Lesson 5 - Boundaries

Objectives
• To Create suitable defined localised areas where machining is to be
limited.
• Create Private boundaries that are useful in Templates such as when a
new model is introduced or on an existing toolpath requires and different
size tool, the boundary will automatically be updated.

Exercise 1 - User Defined Boundary

• Import Model… \PMData\Models\cowling.dgk

• Select File > Options > Application Options

• Expand the Boundaries > Private boundaries and untick the Allow new
boundaries to be private & Accept

Choosing to select the above option makes the creation of boundaries non private
when opening any Boundary form.

• Shift-Select the surfaces defining the central pocket.

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• From the Boundary tab select User Defined

• In the User Defined Boundary form change the Model Tolerance to 0.02

select Model then Accept

When we locally select an object or objects such as surfaces, Patterns, Boundary’s

these are classified as model

• The boundary is shown in the selection colour Yellow

• View model from Top and turn on Wireframe then turn off shading

• Create a User Defined Boundary and select Sketch , change

Tolerance to (0.02)

• From the Utilities ribbon select Options followed by Intelligent

Cursor > Snapping Options and untick the Use the Intelligent Cursor &
Accept

Disabling the Intelligent Cursor allows the user to create ‘free form’ sketches without
snapping to entities

• From the Create ribbon select Curves > Bezier and by mouse
clicking produce an oval shape

You will not however be able to close the curve because the Intelligent is turned off

• Select Options once again and turn the Intelligent Cursor back on.

• Snap to the start of the curve to close

• From the Finish ribbon select Accept

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 If when creating a curve and you make an error you have the options to Undo and

Redo
You can Spline the boundary if required by right mouse clicking on the boundary and
then selecting: Edit > Spline Selected and enter a value of (2.0)

• Save the project

as…\COURSEWORK\PMProjects\UserDefinedBoundary

• Do Not Close

Summary
In the above exercise, you are now able to complete the following:

• Import Model
• Create a User Defined Boundary

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Exercise 2 - Shallow Boundary

• Create a Ø16 Ballnose tool from the Tool Database

• From Home > Block create a new Block

• Select Boundary > Shallow Enter the following: Upper Angle (30.0),
Lower angle (0.0), Tolerance (0.02), Thickness (0.0), Tool (BN16), Apply
and Accept

• Un-draw the boundary

• Save the project as…\COURSEWORK\PMProjects\ShallowBoundary

and Close

Summary
In the above exercise, you are now able to complete the following:

• Create a new Tool & Block

• Create a Shallow Boundary

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Exercise 3 - Rest Boundary

• Import Model…PMData\Models\cowling.dgk

• From Home > Block create a new Block

• Create a Ø16 Ballnose and Ø8 Ballnose tool from the Tool Database

• Select Boundary > Rest Enter the following: Detect Material thicker
than (0.2), Expand Area by (0.0), Tolerance (0.02), Thickness (0.0), Tool
(BN8), Reference Tool (BN16), Block - Limit (Tool Centre to Block Edge)
Apply and Accept

• Save the project as…\COURSEWORK\PMProjects\RestBoundary and

Close

Summary
In the above exercise, you are now able to complete the following:

• Import Model
• Create new Tools & Block
• Create a Rest Boundary

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Exercise 5 - Block Defined Boundaries

• Open project…\PMData\Projects\MultiBlock

• Activate workplane Compt1-Datum

• Select all six components and select Boundary > User Defined and select
Model & Accept

• From Home > Block create a new Block using Defined by Boundary and
Type Model, select Calculate & Accept

• From the Boundary tab select None from the drop-down list from the
Active ribbon

• From Toolpaths in the PowerMill Explorer right click on D12TR1-RGH1 and

select Edit > Set Named > Parameter

• Type Block in the Edit Parameter Name & Accept

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 The current block definition will now be active in the unprocessed model area
clearance strategy

• Right click on Toolpaths in the explorer and select Batch Process

Batch Process will sequentially calculate all valid, un-processed strategies

• Save the project as…\COURSEWORK\PMProjects\MultiBlock and Close

Summary
In the above exercise, you are now able to complete the following:

• Create a parameter from a block made from an active boundary

• Batch process numerous toolpaths using only one toolpath

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Exercise 6 - Private Boundary

• Open project…\PMData\Projects\PrivateBoundaries

• From File > Options > Application Options select Boundaries > Private
Boundaries and tick Allow new boundaries to be private & Accept

• From the Toolpath tab select BN10-CZ-SEM1 from the drop-down menu
on the Active ribbon

• Open Settings and enable editing

• In the Limit page create a Shallow Boundary with the following:

Upper Angle (40.0), Tolerance (0.10), Thickness (0.50), Apply and Accept

• Select Calculate & Close

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 Initially the Boundary 1 will be visible in PowerMill explorer until the toolpath is
calculated then it will disappear from the Boundaries folder, however the folder
name Boundaries is displayed in bold text to notify the existence of a private
Boundary
Private boundaries can be displayed by right clicking on the Boundaries folder and
selecting Display Private Boundaries

• Open Settings & Create a new toolpath based on this one

• Rename the Toolpath Name BN10-CZ-FIN1, then change the following:

Tolerance (0.01), Thickness (0.0), Stepdown (0.30) then Calculate &
Close

A new private boundary with the same parameters as toolpath BN10-CZ-FIN1 has
been created

• Save the project

as…\COURSEWORK\PMProjects\PrivateBoundaryFinish and Close

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Summary
In the above exercise, you are now able to complete the following:

• In this lesson, we have created a Private boundary which is owned by the

toolpath that is using it. If The parameters are changed within that toolpath
and re calculated the Boundary is automatically updated with those
parameters

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reserved