking and dragging the mouse changesthat dimensions. You can either drag it to the appropriate length:

Or you can click on a feature of the model to define a specific dimensionof the block. So, in this case clicking on the edge of the hole in the model,


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automatically changes the width of the block.

Clicking in the graphics area (or on another entity) deselects the blockand removes the instrumentation.


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ToolsRouting Tools are now supported in PowerMILL. They are definedin a very similar way to Form Tools .

The Create Tool from Catalogue option is no longer available onthe Create Tool menu on the Tool Toolbar . It is now only available onthe Tools Explorer right click menu. The Tool Toolbar only includes

buttons relating to direct tool creation.

Routing Tool

Routing tools often have a ballrace on the end which is used to guide thetool against the edge of a workpiece. The toolpath produced with arouting tool is a kind of profile or swarf cut, generated using a standardEnd Mill with diameter selected to match the position of the actual (orimaginary) ballrace used to guide the tool.

You can create a toolpath using a routing tool and then simulate thetoolpath to see the effect of the routing tool.

You can create your own routing tools by defining a half-profile of yourRouting Tool in terms of line and arc spans.


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The Routing Tool option is available from the pull-out list on theTool toolbar. Selecting it displays the following dialog:

This dialog is the same as the Form Tool dialog, except that there is anadditional option of End Mill Diameter , which is the effective diameterthat PowerMILL uses when creating the toolpath.

For an example of how to create a routing tool, see "Creating a RoutingTool" below.

Unlike a Form Tool , a Routing Tool can be concave.

Creating a Routing ToolThis example takes you through the creation of a routing tool.

1. From the Create Tool pull-out list on the Tool toolbar,select the Routing Tool option.


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2. Click Load Tool Profile on the Tool Creation toolbar,move to the Examples directory, and select Tool_Routing.dgk .In this case, you can use Tool_Routing.dgk from the Examples directory.

3. Now create a simple Pattern toolpath.

4. Create a Block .

5. Right-click the Models menu in Explorer, select Create Plane -From Block from the context menu, and then enter a suitable Zlimit for the plane when prompted.

6. Select View - Toolbar - Pattern from the menu to display thePattern toolbar.

7. Click Create Pattern on the Pattern toolbar (or selectCreate Pattern from the Patterns context menu in Explorer).

8. Click Insert Model into Active Pattern on the Pattern toolbar


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9. Create a Pattern Finishing toolpath by selecting CreateToolpath from the Toolpaths context menu in Explorer:

The result should look something like this:


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10. If you simulate the toolpath you can see the effect of the routingtool. Click the Toggle button on the Simulation toolbar andthen Play the simulation:


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Point Distribution

A new Main Toolbar button of Point Distribution is nowavailable.

In previous versions of PowerMILL the Mesh frame was on theTolerance tab of the Options dialog (available from the Tools -Options menu option).

The Point Distribution dialog controls the point distribution ofevery toolpath in PowerMILL.

Output Point Distribution (see "Point Distribution - Output PointDistribution" on page 27) - controls the point distribution of a toolpath.

Point Separation (on page 29) - allows you to enter the maximumdistance between toolpath points.

Mesh (see "Point Distribution - Mesh" on page 29) - defines the size ofthe mesh relative to the machining tolerance. The smaller the MeshFactor , the finer the mesh, and consequently the toolpath takes longer tocalculate, but it is more accurate.


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Point Distribution - Output Point DistributionOutput Point Distribution

Output Type - controls the point distribution of a toolpath.

Tolerance and Keep Arcs - automatically removes unnecessary points in the toolpath while maintaining tolerance.

You can see the points are not equispaced, as unnecessary pointshave been deleted. Also, some of the points are blue: these indicatethe arc centres. The red points either side of the blue ones are thearc ends.

Tolerance and Replace Arcs - this is similar to Toleranceand Keep Arcs except that all arcs are replaced by straight linesegments (polylines). This option is good for machine tools whichdon't handle arcs well.


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Redistribute - allows the insertion of new points. This ensures aconstant distance between points, only inserting extra points if theyare necessary to keep tolerance. This can be especially useful whenusing the Maximum Point Separation option. Redistribute

may increase toolpath creation time but reduce time on theMachine Tool. This option is good for machine tools that canhandle large numbers of equispaced points.

Fit Arcs - produces toolpath with arcs inserted wherever possible.This option is good for machine tools which handle arcs well. Thisoption is only available for 3-Axis toolpaths.

The blue points indicate the arc centres.

The end points of the arcs are the red points either side of a blue point.

Attach the tool and step through the toolpath to see this clearly.


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Tolerance Factor - determines the number of points removed. Thismust have a value between 0 (a minimum number of points are removed)and 1 (maximum point removal whilst maintaining tolerance, so that thetoolpath contains the minimum number of points).

Point Separation

Limit Point Separation - when checked, allows you to enter themaximum distance between toolpath points.

Maximum Point Separation - maximum distance between

consecutive toolpath points.These options are not available if you select an option of Fit Arcs .

Point Distribution - Mesh

Mesh Factor - this effects the triangulation tolerance and must have avalue between 0 and 1 The smaller the Mesh Factor , the finer themesh, and consequently the toolpath takes longer to calculate, but it ismore accurate.

Checking the Limit Maximum Triangle Length checkbox thenenables the Maximum Triangle Length field where you can enter yourvalue.

Maximum Triangle Length - the maximum length of the hypotenuseof the triangle.

Limiting the maximum triangle length will decrease the faceting on gently curved surfaces. But, it will also increase machining time asmore triangles are generated. So, only limit the triangle lengthwhere faceting causes a problem.


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In previous versions of PowerMILL, Head Clearance was on the Tool- Options - Toolpath dialog.

Automatic Collision Checking - controls collision checking oftoolpaths during toolpath calculation.

When checked, the tool shank and holder are collision checked.The resulting toolpath only contains the non-colliding (safe)moves. This can lead to gaps in the toolpath.

If unchecked, the tool shank and holder are not collision checked.

Collision checking using the Toolpath Verification dialogwill check against shank and holder regardless of this option.

Shank Clearance - represents a specified safe area around the

tool shank which is taken into account when checking forcollisions.

Holder Clearance - represents a specified safe area around thetool holder which is taken into account when checking forcollisions.


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Holder Clearance

Shank Clearance

Buttons

Apply - applies the values entered, but leaves the dialog displayed.

Accept - applies the values entered and closes the dialog.

Cancel - closes the dialog without applying the values.

In previous versions of PowerMILL, Automatic Collision Checking was on the General tab on the Thickness dialog .


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Tool Axis LimitsYou can now control the translucency of the Tool Axis Limits.

Checking the Draw Limits checkbox enables the Translucency(Percentage) field.

A value of 0 gives the same result as before:


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However, a value of 50 gives the following:

This is very similar to the Block Translucency and can be useful to helpyou create the correct Tool Limits.


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Automatic Collision AvoidanceAutomatic Collision Avoidance is a new 5-Axis option that willautomatically tilt the tool axis, in a user defined way, to avoid collisions

between the shank / holder of the tool assembly and the model. This onlyworks when machining with the tip of the tool. This option is available on

the Tool Axis dialog.

Automatic Collision Avoidance is available for all Finishing strategies except for:

Offset - including 3D Offset, Interleaved Constant Z, Offset Flat,Optimised Constant Z, Parametric Offset.

Profile.

Rotary.

Swarf - including Swarf and Wireframe Swarf.

Constant Z and Corner finishing strategies can only use AutomaticCollision Avoidance when using tools with hemispherical cuttingends. This is the same limitation as described in New Multi-AxisStrategies (see "Multi-Axis Strategies" on page 95).

Automatic Collision Avoidance is NOT available for any toolpath strategies on the Drilling, Area Clearance or Ports tabs.

When using Automatic Collision Avoidance , a toolpath is createdusing the original tool axis for as long as possible. When a collision isdetected, the tool is automatically tilted towards the Tilt Tool Axis untilthe collision is avoided (by a user defined clearance around the tool) andcontinues creating the toolpath. Again, on collision, the axis will bechanged and so on across the model.

There are several important things to remember when using this option: It is very important to set appropriate tool axes (both original and

tilt). Set a Tool Axis that will machine as much as possible beforehaving to tilt to a new one.

The Tool Axis will tilt the least amount possible, in the directionspecified, to avoid colliding with the tool assembly (tip, shaft,shank and holder), and will return to its original axis whenever

possible.

You can only machine with the tip of the tool.


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The tilting will respect any tool axis limits.

Initially it is advisable to deselect the Automatic CollisionChecking on the Automatic Verification dialog until youare sure that you can produce a good toolpath. This will avoid

problems caused by different clearances on the AutomaticVerification dialog and the Tool Axis Direction - CollisionAvoidance dialog.

The benefits of this approach are that it allows you to use a shorter toolthan you otherwise could if you were only using 3-Axis strategies.

Tool Axis - Collision AvoidanceThis area of the dialog automatically tilts the tool axis, in a user definedway, to avoid collisions between the shank / holder of the tool assemblyand the model.

This tab is only available if you check the Automatic CollisionAvoidance checkbox on the Definition tab.

Tilt Tool Axis - specifies how the tool will move to avoid anycollisions.

Lean - if a collision is detected, the tool axis will move from theoriginal axis (specified on the Definition tab) in the Leandirection until the collision is avoided.

Lead - if a collision is detected, the tool axis will move from theoriginal axis in the Lead direction until the collision is avoided.


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If you specify a Towards Line or From Line then you can seethe specified line:

If you specify a Fixed Direction then you can see the specifiedline with an arrow on it to indicate the direction:

If you specify a Lead , Lean or Surface Normal it does nothing.

Tool Clearances

The tool clearances specify the clearance around the tool shaft, shank andholder.

Shank Clearance - represents a specified safe area around thetool shank which is taken into account when checking forcollisions.


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Holder Clearance - represents a specified safe area around thetool holder which is taken into account when checking forcollisions.

Holder Clearance

Shank Clearance

Tool Shaft Clearance

PowerMILL automatically adds a small tapered clearance aroundthe shaft of the cutter.

Constant Z Collision Avoidance ExampleThis is a slightly more complex example. It uses a Constant Z toolpathon the bucket.dgk model. The toolpath has been limited to just theinside of the bucket:


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The Tool Axis Direction has a Definition with a Tool Axis ofVertical :

Make sure that the Automatic Collision Avoidance is checked. Onthe Collision Avoidance tab set the following:

Tilt Tool Axis - Lean

Shank Clearance - 1.0

Holder Clearance - 3.0


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If you look at the Constant Z toolpath, the tool starts off vertical:

Then a lean angle is applied so that the tool holder just clears the model:

As the toolpath proceeds down the model, the lean angle changes so thatthe tool holder just clears the model:


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And so on down the model:

Raster Collision Avoidance ExampleThis simple example uses a raster toolpath over a step to show the effectof Collision Avoidance.

If you create a simple Raster toolpath over this, you will get collisions ofthe shank as it climbs or descends the step.

One way round this is to increase the length of the tool.

Another is to change the toolpath strategy.


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The third is to use Collision Avoidance . In this case, the initial ToolAxis is Vertical .

1. Check the Automatic Collision Avoidance checkbox and thenselect the Collision Avoidance tab.

2. Enter a Tool Tilt Axis of Lead , a Shank Clearance of 1.0 anda Holder Clearance of 1.0 .


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3. Create a new raster toolpath. You can see that the toolpath now tiltson the steep portions to avoid the tool holder colliding.

4. However, the toolpath is still 3-Axis on the flat portions where thetool holder doesn't collide.

In summary, the tool tries to respect the original Tool Axis Definition for as much of the toolpath as possible. Only when this isn't possible doesthe tool axis change, in the direction specified in the CollisionAvoidance Tilt Tool Axis , until the tool assembly no longer collides.


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Setup SheetsThere are several enhancements to setup sheets.

You can now control the number of toolpaths shown on each pageof the summary sheet. This is controlled on the Options tab on theSetup Sheets dialog. (see "Options" on page 47)

You can now specify which set of setup sheets you want togenerate, by selecting the relevant Write check box in theTemplates frame in the Setup Sheets - Paths dialog.

The axis preview graphic (bottom left hand corner) is no longerincluded in the setup sheet snapshot images. This will avoidconfusion with the workplane.


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A Project header sheet is now available. This is available from theSetup Sheets - Settings menu option and selecting the Paths tab. This enables you to collate the information that is common toall NC Programs in the project into a single setup sheet. Typically

this is information such as Customer Name, Order number, Project Notes, and so on.

One variable has had its meaning changed: {project.notes} nowrefers to project level notes rather than NC Program notes.

Several additional variables (see "Additional Variables available onSetup Sheets" on page 48) are now available.

The export pathname is now saved between PowerMILL sessions.

Variables can now use either curly brackets { } or percent symboland square brackets %[ ]. You no longer have to remember whichvariables need which type of brackets.


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Word wrapping (the splitting of long words over several lines) oftoolpath names, NC Program names and file names is now thedefault behaviour. This is controlled by the style.css style sheet.The style sheet contains the line:

word-break: break-all; /* N.B. This is a proposed extension to theCSS standard! */

to disable word wrapping simply comment out this line:

/* word-break: break-all;*/ /* N.B. This is a proposed extension tothe CSS standard! */

Anything starting with /* and ending with */ is a comment. Soin the first case word-break: break-all; is not commented out,whereas it is in the second.

Options


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Summary Page Breaking

Pagination Mode - controls the pagination for Summary pages.

Automatic - PowerMILL determines the optimum number oftoolpaths on a page.

Off - toolpaths are placed on a single summary page. There is no pagination.

User - you determine the number of toolpaths on each summary page.Selecting this option enables the Toolpaths on a Page field.

Toolpaths on a Page - defines the number of toolpaths you want oneach summary page. This option is only available if you have a Mode ofUser .

Additional Variables available on Setup SheetsThe following new variables are now available:

Variable Description

{ncprogram.notes} NC Program level notes.

{ncprogram.tool_datum} Tool tip (or Tool Centre)depending on the Tool Valuesetting on the NC Programdialog.

{ncprogram.model.limits.x.min}

The minimum value in X of theModel Limits with respect to the

NC Program output workplane.

{ncprogram.model.limits.x.max}

The maximum value in X of theModel Limits with respect to the


{ncprogram.model.limits.y.min}

The minimum value in Y of theModel Limits with respect to the


{ncprogram.model.limits.y.max}

The maximum value in Y of theModel Limits with respect to the


{ncprogram.model.limits.z.min}

The minimum value in Z of theModel Limits with respect to the



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{ncprogram.model.limits.z.max}

The maximum value in Z of theModel Limits with respect to the


{setupsheets.model.file_path}

Model file path. This should beused in preference to{PD_CADModel} .

{setupsheets.model.file_name}

Model file name

{workplane.ncangle.x} X angle of the toolpathworkplane axis relative to therespective NC Program outputworkplane axes.

{workplane.ncangle.y} Y angle of the toolpathworkplane axis relative to therespective NC Program outputworkplane axes.

{workplane.ncangle.z} Z angle of the toolpathworkplane axis relative to therespective NC Program outputworkplane axes.

{height_above_model} Distance along the Z axis between the lowest point in thetoolpath and the top of themodel.

{movement_type} Toolpath movement type of 3-Axis, 3+2 Axis or 5-Axis.

{ncprogram.statistics.tool_lifts}

Number of tool lifts in the NCProgram.

{ncprogram.statistics.cut_time} Cutting time of an NC Program.


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Model EnhancementsThe following model enhancements have been introduced:

If a model is deleted and reimported (say for a design change) thecomponent thickness information is retained. For more informationsee Modifying Models Retains Thickness (on page 50).

Less memory is required to machine large models.

A new model type of Reference Model (on page 52) allows youto have a model containing reference surfaces which will NEVER

be considered for machining or collision checking.

Deferred Models (on page 53) are represented in the explorerwith a .

Models containing trimmed surfaces use less memory.

Modifying Models Retains ThicknessIf a model is deleted and reimported (say for a design change), thecomponent thickness information is retained. In previous versions itwould have been lost.


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This functionality is available from the Reimport Model option fromthe Models Object right click menu.

The Reimport applies the original thickness information based onthe component names.


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Reference ModelA new model type of Reference Model allows you to have a modelcontaining reference surfaces which will NEVER be considered formachining or collision checking.

1. Selecting Import Reference Surfaces from the Models rightclick menu displays the Import Reference Surfaces dialog.This is a standard File Open dialog.

2. Move to the correct directory and select the required model. The

reference model is imported into PowerMILL.You can see the difference between a Reference SurfacesModel and a Model .

Model is shown in blue in the explorer.

Reference Surfaces is shown in grey in the explorer.


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The Reference Surface Model has all the functionality of an ordinarymodel except that:

The surfaces are set to Ignore so they are never considered formachining or collision checking.

You cannot apply a Thickness to the model.

A Reference Surface Model can be particularly useful when tryingto create complex toolpaths requiring reference surfaces. Thisallows you to replace one set of reference surfaces with anotherwithout having to reprocess all of the toolpaths.

Deferred Models

As before, you have the option not to load a model on importing a project(from the Tools - Options - Import - Defer Loading menu option).

You can see the difference between a Deferred Model and a Model .

Deferred Model is shown with a in the explorer.

Model .

Clicking on loads the model.

Calculating a toolpath or boundary also loads any deferred models.


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Feature SetsThere are several enhancements to Feature Sets .

Hole Creation (on page 55) now allows you to select whetheryou create compound holes and holes from partial geometry as wellas Multi-Axis.


A new option on the Edit - Feature Sets Object right clickmenu of Copy Holes to Pockets converts holes to pockets sothat you can machine the holes using Area Clearance strategies.

The colour of holes can now be either the Model colour or theFeature Set colour. This is controlled from the Tools - Option -View menu which has an additional option of Use Model Colourfor Holes .

Use Model Colour for Holes - when selected, the holes are theModel colour. When deselected, the holes are the Feature Set colour.

You can edit Feature Colours.


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Hole Creation

Multi-Axis - this only has any effect when you use the RecogniseHoles in Model menu option. If selected, all the holes are placed in onefeature set. If deselected, the holes are sorted into feature sets byworkplane. This is only available if Hole is selected in the Type field.

Compound Holes - If selected, one compound hole containing severalcomponents is created. If unselected, several individual holes are created(superimposed on each other).

You can see the difference between the representation of a compoundhole and an individual hole in the explorer.

For more information, see Compound Holes (on page 105).

Create From Partial Holes - enables the creation of holes from amodel that has poorly or incompletely defined holes. For example,PowerMILL will create a hole from a pair of arcs.

This option should always be used as a last resort as it may findmany unwanted (or unexpected) holes.


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Edit Feature ColourA new button, Edit Colour , is now available on the Feature dialog.

Edit Colour - changes the colour of the selected feature. Clickingon this displays the standard Windows Color dialog. Select therelevant colour and click on OK to close the dialog.


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Boundary and Pattern EnhancementsThe following enhancements to Boundaries have been introduced:

There are several changes to Stock Model Rest Boundaries (see "Stock Model Rest Boundary" on page 58).

A new option of Transform Copy (on page 59) is now availableon the Transform Boundary dialog. This is also available forPatterns and Workplanes .

Improved quality and faster calculation times for ShallowBoundaries that don't use ball nosed tools.

Automatic collision checking is available for ShallowBoundaries .

When inserting a toolpath into a pattern only selected segmentsare inserted. If no segments are selected the whole toolpath isinserted.


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Stock Model Rest Boundary

There are several changes to Stock Model Rest Boundaries :

Default values are picked up from the active Stock Model .

By default, the Stock Model and Tolerance are the values set inthe active Stock Model, and the Detect Material Thickness isthe same as the Rest Thickness in the active Stock Model.

There is a new option of Detect Material Thicker Than on thedialog. The calculation ignores rest material thinner than the valuespecified here

Although the Detect Material Thicker Than value has a defaultvalue of the Rest Thickness in the active Stock Model, you canchange this to any other value. If you do change the value,PowerMILL will internally calculate the appropriate Stock Model.

The tolerance of the Stock Model no longer needs to be the same asthe Stock Model Rest Boundary (although it is by default). If youdo change the value, PowerMILL will internally calculate theappropriate Stock Model.


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Transform CopyA new option of Transform Copy is now available on the TransformBoundary dialog (available from the Edit - Transform menu optionon the Boundary Object right click menu). This offers the samefunctionality as Transform Copy on the Transform Toolpath dialog.

Transform Copy - when checked, the boundary specified above iscopied when transformed and is given the name of the original

boundary with the addition of _1 . When unchecked, the current

boundary is replaced by the new transformed boundary which hasthe same name as the original toolpath.


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Stock ModelsThere are various enhancements to Stock Models:

When you create a Stock Model Rest Boundary PowerMillautomatically selects values from the active stock model. For moreinformation see Stock Model Rest Boundary (on page 58).

By default the Stock Model state is NOT locked. This makes iteasier to invalidate the stock model without explicitly unlockingeach state and then invalidating each state.

The representation of stock models in the explorer has changed.

shows an input to the stock model.

shows an output from the stock model.shows that a batch stock model exists. This means that

PowerMILL knows all the relevant parameters to create the stockmodel at a later date. Each state node has if it hasn't beencalculated.

You can now apply new toolpaths to a Stock Model entity so thatits state appears after an output reference in the stock model tree.

The Stock Model Object right click menu has an additional item

of Volume . This calculates the Stock Model's volume.

State - the active state of the stock model.

Volume - volume of the stock model in the model units (in thiscase mm 3).


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The Stock Model Object right click menu has an additional itemof Edit - Make Invalid . This invalidates all the calculations of thestates and unlocks them. This enables you to resolve dependencyissues between this stock model and other entities.


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Leads and LinksThe Leads and Links enhancements include:

The Allow Start Points to be Moved option on the Lead In and Lead Out tabs of the Leads and Links dialog nowmoves the start point of a closed toolpath segment. The start pointwill be either as close as possible to the preceding cutting path ormidway along the longest span.

Smooth Multi-Axis leads and links are now available. These keepthe velocity of all axes and the tool axis constant at the point oftransition. This is true for any lead, link or extension that joins ontoa toolpath segment


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Tool NotesYou can now attach notes to tools. You can output Tool Notes to the tapfile and display them in setup sheets.

The Description field on the Cutting Data tab on the Tools dialogallows you to enter tool notes. Text entered here is written in the cutfile asa 29000 record.


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OptionsThe Tools - Options - Tolerance dialog has been simplified.Version 7.0 Version 6.0

The Toolpath Points area is now on the Point Distribution (on page26) dialog .

The Mesh area is now on the Point Distribution - Mesh (on page 29)dialog .


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What's New in PowerMILL 7.0 Toolpath Generation 65

Interleaved Constant ZA new finishing strategy of Interleaved Constant Z Finishing isnow available.

Interleaved Constant Z Finishing strategy creates Constant Z toolpaths in the steep areas of a model and 3D Offset toolpaths in theshallow areas. This differs from Optimised Constant Z Finishing asyou can specify when to change from 3D Offset machining toConstant Z machining using the Threshold Angle field, and you canspecify an Overlap where both 3D Offset and Constant Z toolpathsare created.

Also Optimised Constant Z Finishing only uses whole segments,whereas Interleaved Constant Z Finishing will split segments at theshallow boundary. This means that Interleaved Constant ZFinishing toolpaths have far more retracts than Optimised ConstantZ toolpaths.

Toolpath Generation


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66 Toolpath Generation What's New in PowerMILL 7.0

Threshold Angle - the surface slope, measured from the horizontal,that determines the split between Constant Z and 3D offset machining.

Shows the 3D Offset toolpath in the shallow areas.

Shows the Constant Z toolpath in the steep areas.


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Offset Overlap - the size of the overlap area where Constant Z and3D Offset machining occur. This minimises marks on the model caused

by a sudden switch from Constant Z to 3D offset machining.

Shows the 3D Offset toolpath overlapping into the steep areas.Shows the Constant Z toolpath.

Direction - defines whether you want Climb , Conventional or Any (both climb and conventional milling).

Use Separate Offset Stepover - allows you to define a differentstepover for the steep and shallow portions of the toolpath. Normally thestepover is defined by the Stepover field on the left hand side of thedialog. If you select this option, then only the steep (or Constant Z)

portion of the toolpath is defined by the Stepover field on the left handside of the dialog.


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Shallow Stepover - defines the stepover of the shallow (or 3DOffset) portion of the toolpath.

Shows the 3D Offset toolpath stepover in the steep areas.

Shows the Constant Z toolpath stepover in the shallow areas.


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Surface Finishing

A new finishing strategy of Surface Finishing is now available.Surface Finishing is similar to Surface Projection Machining ,except that there is no projection. Surface Finishing just machines theselected surface and will not attempt to machine any other surfaces.

These options are very similar to the Surface Projection toolpathoptions.

Surface - determines how the selected surface is machined.

Surface Units - describes how the stepover and limits are defined.

Surface Side - defines whether the Outside is machined


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or whether the Inside is machined.

Pattern - defines the limits and orientation of the toolpath.

Surface Finishing ExampleThis example compares the results of Surface and Surface Projection

finishing using SurfaceFinishing.dgk from the Examples file.The results of Surface Finishing can be particularly beneficial whenwanting to machine a single surface in a cavity.


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3. Accept the default options on the Surface Finishing dialog andclick on Apply . Click on Cancel to close the dialog. You can seethe toolpath that is created:

4. Looking in detail:


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5. You can now repeat the process but use a strategy of ProjectionSurface Finishing again using the default options. In this casethe following toolpath is created:

6. Obviously you can spend time changing the limits so that notoolpath is created on the top surface.

7. Looking in detail you can see that, using the defaults, not as muchof the selected surface is machined using the Projection SurfaceFinishing strategy as opposed to the Surface Finishingstrategy:


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Surface Projection FinishingA new algorithm produces better toolpaths. They have:

Less fragmentation.

Regions are no longer missed.

In PowerMILL V 6.0 this is the result you might get:

In PowerMILL version 7.0 it is improved to this:

Improved surface finish.

The Stepover field is now respected.

In previous versions there was a problem in some passes whichwere almost twice the width of the stepover value between passes.

Two new parameters of Smoothing Tolerance and A ngular

Smoothing Tolerance (see "Smoothing" on page 75) are nowavailable.


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SmoothingSurface Projection Finishing has two new options:

Smoothing Tolerance

Angular Smoothing Tolerance

Smoothing Tolerance - the tolerance to which the splined curve mustfollow the surface pattern. If this is set to 0 then an automatic tolerance isused.

Angular Smoothing Tolerance - the tolerance to which the surfacenormals of the splined curve must match the normals of the surface

pattern. If this is set to 0 then an automatic tolerance is used.

This strategy initially generates a pattern on the surface (to the specifiedlimits) and then splines the pattern and generates the toolpath from this

pattern, by projecting it onto the surface.


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End Curve - a pattern defining the end of the toolpath.

Shows the End Curve .

Shows the Start Curve .

Offset Direction - determines how the two curves are joined.

Across - the toolpath goes from a point on the start curve to oneon the second curve. An example of an Across toolpath is shown

below.


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Along - the toolpath is more like an offset toolpath radiating outfrom the start curve to the end curve. An example of an Along toolpath is shown below.

Limiting Method - determines how the pattern limits the toolpath.

Tip Position - the tip of the tool follows the pattern.

Contact Position - the contact point of the tool follows the pattern

Maximum Stepover - this strategy determines its own stepover basedon the tool radius and tolerances used. However, if the automaticallygenerated stepover is too large, you can restrict it by specifying aMaximum Stepover .

Maximum Offsets - controls the maximum number of offsets.


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Port Machining

A new Port strategy tab is available on the Toolpath StrategiesNew dialog. There are three types of Port Machining available:

Port Area Clearance (on page 82).

Port Plunge Finishing (on page 88).

Port Spiral Finishing (on page 91).

The Ports tab on the Toolpath Strategy New dialog defines howthe model will be port machined.

In all cases the strategies create toolpaths in a port (or tube) and thetoolpath retracts back safely up the port. An approximate centreline of the

port is required.

Port Machining strategies only work with spherical tools (ballnosed and spherical tipped disc tools).


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Selecting one of the options from this dialog and then clicking on the OK button creates a batch toolpath and then displays the Port Machiningdialog:

The left side of the dialog is standard for all toolpaths and defines the parameters used to create the toolpath (such as the tool, tolerance,stepover, boundary, leads and links required for toolpath).

The right hand half of the dialog contains data that is specific to one typeof toolpath or a particular strategy type.

The batch toolpath is automatically created in the explorer.


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You can tell that it is a batch toolpath because of the .

This is converted to a complete toolpath once you enter the relevantvalues on the finishing dialog and click on the Apply button on theMachining dialog.

For more information on the New dialog see Toolpath Strategies in thereference documentation.

Port Area ClearancePort Area Clearance enables rapid removal of material inside a port.

Pattern - the pattern serves three purposes:

1. Indicates the port to machine. The pattern must be entirely withinthe port you want to machine.

2. Controls the orientation of the slices. The slices are normal to the pattern. If you use Workplane Limits then the workplanes overridethe pattern.

3. Determines which end of the port is machined first.


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A typical pattern can be seen in below.

Clearance (on page 92) - the tool shank and holder clearance. This is inaddition to any Thickness defined and is added to the side of the tool to

avoid collision with cusps or un-machined material. Port Machining usesa series of 3+2 Axis machining strategies wherever possible. Theclearance value dictates when PowerMILL needs to change from one axisto the next.

Limits (on page 84) - determines what portion of the model is machined.By default the whole model is machined.

Ramping - determines how the tool descends into the block.

Slope Angle - the angle of descent as the tool ramps into the block.

Ramp Diameter (TDU) - the ramp moves are made in a circlespiralling down into the block. The Ramp Diameter controls themaximum circle diameter in Tool Diameter Units (on page 86).

Machining Options (on page 84) - determines which ends of the portsare used and how far you machine down each end of the port.


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Limits

Limits - determines what portion of the model is machined and controlsthe direction of the slices. By default the whole model is machined.

The limits are at the tool centre (sphere centre) not the tool tip position.

Workplane Limits - if checked the toolpath is limited to theworkplanes specified below. If workplane limits are used then the

plane of the slices is interpolated between the XY planes of the twoworkplanes.

Upper Limit - select a workplane to define the upper machining limit(say in the figure below).

Lower Limit - select a workplane to define the lower machining limit(say in the figure below).

Limits are useful when:

1. The pattern extends beyond the end of the port.2. The orientation of the port doesn't match the plane normal to the

pattern. Port machining only machines closed slices.

3. You only want to machine part of the port.

Machining Options


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Machining Options - determines which ends of the ports are used andhow far you machine down each end of the port.

Machine - determines which ends of the ports are used and how far youmachine down each end of the port. One end of the port is called End (say in the figure below) and the other Start (say in the figure

below).

Maximum from End - machines as far as possible down one end ofthe port before machining down the other end of the port. Using thediagram above, PowerMILL would machine as far as possible from

before trying to machine from .

Maximum from Start - machines as far as possible down the otherStart end of the port before machining down the other end of the

port. Using the diagram above, PowerMILL would machine as far

as possible from before trying to machine from .

Equally from Ends - machines equally down both ends of the port.

From End Only - machines as far as possible down one end of the port only. Using the diagram above, PowerMILL would machine

as far as possible from .

From Start Only - machines as far as possible down the other Start end of the port only. Using the diagram above, PowerMILL would

machine as far as possible from .


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The Start and End are determined by the direction of the Pattern .Workplane limits override the Pattern direction.

Spiral - spirals inside slices.

Partial - if there are full slices which cannot be machined from eitherend, then Partial machines the maximum possible area (while avoidingcollisions). This calculation is slower and some rest material will remain.

Tool Diameter Units

Tool Diameter Units - is the distance relative to the tool diameter. Sowith a 10mm tool and a TDU of 2, this gives an actual value of 20mm.

Port Machining Area Clearance Machining Strategy

PowerMILL will start machining the port with a 3-Axis strategy if it can.


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Once it can no longer create the toolpath without a collision, PowerMILLautomatically creates a tool axis which will enable further 3+2 Axismachining. This continues down the port and PowerMILL will thencreate a 5-Axis strategy if necessary.

Once no further toolpath can be created while accessing one side of the port, PowerMILL accesses the port from the other end and applies thesame principle of machining with 3+2 Axis strategies wherever possible.


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Port Plunge FinishingPort Plunge Finishing enables plunge machining inside a port. Plungemachining automatically creates good retract moves. All plunge toolpathsare continuous 5-Axis toolpaths.

Pattern - defines the location of the port and the orientation of thesubsequent machining. For more information, see Port Area Clearance(on page 82).

Clearance (on page 92) - the tool holder, shank and side of cutterclearance.


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Limits (on page 84) - determines what portion of the model is machined.By default the whole model is machined.

Direction - defines whether you want Climb , Conventional or Any (both climb and conventional milling).

Merge (on page 89) - determines how the machining from either end ofthe port meets.

Merge

Merge - determines how the machining from either end of the portmeets.

Merge Point - determines how far (as a percentage) you machinedown each end of the port.

Lift Start - the distance before the Merge Point that the tool starts tolift.

Overlap -the distance centred on the

Merge Point that the toolpathsoverlap. This is an actual value (not a percentage).

Lift Height - the distance away from the port walls (into the centre)that the tool lifts at the Merge Point . The lift at the end of thetoolpath segment will be greater.


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Lift Start and Lift Height are needed to minimise the effects oftool springback. When you machine the port from the first end, thetool is plunging into thick material and the resulting forces push thetool away from the side of the port (leaving small amounts ofmaterial on the port). Now you machine from the other end. Initiallythere are similar forces on the tool (causing springback), but whenthe tool reaches the start of the overlap distance, the forces

suddenly change and the tool springback suddenly reduces. Thislooks like a "dig in" but is actually just machining to the requireddepth. The Lift Start and Lift Height values minimise this effect.


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Port Spiral FinishingPort Spiral Finishing enables spiral machining inside a port.

Pattern - defines the location of the port and the orientation of thesubsequent machining. For more information, see Port Area Clearance(on page 82).

Clearance (on page 92) - the tool holder, shank and side of cutterclearance.


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Area Clearance EnhancementsThere are a few enhancements to Area Clearance:

There is now a Spiral option on the Offset Area Clearance strategy (see below).

Faster creation of offset toolpaths which contain many contours.

Improved ordering to reduce air time.

Spiral Offset Area ClearanceThere is now a Spiral option on the Offset Area Clearance strategy.

Clicking on the Arrow key displays the Offset MachiningAdvanced Settings . This has an additional option of Spiral :

Spiral - when selecting this option, spiralling will occur (where the

original offsets are closed and have one-to-one nesting).It converts this:

To this:


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The Spiral option is always available except when you selectMinimise Air Moves or Restrict Tool Overload .

The Spiral option is best used in conjunction with a small

Smoothing Allowance (no more than 10%).


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Multi-Axis StrategiesAll 3-Axis strategies (except Plunge Milling and Drilling) can now beused in 5-Axis mode when using tools with a hemispherical end.

Ball Nosed SphericalTipped Disc

3-to-5-Axis conversion is only possible if you specify a Thickness

. It is NOT possible if you specify a Radial and Axial Thickness .


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Projection Finishing EnhancementsThe Pattern frame of the Point Projection (on page 97), LineProjection (on page 98) and Plane Projection (on page 99) Finishingstrategy dialogs have changed to improve consistency. Only the changesto the dialogs are described here.

Point Projection

Direction - specifies whether the direction is Clockwise orAnticlockwise .

Ordering - replaces the Join Up and One Way fields in previousreleases.

Sequence - replaces the Order field in previous releases.

Elevation Angle - this no longer has the Stepover field as this isavailable from the left hand side of the dialog.

Azimuth Angle - this no longer has the Stepover field as this isavailable from the left hand side of the dialog.

Angular Stepover - replaces the Stepover field in the AzimuthAngle frame in previous releases.


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Line Projection

Direction - specifies the direction of the Spiral Style . It can be eitherClockwise or Anticlockwise .

Ordering - replaces the Join Up and One Way fields in previous

releases.Sequence - replaces the Order field in previous releases.

Angular Stepover - replaces the Stepover field in the AzimuthAngle frame in previous releases.

Height - this no longer has the Stepover field as this is available fromthe left hand side of the dialog.


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Plane Projection

Pattern Direction - replaces the Style option in previous releases. Thetwo options available are now U and V (the surface parametric directions)which are more meaningful than the previous Across and UpDown .

Ordering - replaces the Join Up and One Way fields in previousreleases.

Sequence - replaces the Order field in previous releases. Height - this no longer has the Stepover field as this is available fromthe left hand side of the dialog.

Width - this no longer has the Stepover field as this is available fromthe left hand side of the dialog.


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Toolpath Editing EnhancementsMove Start Points has been improved so that it works on toolpathsegments which:

contain arcs;

appear closed but actually contain small (within tolerance) gaps.

The Toolpath Listing dialog (available from on the Toolpathtoolbar) can be resized, using , to allow you to display more toolpathsegments.


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General Toolpath EnhancementsThere are several general toolpath enhancements:

There is improved ordering of segments in Embedded PatternFinishing Toolpaths.

There is an improved algorithm used in creating CornerFinishing toolpaths producing much improved toolpaths.

Stitches now lie in planes so that in steep areas they are, in effect,Constant Z toolpaths and in shallow areas they lie in a plane. Thisminimises the numbers of crossing stitches.

There is a new algorithm which offers improved trimming oftoolpaths inside 3D boundaries.

The Tool Axis Lean Angle on Swarf and Wireframe SwarfFinishing toolpaths is now limited to a maximum of 75 .

Circular Arc Links in multi-axis toolpaths now have a smoothchange in the tool axis over the link.

There is improved ordering of Constant Z toolpaths.

When saving toolpath Templates , you now have the choice of

whether to save all parameters or only those that are ticked.


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When Save Checked Parameters Only is not ticked all the parameters are saved.

Save Checked Parameters Only - when ticked only the parameters loaded with the toolpath are ticked. So, if a toolpath iscreated from a default template, NO parameters are ticked. Ifhowever, you read in a project and create a template from one ofthe toolpaths in the project then everything is ticked, as the toolpathwas last read in with all its parameters. This option enables you torecall, at a later date, exactly which parameters your templatecontains.


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Variable Feed RatesWhen a toolpath has variable feed rates, clicking on the light bulb (bythe toolpath) displays an information dialog that shows a key to thevarious colours:


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Drilling EnhancementsThe philosophy of drilling has changed to be more consistent with theother machining strategies.

You now:

decide how to drill the holes (by filling in the Drill dialog);

apply the strategy to the currently selected holes (or all the holes ifnone are selected).

In previous versions you:

selected the holes;

decided how to drill the holes.The drilling information was "attached" to the hole.

There are many drilling enhancements:

The use of Compound Holes (on page 105).


Several enhancements to Profile Drilling (see "Profile" on page

111). Use Drilling Cycles (on page 112) is now available on the

Drilling dialog.

Gouge Checking (on page 113) against a model is optional.

The Multi Axis option has been removed. PowerMILL knowswhen a drilling toolpath is Multi-Axis (see "Multi-Axis Drilling"on page 113) and defines the appropriate toolpath.

There are several new drilling factors:

A Retract Feed Rate (on page 113) for Single Peck andDeep Drilling Cycles .

Feed Rate Reduction (on page 115) allows you to reduce thefeed rate towards the top or bottom of a hole for Single Peck ,Ream and the Boring cycles.

A Subsidiary Peck (on page 117) for Deep DrillingCycles .

An Overlap Angle (see "Profile" on page 111) LeadDistance and Final Profile Pass for Profile Drilling .


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You can now create a Chamfer with a tool larger than the holewithout having to define the hole as a tapered hole.

There are some Drilling Method enhancements (on page 119).

You can now select all diameters and lengths in CompoundHoles (see "Selection by Component" on page 119).

Compound HolesCompound Holes contain several superimposed holes. Taking thisexample:

If you create a Compound Hole you will create one holecontaining two components:

The first component has a length and diameter . This has aComponent of First .

The second component has a length and diameter . This hasa Component of Second or Last .

If you create individual holes you will create two holes:

The first hole has a depth and diameter .

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