Professional Documents
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PowerMILL 7.0
By Delcam plc
Acknowledgements
This documentation references a number of registered trademarks and
these are the property of their respective owners. For example, Microsoft
and Windows are either registered trademarks or trademarks of
Microsoft Corporation in the United Stated and/or other countries.
Patents
The Raceline smoothing functionality is subject to patent applications.
Patent pending: GB 2374562 Improvements Relating to Machine
Tools
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
Introduction 1
Toolpath Preparation...............................................................1
Toolpath Generation ...............................................................4
Toolpath Verification..............................................................6
Toolpath Output ......................................................................7
User Interface..........................................................................8
General ....................................................................................9
Toolpath Preparation 10
Interface to Modelling...........................................................10
Surface Modelling ......................................................13
Wireframe Modelling .................................................13
Curve Modelling.........................................................14
Block .....................................................................................15
Edit a Block Graphically ............................................15
Routing Tools........................................................................18
Routing Tool Dialog ...................................................21
Point Distribution..................................................................23
Point Distribution - Output Point Distribution ...........23
Point Separation..........................................................25
Point Distribution - Mesh ...........................................26
Automatic Verification .........................................................27
Automatic Collision Avoidance............................................31
Tool Axis - Collision Avoidance................................32
Constant Z Collision Avoidance Example .................35
Raster Collision Avoidance Example.........................38
Setup Sheets ..........................................................................41
Setup Sheets Options ..................................................43
Additional Variables available on Setup Sheets.........44
Tool Axis Limits ...................................................................46
Model Enhancements............................................................48
Modifying Models Retains Thickness........................48
Reference Model.........................................................50
Deferred Models .........................................................51
Toolpath Generation 63
Interleaved Constant Z ..........................................................63
Surface Finishing ..................................................................67
Surface Finishing Example.........................................68
Surface Projection Finishing.................................................72
Smoothing...................................................................72
Parametric Offset Finishing ..................................................74
Port Machining......................................................................78
Port Area Clearance....................................................80
Port Plunge Finishing .................................................86
Port Spiral Finishing...................................................89
Area Clearance Enhancements .............................................91
Spiral Offset Area Clearance......................................91
New Multi-Axis Strategies ...................................................93
Projection Finishing Enhancements......................................94
Point Projection ..........................................................94
Line Projection............................................................95
Plane Projection ..........................................................96
Toolpath Editing Enhancements ...........................................97
General Toolpath Enhancements ..........................................98
Variable Feed Rates ..............................................................99
Drilling Enhancements....................................................... 100
Use Drilling Cycles ................................................. 101
Multi-Axis Drilling.................................................. 101
Gouge Checking ...................................................... 101
Retract Feed Rate..................................................... 101
Subsidiary Peck ....................................................... 103
Profile ...................................................................... 104
Chamfer ................................................................... 105
Drilling Method Enhancements............................... 105
General 113
Folders................................................................................ 113
Dynamic Sectioning........................................................... 116
Example Using Dynamic Sectioning....................... 119
Copy and Paste................................................................... 122
Copying Between Entities ....................................... 122
Copying Data from Information Dialogs ................ 123
PowerMILL Licences ........................................................ 124
Changes to the Thickness Dialog....................................... 125
Selecting Similar coloured items ....................................... 126
Preview 127
Preview - Caution............................................................... 127
Enabling Preview Software................................................ 128
PowerMILL 7.0 offers all the original features of PowerMILL 6.0, but
with numerous improvements. This document is still in the process of
being written. This is not a complete list of all the improvements. A
complete What's New will be available in time for the full release of
PowerMILL 7.0. The most significant improvements are:
Toolpath Preparation
The interface to Modelling has been improved and is integrated inside
PowerMILL. This means that you can use the standard PowerMILL
interface (such as the View Toolbar). There are three types of modelling
available:
Surface Modelling (on page 13).
Wireframe Modelling (on page 13).
Curve Modelling (on page 14).
You can now Edit a Block Graphically (on page 15).
Routing Tools (on page 18) are now supported in PowerMILL. They are
defined in a similar way to Form Tools. You can create a toolpath using a
routing tool and then simulate the toolpath to its effect.
A new Main toolbar button of Point Distribution (on page 23)
controls the point distribution of every toolpath.
A new Main Toolbar button of Automatic Verification (on page 27)
enables automatic verification of toolpaths on creation.
Automatic Collision Avoidance (on page 31) is a new 5-Axis option
that will automatically tilt the tool axis, in a user defined way, to avoid
collisions between the shank / holder of the tool assembly and the model.
Interface to Modelling
The interface to Modelling has been improved. The modelling capability
now starts inside PowerMILL and you can use the standard PowerMILL
interface (such as the View Toolbar). There are three types of modelling
available and PowerMILL chooses the most appropriate type depending
on where you access the modelling functionality. PowerMILL Modelling
Version 7.0 is available on the PowerMILL installation CD or the Delcam
web site (accessible from Help - Check for PowerMILL Updates
menu).
Surface Modelling - previously this functionality was available
from PS-Surfacer.
Once you have created what you want click on the to accept the
changes and return to the PowerMILL main window.
Wireframe Modelling
Clicking on the Wireframe Modelling button displays
PowerMILL's wireframe modelling functionality.
Curve Modelling
Clicking on the Curve Modelling button displays PowerMILL's
curve modelling functionality.
Once you have created the relevant curves click on the Save button
and then to accept the changes and return to the PowerMILL main
window.
Clicking in the graphics area (or on another entity) de-selects the block
and removes the instrumentation.
This dialog is very similar to the Form Tool dialog except that there is
one additional option of End Mill Diameter.
Name - defines the name of the tool. As with other entities, the default
name is a number.
Geometry - this area allows you to create your own tool.
End Mill Diameter - this is the effective diameter that PowerMILL uses
when creating the toolpath.
Tool ID - user defined name allocated to the tool and added to the cut
file. By default this is the same as the Name.
Number of Flutes - the number of flutes on the tool.
Tool Assembly - displays the defined tool tip, tool shank and tool
holder. For more information see the Tool Tip Dialog.
You can see the points are not equispaced as unnecessary points
have been deleted. Also some of the points are blue, these indicate
the arc centres. The red points either side of the blue ones are the
arc ends.
Tolerance and Replace Arcs - this is similar to Tolerance
and Keep Arcs except that all arcs are replaced by straight line
segments (polylines). This option is good for machine tools which
don't handle arcs well.
Redistribute - allows the insertion of new points. This ensures a
constant distance between points, only inserting extra points if they
are necessary to keep tolerance. This can be especially useful when
using the Maximum Point Separation option. Redistribute may
increase toolpath creation time but reduce time on the Machine
Tool. This option is good for machine tools that can handle large
numbers of equispaced points.
Point Separation
These options are not available if you select an option of Fit Arcs.
Mesh Factor - this effects the triangulation tolerance and must have a
value between 0 and 1 The smaller the Mesh Factor the finer the mesh
and consequently the toolpath takes longer to calculate but it is more
accurate.
Checking the Limit Maximum Triangle Length checkbox then
enables the Maximum Triangle Length field where you can enter your
value.
Maximum Triangle Length - the maximum length of the hypotenuse
of the triangle.
Head Clearance - represents the length of the tool, holder and machine
head combined. The default value is set to 600 mm. This value can be set
even if you do not define a shank or holder. If the height of the tool is less
than the Head Clearance value then an additional component is added
to the tool assembly. This component has the same diameter as the last
item in the tool assembly and a length such that the total tool assembly
length specified is the same as the Head Clearance value.
The height of the tool is just the cutter if Automatic Collision
Checking is Off and is the cutter, shank and holder if Automatic
Collision Checking is On.
For disc cutters, if a shank holder is defined, then additional components
are added to give the total tool assembly a length equal to the Head
Clearance value.
If you define a tool assembly which is longer than the Head Clearance
value then the Head Clearance value is ignored.
In previous versions of PowerMILL Head Clearance was on the Tool
- Options - Toolpath dialog.
Automatic Collision Checking - controls collision checking of
toolpaths 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.
Tilt Tool Axis - specifies how the tool will move to avoid any
collisions.
Lean - if a collision is detected the tool axis will move from the
original axis (specified on the Definition tab) in the Lean
direction until the collision is avoided.
If you specify a Fixed Direction then you can see the specified
line with an arrow on it to indicate the direction.
Tool Clearances
The tool clearances specifies the clearance around the tool shaft, shank
and holder.
Holder Clearance
Shank Tolerance
Tool Shaft Clearance
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 that
the tool holder just clears the model.
If you create a simple Raster toolpath over this you will get collisions of
the shank as it climbs or descends the step.
4. However, the toolpath is still 3-Axis on the flat portions where the
tool holder doesn't collide.
Variable Description
{ncprogram.notes} NC Program level notes.
{ncprogram.tool_datum} Tool tip (or Tool Centre)
depending on the Tool Value
setting on the NC Program
dialog.
{ncprogram.model.limits.x.min The minimum value in X of
} the Model Limits with
respect to the NC Program
output workplane.
{ncprogram.model.limits.x.max The maximum value in X of
} the Model Limits with
respect to the NC Program
output workplane.
{ncprogram.model.limits.y.min The minimum value in Y of
} the Model Limits with
respect to the NC Program
output workplane.
{ncprogram.model.limits.y.max The maximum value in Y of
} the Model Limits with
respect to the NC Program
output workplane.
This is very similar to the Block Translucency and can be useful to help
you create the correct Tool Limits..
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.
The Description field on the Cutting Data tab on the Tools dialog
allows you to enter tool notes. Text entered here is written in the cutfile as
a 29000 record.
Hole Creation (on page 58) now allows you to select whether
you create compound holes and holes from partial geometry as well
as Multi-Axis.
Compound Holes have a Hole Index (on page 60) which allows
you to select the relevant portion.
A new option on the Edit - Feature Sets Object right click menu of
Copy Holes to Pockets converts a holes to pockets so that you
can machined the holes using Area Clearance strategies.
The colour of holes can now be either the Model colour or the
Feature Set colour. This is controlled from the Tools - Option -
View menu which has an additional option of Use Model Colour
for Holes.
Use Model Colour for Holes - when checked the holes are the
Model colour. When unchecked they are the Feature Set colour.
Hole Creation
Hole Index
This topic has not been fully documented yet.
The Toolpath Points area is now on the Point Distribution (on page
23) dialog .
The Mesh area is now on the Point Distribution - Mesh (on page 26)
dialog .
Interleaved Constant Z
A new finishing strategy of Interleaved Constant Z Finishing is
now available.
Interleaved Constant Z Finishing strategy creates Constant Z
toolpath in the steep areas of a model and 3D Offset toolpath in the
shallow areas. This differs from Optimised Constant Z Finishing as
you can specify when to change from 3D Offset machining to
Constant Z machining using the Threshold Angle field and you can
specify an Overlap where both 3D Offset and Constant Z toolpaths
are created.
Also Optimised Constant Z Finishing only uses whole segments
whereas Interleaved Constant Z Finishing will split segments at the
shallow boundary. This means that Interleaved Constant Z
Finishing toolpaths have far more retracts than Optimised Constant
Z toolpaths.
4. Looking in detail:
Smoothing
Surface Projection Finishing has two new options:
Smoothing Tolerance
Angular Smoothing Tolerance
The Ports tab on the Toolpath Strategy New dialog defines how
the model will be port machined.
In all cases the strategies create toolpaths in a port (or tube) and the
toolpath retracts back safely up the port. An approximate centreline of the
port is required.
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 type
of toolpath or a particular strategy type.
The batch toolpath is automatically created in the Explorer.
Limits
The limits are at the tool centre (sphere centre) not the tool tip
position.
Workplane Limits - if checked the toolpath is limited to the
workplanes specified below. If workplane limits are used then the
plane of the slices is interpolated between the XY planes of th two
workplanes.
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).
Machining Options
Machining Options - determines which ends of the ports are used and
how far you machine down each end of the port.
The Start and End are determined by the direction of the Pattern.
Workplane limits override the Pattern direction.
Spiral - spirals inside slices
Port Machining
PowerMILL will start machining the port with a 3-Axis strategy if it can.
Once no further toolpath can be created whilst accessing one side of the
port PowerMILL accesses the port from the other end and applies the
same principle of machining with 3+2-Axis strategies wherever possible.
Pattern - defines the location of the port and the orientation of the
subsequent machining. For more information see Port Area Clearance (on
page 80).
Clearance - the tool shank and holder clearance.
Merge
Merge - determines how the machining from either end of the port
meets.
Pattern - defines the location of the port and the orientation of the
subsequent machining. For more information see Port Area Clearance (on
page 80).
Clearance - the tool shank and holder clearance.
Limits (on page 81) - determines what portion of the model is
machined. By default the whole model is machined.
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:
Point Projection
The options you select on the the Drilling dialog (including the sate
of the Use Drilling Cycles) are also selected on the NC
Program dialog by default, but you can change your mind on th
eNC Program dialog.
Multi-Axis Drilling
The Multi Axis option has been removed. PowerMILL knows when a
drilling toolpath is Multi-Axis and defines the appropriate toolpath.
All multi-axis drilling toolpaths are identified with a in the bottom
right hand corner of the Drilling dialog.
Gouge Checking
Gouge checking of drilling toolpaths is optional. There are times where
holes are capped, partially capped, not modelled or partially modelled
which all show the required drilling toolpath to be gouging. To avoid
these problems you now have the opportunity to not Gouge Check the
Drilling toolpath.
down 1
up 0.1
down 1.1
up 01.
down 1.1
up to the clear plane
down 4
up 0.1
down 1.1
up 01.
down 1.1
up to the clear plane and so
on...
One of the main differences is that the first profile takes place at Peck
Depth rather than at the top of the hole.
There are also several additional options on the Advanced Profile Drilling
dialog.
Overlap Angle - the angle (between 0° and 90°) over which the
profile overlaps.
Lead Distance - the length of the Lead move before (or after) the
drilling toolpath.
Final Profile Pass - allows you to have a different allowance for the
final profiling pass. For more information see Profiling.
Stock Models
There are various enhancements to Stock Models.
When you create a Stock Model Rest Boundary PowerMill
automatically selects values from the active stock model. For more
information see Stock Model Rest Boundary (see "Stock Model
Rest Boundaries" on page 53).
By default the Stock Model state is NOT locked this makes it
easier to invalidate the stock model without explicitly unlocking
each state and then invalidating each state.
The representation of stock models in the explorer has changed.
The Stock Model Object right click menu has an additional item
of Edit - Make Invalid. This invalidates all the calculations of the
states and unlocks them. This enables you to resolve dependency
issues between this stock model and other entities.
Folders
Folders give you an easy way to organise your data.
You can create a Folder in any of the explorer entities, but they are
probably of greatest use for organising tools and toolpaths.
Once you have created a folder it then has its own right click menu
allowing you to Create, Copy (Edit - Copy Folder) and Delete folders as
well as all the standard options for that entity type.
Key Description
→ moves the front clipping plane forward
← moves the front clipping plane back
CTRL + → moves the back clipping plane forward
CTRL + ← moves the back clipping plane back
Key:
→ right arrow key
← left arrow key
anything in bold is a key
The keyboard focus has to be in the graphics window (click in the graphics
window to give it the focus) for these shortcuts to work.
4. Check the back option and move the slider immediately above this
option to display a dynamic section. You will see the model being
"cut away".
You can copy and paste data within PowerMILL of from one
PowerMILL session to another.
Only closed segments are pasted into boundaries.
Only wireframe geometry can be pasted from models to boundaries
or patterns.
Preview - Caution
Preview features are provided to offer new functionality in their early
stages of development so that you can assess their functionality.
Frequently these features offer new and enhanced functionality requested
by users. They are placed in the program for your experimentation.
Delcam recognises that they have a minimal user interface and could be
incomplete or inconvenient to use.
Preview features are designed to give you an insight into our development
direction and we would appreciate constructive comments on how to
improve functionality and how to present the user interface. Please
provide feedback via your system supplier.
Although it is Delcam's intention to integrate Preview features
into the main functionality of the programme there is no
guarantee that this will happen or that they will be
implemented in exactly the same way.
Preview features are under continuous development: their behaviour may
have changed since this document was printed. For up-to-date
information on the detailed workings of a preview feature please refer to
the release notes. It is also possible that existing parameters may be
interpreted by preview features in different ways to the main program, so
that keying in the same data to the main and preview features may
produce different results.
The tables in the following sections show a complete list of the buttons
used in PowerMILL 6.0 and PowerMILL 7.0.
Toolbars
Main Toolbar Buttons (on page 130).
Boundary Toolbar Buttons (on page 132).
Boundary Types Buttons (on page 133).
Pattern Toolbar Buttons (on page 134).
Simulation Toolbar Buttons (on page 135).
Tool Toolbar Buttons (on page 136).
Tool Dialog Buttons (on page 137).
Toolpath Toolbar Buttons (on page 138).
Reorder Toolpath Buttons (on page 139).
View Toolbar Buttons (on page 140).
Shading Toolbar Buttons (on page 140).
ViewMill Toolbar Buttons (on page 142).
Dialogs
Block Dialog Buttons (on page 144).
Toolpath Strategy Buttons (on page 145).
Transform Dialog Buttons (on page 151).
Tool Types
Shank Holder
Holder Toolbar
ISO Views
Zoom Buttons
Last View
Refresh
Shading options
Wireframe
Thickness Shade
Drilling Strategies
The table below shows a complete list of the Block buttons used in
PowerMILL 6.0 and PowerMILL 7.0.
Drilling Methods
Finishing Strategies
The table below shows a complete list of the Finishing Strategy
buttons used in PowerMILL 6.0 and PowerMILL 7.0.
Constant Z Finishing
Corner Automatic
Finishing
Corner Multi Pencil
Finishing
Corner Pencil Finishing
Optimised Constant Z
Finishing
Not Available Parametric Offset Finishing
Pattern Finishing
Profile Finishing
Projection Surface
Finishing
Radial Finishing
Raster Finishing
Rotary Finishing
Spiral Finishing
Swarf Finishing
Copy Toolpath
Thickness
Axial Thickness
Radial Thickness
Z Heights
Delete Z Heights by
Picking
Boundary List
Machine Between
Sorting Buttons
The table below shows a complete list of the Sorting buttons used in
PowerMILL 6.0 and PowerMILL 7.0.
Translate in Y
Translate in Z
Rotate in X
Rotate in Y
Rotate in Z
Scale in X
Scale in Y
Scale in Z
Mirror XY
Mirror ZX