Apostila PowerMILL 5.5 - 5 Eixos

PowerMILL 5.
5 - Five Axis
Course
Training Centre
Tel: 0121 683 1050
Fax 0121 7665511
Delcam plc,
Talbot Way,
Small Heath Business Park,
Birmingham, B10 0HJ.
www.delcam.com
Customer Support
Tel: 0121 683 1010
Fax: 0121 7665542
Important Notice
This document is supplied as part of a Delcam Training Course. It is not
intended to be distance learning material: rather as an aid for Tutors
when presenting material to course delegates and as a subsequent aid
memoir to those delegates.
Delcam does not accept responsibility for any personal belongings /
valuables whilst on the premises. Delegates are advised to keep their
belongings on their person at all times.
Delcam plc. has no control over the use of the software described in this
document and cannot accept any responsibility for any loss or damage
howsoever caused as a result of using the software. Users are advised
that all results from the software are checked by a competent person in
accordance with good quality control procedures.
The software described in this document is furnished under a license
agreement and may be used only in accordance with the terms of such
license.
Contents
PowerMILL5.5 - Five Axis Contents

Chapters
Page Number
1. 3+2 Axis Machining and Drilling
1 - 22
2. Five Axis Tool Alignments
23 - 42
3. Surface Projection Finishing
43 - 52
4. Five Axis Pattern Finishing
53 - 68
5. Five Axis Profile Finishing
69 74
6. Five Axis Embedded Pattern Finishing
75 - 78
7. Swarf Finishing
79 - 86
8. Rotary (4th Axis) Machining
87 - 92
9. Positional Tool Movements
93 - 94
10.Tool Axis Limits
95 - 110
11.Toolpath Simulation
111 -116
12.Appendix
117 -122
Issue PMILL 5.5
Contents
Issue W1/3
Contents
PowerMILL
1. 3+2 Axis Machining
1. 3 + 2 Axis Machining
Introduction
On a 3 + 2 Axis Machine it is possible to index the head and/or bed to realign the tool prior to
performing standard X Y Z transitions. This is achieved either by manual adjustment or as
part of the cnc control.
It is possible for customers who do not possess a PowerMILL Multi-Axis licence to create
3+2 strategies by using individual Workplanes to control Tool Alignment and output ncdata
via the NC Preferences form with the Automatic Tool Alignment set to Off.
It is however both faster and easier to create 3 + 2 toolpaths if the Multi-Axis licence is
available as it provides access to a larger range of options with minimal dependency on
individual Workplanes. Either way PowerMILL enables components normally requiring a
series of separate 3-Axis operations to be machined in one set-up. This could include direct
machining of undercut features or sidewalls deeper than the maximum tool length.
It is essential to apply suitable Toolpath - Leads, Links, and Extensions to eliminate any
potential gouges.
3 + 2 Axis - Machining Example

Delete all entities and Import the 3plus2b.dgk model from the directory
five_axis/3plus2_as_5axis.
Select an Isometric view and consider the machining options. Note the relatively
high sides of the component and the orientation of the three recesses making it
impossible to machine aligned to the Z-Axis alone.
Create a Workplane at the component datum and rename it as DATUM
Issue PMILL 5.5
PowerMILL
Create another Workplane and move it by a distance of Z175 to clear the top of
the component and Rename it as ztop175_A.
Activate the Workplane - DATUM.
Note: Workplane alignment for compound angles is easier to achieve using PowerSHAPE
(If familiar with the commands). A limited functionality version called the PS-Sketcher is
accessible as standard from PowerMILL. Create a simple, two point Pattern to enable
access to the PS Sketcher, Select the model and Insert - PS Sketcher. Create, reposition,
and re-orientate Workplanes dynamically as required. Otherwise use the long method from
within PowerMILL as described below.
Create a new Workplane and Rename it as x0el30_B (This will be activated).

Using the Model Measurement tool
, snap or box the wireframe defining the
centre of the recess base positioned along the X-Axis. The form will display the
current coordinates at this point (shown below left). Do not close the form as data
is to be individually copied and pasted into the Workplane - Edit Move By
options.
Reposition the Workplane centrally at the bottom of the recess using values
copied from the Measuring tool form via the PowerMILL Calculator (X move
data shown above right).
Move the Workplane along X by Pasting the value into the Box (above right)
opened by clicking X0el30_B - Edit -Move By and then repeat the whole
procedure for the Z move.
Issue PMILL 5.5
PowerMILL
Use the Model Measurement tool to select the bottom and top coordinates of the
line running up the pocket (Defined from O to X below). This will provide angular
data to enable a Workplane - Rotation about the Y-Axis (XZ Angle) such that the
Z-Axis is normal to the pocket (add a negative sign if necessary).
Then align it about the Z-Axis (normal to the base of the recess) ensuring that the
X-Axis is pointing in the anticlockwise direction as viewed from the top of the
component (If not already the case).
Create another Workplane for the 2nd recess and rename it as x120el30_C.
Activate the Workplane - DATUM then Select and Rotate the Workplane x120el30_C around the Z-Axis by 120 degrees
Repeat for the 3rd recess, rotating a copy of the Workplane a further 120 degrees
and renaming it as x240el30_D.
Issue PMILL 5.5
PowerMILL
The component is now ready to be machined creating separate strategies relative to

the 4 different tool alignments A, B, C, and D. (Workplanes ztop175_A,
x0el30_B, x120el30_C, and x240el30_D relate to tool alignments A, B, C, and D
respectively).
It is advised that the Rapid Move Heights and

Start Point for each toolpath be above the top
of the component to allow for safe movement
between individual machining Workplanes
(as shown left).
The Settings for Rapid Move Heights

and Start Point
as applied to the
local recesses are as shown above and as entered into the forms below.
Once all Workplanes have been created a series of toolpaths can be created switching from
one Workplane to the next to provide suitable Tool Alignments. Each individual toolpath is
effectively a 3-Axis operation relative to the currently active Workplane.
Issue PMILL 5.5
PowerMILL
Suggested Roughing/Semi-Finishing Strategy

TOOL
WORKPLANE
STRATEGY
STOCK
TOOLPATH
3-Axis ROUGHING
DIA 40 End Mill
ztop175_A
OFFSET
1.0mm
Stepover 35 - Stepdown 10
em40a1
3+2 ROUGH RECESSES

DIA 10 Slot Drill
x0el30_B
OFFSET
0.5mm
sd10b1
DIA 10 Slot Drill
x120el30_C
OFFSET
0.5mm
sd10c1
DIA 10 Slot Drill
x240el30_D
OFFSET
Stepover 5 - Stepdown
0.5mm
sd10d1
3+2 SEMIFINISH RECESSES

DIA 6 Ball Nose
x0el30_B
OPTIMISED CONST Z
0.5mm
bn6b1
DIA 6 Ball Nose
x120el30_C
OPTIMISED CONST Z
0.5mm
bn6c1
DIA 6 Ball Nose
x240el30_D
OPTIMISED CONST Z
Stepdown 1
0.5mm
bn6d1
After the creation of toolpaths for 3 + 2 Axis valid ncdata can only be output using a
compatible post-processor. For programs containing multi-alignment toolpaths the NC
Programs output options create the ncdata from a common, initially activated datum (In this
case the Workplane - ztop175_A). This option is selected in the NC Preferences form.
Issue PMILL 5.5
PowerMILL
3+2 Axis Stock Model Application

The Stock Model represents the un-machined stock at any point in the machining process. It
is applied by first creating a Stock Model entity by applying a Block, followed by various
toolpaths. After each update, the stock model adjusts itself to show the un-machined material
remaining on the block.
Delete all and Reset forms.

Import the model Lower_Die.dgk from the local directory
PowerMILL_Data\five_axis\PressTools
The model contains an undercut region that would be difficult to machine using the normal 3axis roughing and finishing strategies. By using the 3+2 option, with an individual
Workplane controlling tool alignment, the undercut can be roughed and finished with
standard toolpaths.
Open the Block form and Calculate to Min/Max limits.

Select the icon
to Lock the block to the global co-ordinate system.
Accept the form.
By locking to the global co-ordinate system the blocks orientation and position remain
unchanged when activating alternative workplanes.
Create a 16 ball nosed tool and Rename 16bn.

Create a 6 ball nosed tool and Rename 6bn.
Activate the work plane Machine_Top
Reset Safe heights
with Rapid Move Type set to Skim.
Reset Start Point
as Automatic Block Centre Safe Z.
Activate the tool 16bn.
Issue PMILL 5.5
PowerMILL
Select the Toolpath Strategies icon

and from the 3d Area Clearance tab the
Raster Area Clearance option and enter the values exactly as shown below.
Rename Top_Ruf.
Angle 0.0
Apply and Accept the form.
and from the Finishing tab the Raster
Finishing option and enter the values exactly as shown below.
Rename Top_Fin
Angle 90.0
Start Corner Upper Left.
Style One Way.
Lead/Links
Lead in :Vertical Arc Angle 90 Radius 3
Lead out :None.
Links
: Short
On Surface
Long/Safe Skim

Issue PMILL 5.5
PowerMILL
The top surfaces of the model have been roughed and finished to size. Toolpaths shown in the
following illustration ( Lead/Links undrawn.)
Animate each toolpath in turn to observe the results.

In the PowerMILL explorer right mouse click Stock Models to open the local
menu and select Create.
A stock model has been created in the explorer window but will remain empty until items are
added to it.
Right Click over the toolpath Top_Ruf in the explorer window and select the
option Add to Stock Model.
Issue PMILL 5.5
PowerMILL
Right Click over the toolpath Top_Fin in the explorer window and select the
Both toolpaths have been added to the Stock Model but the Stock Model itself has yet to be
calculated.
Right Click over the Stock Model in the explorer window and select the option
to Calculate.
Select a View from Right (X)

The Stock Model clearly displays the un-machined material.
Issue PMILL 5.5
PowerMILL
Activate the work plane Machine_Side.

Select a View from Right (X)
The Machine_Side workplane enables vertical tool

alignment for the undercut region to be machined.

Reset Safe heights
with Rapid Move Type set to Skim and Start Point
and from the 3d Area Clearance tab the
Raster Area Clearance option and enter the values exactly as shown below.
Rename Side_ruf
Select Rest Machining and use Stock

Model 1.
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Issue PMILL 5.5
PowerMILL
Selecting the Rest Machining

option ensures that all cutting is
contained within the Stock Model,
therefore avoiding any unnecessary
moves into areas that have been
previously machined.
Right Click over the toolpath Side_ruf in the explorer window and select the
The toolpath has been added to the Stock Model, which will need to be re-calculated.
Right Click over the Stock Model in the explorer window and select the option
to Calculate.
The Stock Model is re-calculated and displays the remaining material.
Issue PMILL 5.5
11
PowerMILL
A boundary can be created around the stock model rest material that identifies the difference
between the Stock Model and the actual model. This boundary can then be used to finish the
component in the Rest areas only without the cutting tool encroaching into regions that have
already been machined.
Right Click over Boundaries in the explorer window and select Create
Boundary - Stock Model Rest.
The Stock Model Rest dialog is displayed.
Select Stock Model 1 and Expand Area By 1.0

Set Tolerance 0.02
Select the tool 6bn.
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Issue PMILL 5.5
PowerMILL
The Boundary has been created around the

remaining stock material on the component.

and from the Finishing tab the Raster
Finishing option and enter the values exactly as shown below.
Rename Side_fin.
Start Corner Lower Right.
One Way set.

Select Boundary 1
Lead/Links
Lead in :Vertical Arc Angle 90
Radius 3
Lead out :None.
Links
: Short
On Surface
Long/Safe Skim
Issue PMILL 5.5
13
PowerMILL
The toolpath is shown limited to the boundary

(Lead/Links Undrawn)
Add the toolpath Side_fin to the Stock Model and re-calculate.

Activate the work plane Machine_Top
Select View ISO 3.
Right click over NC Programs in the explorer window and select Create NC
Program.
Select All toolpaths and Add to NC Program
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Issue PMILL 5.5
PowerMILL
Close the NC Program dialog box.

Raise the Viewmill toolbar
and Toggle
the viewmill window.
Set the Icon to View Complete NC Program.

Start the Simulation
and view the virtual machining of the component.
Issue PMILL 5.5
15
PowerMILL
3+2 Axis - Drilling Example (For users with MultiAxis licence)

The PowerMILL - Drilling options operate on Hole Features and not directly on the
Model. This enables drilling to take place without the need to modify or trim back the
existing surface data.
Delete all entities and Import the model drill5ax_ex1 from the directory
five_axis/drill_5axis.
Define the material Block to the component limits and view the model along the
Y-Axis.
Any cylindrical surfaces within the selection will automatically be recognised as Hole
Features. The orientations of the Holes are controlled with the top being the closest to
the Max or Min, Z dimension of the Block.
It is possible to Reverse the Holes in a Feature Set using the local Edit options
combined with dynamically selecting the relevant Hole Features.
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Issue PMILL 5.5
PowerMILL
Reset the Rapid Move Heights
(Safe Z, Start Z) and then, set the Start

Point
Select all the surface data in the graphics window and then right mouse click
Feature Sets in the PowerMILL Explorer.
Select the option Preferences.
This will open the Feature Form.
Create the Feature Set entering the values into the form Exactly as shown
Multiaxis option selected.
Apply and Close the form.

Issue PMILL 5.5
17
PowerMILL
Any cylindrical surfaces within the selection will automatically be recognised as Hole
Features.
Undraw the model to view the newly created features.
Hole features are defined with a specific top and bottom.
Top of hole (no cross)
Bottom of hole (crossed)

The orientations of the Holes are controlled with the top being the closest to the Max or Min,
Z dimension of the Block. On closer inspection three of the hole features have an incorrect
orientation. These are to be to be reversed.
Incorrect Orientation
18
Issue PMILL 5.5
PowerMILL
Select the Three incorrectly orientated holes.
Right mouse click over the Feature Set in the explorer window.
Select Edit, Reverse holes.
All holes now have the correct orientation and are ready for drilling.
Create a 5mm drill of length 90.

Add a holder component Upper dia 50 lower dia 30 length 30 overhang 80
Add a holder component Upper dia 50 lower dia 50 length 30
Issue PMILL 5.5
19
PowerMILL

and select the Drilling option located in
the New strategies form.
Rename the toolpath 5mm drill.
In the Drilling form click the Select tab to open the Feature Selection form.
Select and Close the Feature Selection form.This will select all the diameters
from the list.
With the Multiaxis option selected on the drilling form Apply and Close to create
the drilling toolpath.
Animate the toolpath.
The multiaxis licence enables the user to

create a single feature set from components
that lie in different workplanes and machine
them in one go.Without the licence the
recognise holes in model option can be used
from the feature set menu to create the hole
features.This command splits the features by
alignment but also creates separate
workplanes with the Z axis aligned to each
Feature Set.
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Issue PMILL 5.5
PowerMILL
The two 6mm Hole Features are to be Tapped. The point angle of the 5mm Drill has left a
conical shape at the bottom of the holes. When the holes are Tapped it will be necessary to
stop short within the full diameter range by applying a suitable Axial Thickness value.
Create a 6mm Tapping Tool of length 25.

Add a Shank, Upper - Dia 4, Lower Dia 4, Length 40
Add a Holder, Upper- Dia 30, Lower Dia 30, Length 20, Overhang 60.
Select the two 6mm Hole Features in the Graphics Window.

followed by the Drilling option located
in the New strategies form.
Rename toolpath 6mmtap.
Set Cycle Type - Tapping, Operation - Drill to Hole Depth, and Pitch - 1mm.
Input an Axial Thickness value of 5mm.
Axial Thickness
Apply and Close the form to create the toolpath.

Issue PMILL 5.5
21
PowerMILL
View the model along the Y axis.

Right click over the 6mmtap toolpath in the Explorer window and select Attach
Active Tool to Start.
Left click in the graphics window and use the Right/Left Cursor keys to step
through the toolpath.
The selected holes have been Tapped to a distance 5mm short of the full depth.
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
2. Five Axis Tool Alignment

Introduction
In 5-Axis applications where the machine tool head and/or table, rotates simultaneously with
the linear axis movements, PowerMILL provides a range of suitable Tool Alignments and
Machining Strategies.
5-Axis machining enables components normally requiring a series of 3-Axis operations to be
machined in one set-up. Tools can be re-aligned using 5-Axis control to provide access to the
base of steep or undercut features, which are otherwise inaccessible down the Z-Axis.
In 5-Axis applications it is essential that suitable Leads, Links, and/or 3d limiting
techniques are applied to correct any problems identified by the default gouge check. In all
cases it is also advisable to carry out a thorough visual inspection of the results.
Five Axis Tool Alignment and Machining Options

Not all PowerMILL Machining Strategies directly support Five Axis Tool Alignments but
those that do are shown highlighted in the Toolpath Strategies
shown below.
- Finishing options
Machining Strategies that do not directly support Five Axis Alignments can be made to do
so by the application of Pattern finishing (with appropriate options set) as a secondary
operation on the original toolpath.
By default the Tool Axis in PowerMILL is set to Vertical for 3-Axis applications.
Tool alignments for use with 5-Axis operations are available via the Tool axis icon
located in the Main toolbar or directly from Machining Strategy forms (as shown below).
Issue PMILL 5.5
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2. Tool Alignment
PowerMILL
Lead/Lean
Lead allows the tool to be aligned to a specified angle along the toolpath direction and Lean
a specified angle across the toolpath direction. If both angles are zero the tool will be aligned
along the normal of the toolpath. The normal of the toolpath is the direction along which it
is projected onto the surface data during creation. For Pattern finishing this will always be
vertical and for Projection Finishing it will vary depending on the local projection direction.

Create a Block to the sizes displayed in the table.
X
Y
Z
Min
-50
-25
0
Max
50
25
10
Reset safe Z heights and Start point.

Right Click the Models option in the Explorer Window and Create a Plane
from Block at a Z limit of 0.
Create a 5mm ballnose tool of length 50 and rename 5bn.

Create a Raster Finishing Strategy, Rename - Raster Vertical, and set Tol 0.02
Thickness 0 Stepover 5 Angle 0 Style Two Way Short Links On Surface
Apply the toolpath and Cancel to close the form.
Animate the Toolpath.
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
A raster toolpath has been created with the tool aligned vertically to the plane.
Right Click the Toolpath Raster Vertical in the Explorer Window and select
Settings to open the toolpath form.
Make a Copy
of the toolpath and rename Raster Lead@-30.
Select the Tool axis icon
to open the Tool Axis Direction Form.
Define the Tool Axis as Lead/Lean with the Tool Lead Angle set to 30.
Accept the Tool Axis Direction Form, Apply the toolpath and Cancel to close
the form.
A raster toolpath has been created with the tool

axis direction set to Lead -30 Along the Toolpath.
Using the Two Way option the tool axis direction
will alternate at the end of each pass.
Issue PMILL 5.5
25
2. Tool Alignment
PowerMILL
Right Click the Toolpath Raster Lead@-30 in the Explorer Window and select
Re-cycle
the toolpath and change Style from Two Way to One Way.
Apply the toolpath and Cancel to close the form.
With the Style set to One Way the tool axis direction
remains constant.
Right Click the Toolpath Raster Lead@-30 in the Explorer Window and select
Make a Copy
of the toolpath and rename Raster Lean@45.
Select the Tool axis icon
to open the Tool Axis Direction Form.
Define the Tool Axis as Lead/Lean with the Tool Lead Angle set to 0 and Tool
Lean Angle of 45.
Accept the Tool Axis Direction Form, Apply the toolpath and Cancel to close
the form.
A raster toolpath has been created with the tool
Axis direction set to Lean 45 Across the Toolpath.
View from left -X
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
Example2

Import model 3plus2b.dgk from the local directory five_axis/3plus2b_as_5axis.
Create the material Block to component size.

Define a 15mm diameter Ball Nose cutter (bn15).
Input a Safe Z of 185 and Start Z of 180.
In the tool Start Point form set Mode: Fixed and Start Point: Absolute and enter
the Coordinates: X-100 Y0 Z190.
In the Main Toolbar set the Tool Axis

- Lead/Lean values both set to 0. This
will force the tool to be aligned along the projection direction of the machining
strategy onto the model.
Set Leads/Links
as follows:-
Zheights:
Lead In/Out:
Links:
------ Skim 15 Plunge 5

------ Vertical Arc:
Angle 90
------ Short/Long/Safe: Skim
Radius 6

and select the Finishing tab located in
the strategies form.
Enter the values into the Plane Projection Finishing and Tool Axis forms exactly
as shown on the following page and Apply.
Issue PMILL 5.5
27
2. Tool Alignment
PowerMILL
Set One Way
Animate the toolpath and observe the associated cutter alignment.
The resultant toolpath starts at the lower corner and

climb mills upwards with a lead in and lean out
angled.
To compare the effect of applying a different machining strategy the same area of the
component will be machined using Raster Finishing. This time the Tool Axis will be
aligned with a Lean of 30 degrees relative to the downward projection of the Raster
Finishing strategy.
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
Select the Fillet surface and the Spherical surface attached to it.
With the Two surfaces selected Calculate a Block and Modify the values to read
Xmin -70 Xmax -45 Ymin -50 Ymax 50
and select the Finishing option located in
Open the Raster Finishing and Tool Axis forms and enter data exactly as shown
below and Apply and then Cancel.
The resultant toolpath starts at the lower corner and climb mills
upwards with a lead in and lean out angled.
Issue PMILL 5.5
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2. Tool Alignment
PowerMILL
View along the Y-Axis and Animate both toolpaths in turn to compare the results
of the lead/lean option. Note the tool alignment is the same for both toolpaths due
to a suitable Lean value of 40 being applied to the Raster strategy.
Lead/Lean is designed for unidirectional toolpaths the main application being to maintain a
suitable angle of the Tool Axis away from steep features as well as the machine tool table.
The lower part of the component form in the next example is an ideal application for applying
a suitable Lean value using Lead/Lean - Tool Axis alignment.
Example 3

Import the model joint5axis.dgk from the directory
PowerMILL_Data/five_axis/joint_5axismc.
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
Create the material Block to component size and expand by 15mm in X and Y
only.
Define a 25mm diameter Ball Nosed cutter (bn25).
Reset Safe Z and Start Z.
In the Start Point set Mode: Automatic and Start Point: Block Centre safe Z.
Modify Leads/Links
as follows:Zheights:
Skim 45 Plunge 10
Links:
Skim.

Open the Line Projection Finishing and Tool Axis forms and enter data exactly
as shown and Apply.
Set: Lead 0 Lean -30
The resultant machining is illustrated below after the appropriate gouge protection has been
applied (Leads/Links) as specified earlier.
Issue PMILL 5.5
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2. Tool Alignment
PowerMILL
Note: The next section continues with the

machining of the above component.
Toward / From Point
These options allow the Tool Axis alignment to be based on a user-defined point during the
generation of toolpaths. The alignment is towards the Preview pattern for the toolpath and
not the actual toolpath. Toward Point is suitable for aligning to external forms (Upstands)
while From Point is suitable for aligning to internal forms (Pockets). The upper part of the
existing component is an ideal application for the Toward Point tool alignment.
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
Note:- The same alignment condition (above) applies to Toward / From Line (page 8).
Set Leads/Links
Zheights:
Lead In;
Lead Out:
Extensions;
Links;
as follows:-
------ Skim 45
------ Horizontal Arc
------ Vertical Arc
------ Inwards/Outwards
------ Skim
Plunge 10
Angle 90
Radius 6.0
Angle 90
Radius 6.0
Extended Move Distance 30

Open the Point Projection Finishing and Tool Axis forms and enter data exactly
Note the Tool Alignment point is approximately 10mm below the Projection Finishing
focal point to ensure that the spindle axis remains at an elevation angle to the machine tool
table during machining hence avoiding collision.
The resultant machining is illustrated after suitable gouge removal has been applied to the
start and end of the toolpath.
Issue PMILL 5.5
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2. Tool Alignment
PowerMILL
Toward Line / From Line

These options allow tool axis alignment to be based on a user-defined line, specified by point
and Vector, during the creation of the 5-Axis toolpath. The alignment is towards the preview
pattern for the toolpath and not the actual toolpath. Toward Line is suitable for aligning to
external forms (Upstands) while From Line is suitable for aligning to internal forms
(Pockets).
In the Explorer select Model -Delete All.

Import the model 5axisdie.dgk from the local directory five_axis/die_5axismc.
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Issue PMILL 5.5
PowerMILL
2. Tool Alignment
Continue to use the same 25mm diameter Ball Nose cutter.

Define the material Block to the component limits.
In the Start Point set Mode: Automatic and Position: Block Centre safe Z.
Reset Safe Heights.
Set all Leads and Extensions to None, Zheights Skim to 5 and Plunge to 5.

One Way (ticked)
The end result is as shown in the following illustration (Links reset to Skim).
Issue PMILL 5.5
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2. Tool Alignment
PowerMILL
Animate the generated toolpath and then open Leads and Links form
entering values as set out in the following table:
Lead In
-- Extended Move
Distance 10.0
Lead Out -- Extended Move
Distance 20.0
Extensions -- Inward/Outward Vertical Arc Angle 90.0
Links
-- Short
Skim
-- Short/Long
Threshold 10.0
-- Long
Safe Z
-- Safe
Skim
Apply the Leads and links form.
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Issue PMILL 5.5
Radius 10.0
PowerMILL
2. Tool Alignment
Fixed Direction
This allows the tool axis to be set to a fixed angle, specified by Vector, defined by the user. In
this case it is applied to the finishing of an undercut form on the 5axis_fixture.dgk model.
In the Explorer select Model -Delete All.

Reset forms.
Import the model 5axis_fixture.dgk from the local directory five_axis/
Autorail_and_Fixture
Create a 16 Ball nosed cutter (16bn).
Set all Leads and Extensions to None.
The model consists of components constructed on two levels, Fixture: surfs and Part: surfs,
that can be drawn an undrawn by opening the Levels form in the Explorer window. To
demonstrate an application of the fixed direction alignment, only the Fixture: surfs level
needs to be drawn.
Undraw the Part: surfs level from within the explorer window.
Note: Even undrawn surfaces are still registered in PowerMILL and will be machined. To
stop this, you can acquire the level to the Components list and then ignore it when the
toolpath is calculated.
Activate the workplane Car line datum.

Select the surfaces of the location to be machined and calculate a block.
Issue PMILL 5.5
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2. Tool Alignment
PowerMILL
Location to be machined
(Block drawn)
Fixed Direction Tool Alignment Vectors/Angular equivalents

The table represents angular directions and vectors on the XY plane (Z=0).
ANGLE
(Degrees)
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
38
VECTORS
(I
J
K)
1 0.0000 0
1 0.0875 0
1 0.1760 0
1 0.2680 0
1 0.3640 0
1 0.4660 0
1 0.5770 0
1 0.7000 0
1 0.8390 0
1 1.0000 0
1 1.1920 0
1 1.4280 0
1 1.7320 0
1 2.1450 0
1 2.7470 0
1 3.7320 0
1 5.6710 0
1 11.4300 0
0 1.0000 0
Issue PMILL 5.5
PowerMILL
2. Tool Alignment
The tool axis is oriented in a fixed direction relative to the currently active workplane defined
by a specified IJK vector in the Tool Axis direction form. Although it can be difficult to
work out the required IJK vector, this option can enable you to machine undercut areas very
effectively.
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2. Tool Alignment
PowerMILL

as shown below.
Draw Toolaxis (ticked)
Select the Thickness icon

and then the Components tab
to access the Component Thickness form.
Highlight a segment from the list.
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2. Tool Alignment
Select the level Part: surfs from the pull down level selector.
Acquire the selected level

to the Component Thickness list.
Select Ignore from the machining mode pull down option.
Accept the form and Apply the Toolpath.
The tool axis is fixed to the direction specified by the IJK vector. By setting the machining
mode to ignore for the part surfaces only the fixture is machined. The tool axis has also been
drawn indicating the vector direction.
Note: The vector must be defined pointing away from the surfaces to be machined.
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2. Tool Alignment
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Issue PMILL 5.5
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3. Projection Surface
3. Projection Surface Finishing

Introduction
The toolpath is projected along the normals of a Reference Surface onto the main
component with tool alignment as specified by the user. The toolpath runs either across or
along the Reference Surface directions (U or V) with the Stepover being defined by unit
Distance or Parametric division between Surface Curves. In some cases the Reference
Surface may form part or all, of the component to be machined.
To create a Reference Surface the user will require the services of a suitable Surface
Modeller, ideally PowerSHAPE. For the following example the Reference Surface has
already been created and stored as a separate dgk file to be imported as required.
Import in two models joint5axis.dgk and joint_ template1.dgk from the local
directory PowerMILL_data/five_axis).
Create a Block to the component dimensions.

Define a 16mm diameter Ball Nosed cutter.
In the Leads and Links form

set Short Links to On Surface and Long/Safe
Links to Skim adjusting the Zheights to a Skim distance of 30 and Plunge
distance of 5.
Select the Reference Surface joint_ template1.dgk (shown shaded above).
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PowerMILL

in the Main toolbar to open the strategies
form.
Select the Finishing tab followed by the Projection Surface Finishing option.
Enter the values into the Surface Projection Finishing and Tool Axis forms
exactly as shown below and Apply.
Enter the Name - ref1_U
Set One Way
With Pattern Direction set to U the toolpath will

appear along and aligned to the Reference Surface
- Longitudinal direction (as shown below).
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Do not close the form after processing is complete but select the Copy
icon
to re-activate the settings and input the new Name - Ref1_V
Untick the box One way, set the Pattern Direction to V and select Apply.
This time the toolpath will appear along and

aligned to the Reference Surface - Lateral
direction (as shown below).
Both the above toolpaths have a stepover based on a unit Distance value across the
Reference Surface. The Finishing form will now be amended to use Parametric division.
Delete the Reference Surface joint_ template1.dgk and as a replacement,

Import - joint_ template2.dgk and make sure that it is selected.
Apply another Copy of the Surface Projection toolpath named Ref2_U with
Surface Units - Parametric, Pattern Direction - U, and Stepover - 0.1.
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PowerMILL
The Stepover - 0.1 creates 10 equally spaced

tool tracks between each pair of Reference
Surface Curves parallel with the machining
direction.
To even out large variations in Stepover
across the component the Reference Surface
requires the addition of extra, suitably placed
curves.
A modified copy has already been created in
PowerSHAPE to replace the current
Reference Surface as instructed below.
Delete the Reference Surface joint_ template2.dgk and as a replacement,

Apply a Copy of the above Surface Projection toolpath named Ref3_U to create
the following result.
The new toolpath contains a consistant

Stepover.
To provide full flexibility for the shape of the Reference Surface it is possible to
allow it to exist outside the component.
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This is achieved by setting the Finishing strategy Component Thickness option to

Ignore it during the actual toolpath projection (it is still used to control the Tool Axis
alignment).
Delete the Reference Surface - joint_ template3.dgk and as a replacement,
Note: Most of the new Reference Surface

exists outside the component to be machined.
Also this surface is inside out (shaded dark
brown).
Start a Copy of the Surface Projection toolpath named Ref4_U with Surface
Units - Distance, Projection Outwards, Pattern Direction - U, Stepover 1.0
and One Way ticked.
Select the Thickness icon to access the following form (shown on the following
page).
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PowerMILL
Select one of the rows in the form, set Machining Mode to Ignore, and with the
Reference Surface still selected click on the Aquire Components icon.
Select a row.
Set the MachiningMode
to Ignore.
Click the Aquire
Components icon.
The row will display the value 1 in the Components category to show that a single
surface has been assigned to it.
Accept the above form and then Apply the Surface Projection Finishing form to
produce the following toolpath.
Note: The Reference

Surface used to provide
the Tool Alignment has
been ignored during the
toolpath projection onto
the component.
Select File - Delete all and Tools - Reset forms.
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Surface Projection Range.
It may be required, on occasion, to limit the projection range whilst applying the Surface
Projection strategy. This can be necessary if the surface to be machined is within close
proximity to other surfaces that do not require machining or are affecting the surface
projection results. This command is, at present, only available on Preview via typed input
into the Command Window.
Note: Preview features are provided for you to evaluate and should NOT generally be
used for production work. Delcam makes no guarantee that the behaviour of Preview
features will be preserved when they are released.
Import the model Blade Inserts.dgk from the local directory

PowerMILL_data/five_axis/Blade_Sub_Assembly

Define a 6mm diameter Ball Nosed (6bn) cutter of Length 30.
Create a Shank with Upper Dia 6 Lower Dia 6 Length 20.
Create a Holder with Upper Dia 20 Lower Dia 16 Length 30
Add a Holder component Upper Dia 30 Lower Dia 30 Length 20
Set Start Point Mode:Automatic and Position:Block Centre safe Z.
Set Leads and Links as follows
Lead in/out
Extensions
Links
Horizontal arc
Distance 0
Short/Long/Safe
Skim.
Issue PMILL 5.5
Angle 90
Overhang 40
Radius 3
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PowerMILL
Select the Blade Surface to be machined (shown shaded below).
Select the Finishing

tab followed by the Projection Surface Finishing
option.
Enter the values into the Surface Projection Finishing and Tool Axis forms
Rename default_projection_range.
One way Set

Start Corner specified.
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With the projection set to

default, ie. No limit, the
toolpath is projected inwards
towards the surface to be
machined from the extremity
of the model limits. As the
toolpath is projected it will
encounter the neighbouring
surfaces before the surface to
be machined and create the
toolpath as shown.
Projection Range
Contour Produced
This problem can be resolved by specifying a limited distance, usually the radius of the
cutter, as the projection range.
From the View menu at the top of the screen Select the option Toolbar Command Window.
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PowerMILL
Select Settings from the toolpath in the explorer window and make a Copy
of the original toolpath.
Rename the toolpath 3mm_projection_range.
Click the mouse into the Command Window at the bottom of the screen and
enter the following commands.
EDIT SURFPROJ AUTORANGE OFF
EDIT SURFPROJ RANGEMIN 3
EDIT SURFPROJ RANGEMAX 3
This command sequence limits the Surface

Projection distance range to + / - 3mm.
Apply the form to calculate the toolpath.

Animate the toolpath to observe the effect of
the limited projection range.
EDIT SURFPROJ AUTORANGE ON

This command returns to default no limit to the Surface Projection distance range.
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4. Pattern Finishing
4. Five Axis Pattern Finishing

Introduction
The following Finishing strategies; 3D Offset, Constant Z, Optimised Constant Z, Pencil,

and Corner, are examples that do not directly support 5-Axis Tool Alignments.
A 5-Axis conversion is achieved by re-machining using the Pattern finishing strategy. If
Base Position - Automatic is specified the toolpath will be recreated to the selected 5-Axis
Tool Alignment (as illustrated below).
Original
Vertical Alignment
New 5-Axis Alignment
Corner Finishing - conversion to 5 Axis
Import the model pocket_sld.dgk from the local directory

PowerMILL_data/five_axis/vert_pocket.
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PowerMILL

Define a Ball Nosed tool 8mm diameter.

Enter the remaining values into the Corner Pencil Finishing form exactly as
shown below and Apply.
Note: Five Axis tool alignment

options are not directly available
with the Corner Pencil Finishing
strategy (shown below).
The resultant 3-Axis toolpath can
however be machined using the
Pattern Finishing strategy set to
recreate the original toolpath as a
5-Axis Tool Alignment.
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Enter the remaining values into the Pattern Finishing and Tool Axis forms
As displayed on the form the
Use Toolpath box is ticked,
the original Toolpath is
selected as the Pattern, and
the Base Position is set to
Automatic for the 5-Axis Tool
Alignment to work.
The resultant 5-Axis toolpath
is shown below with the
original 3-Axis tooltrack
(inside).
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PowerMILL
Apply Leads/Links as follows:Zheights:

Lead In/Out:
Extensions:
Links:
---------
Skim 15 Plunge 5
Vertical Arc
Angle 90
Radius 6
Inward/Outward
Extended Move
Short/Long/Safe: Skim
Distance 5
Animate the active toolpath to display the 5-Axis tool movement and the contact
points between both the base and sidewalls of the pocket as shown below.
Corner Finishing - conversion to 5 Axis
The previous example involved a unidirectional toolpath to 5-Axis, Pencil machine the
intersection of the sidewalls with the base of a pocket. In this case the 5-Axis Tool
Alignment was achieved using Lead/Lean with values of 0 and 20 respectively. This would
not be an option for a bi-directional toolpath due to Lead/lean being dependant on the
direction (The Lean of the tool would keep switching sides on the alternate toolpath
direction). For the following Stitch Corner example a From Point - 5-Axis Tool Alignment
is applied which is not affected by the toolpath direction.
This example uses the same settings as before using the original 8mm Ball Nosed cutter for
the machining process.
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Define a Ball Nosed tool 16mm diameter to be used as the Reference Tool.
Enter the remaining values into the Corner Stitch Finishing form exactly as
Note: Five Axis tool alignment

options are not directly available with
the Corner Stitch Finishing strategy
(shown below).
The resultant 3-Axis toolpath can
however be used in a Pattern
Finishing strategy set to recreate the
original toolpath as a 5-Axis Tool
Alignment.
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PowerMILL

As displayed on the form the Use
Toolpath box is ticked, the
original Toolpath is selected as
the Pattern, and the Base Position
is set to Automatic for the 5-Axis
Tool Alignment to work.
The resultant 5-Axis toolpath is

shown below.
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Apply Leads/Links as follows:
Zheights:
Lead In/Out:
Extensions:
Links:
---------
Skim 5 Plunge 5
Vertical Arc
Angle 90
Radius 3
Inward/Outward
None
Short/Long/Safe:
Skim
Animate the active toolpath to display 5-Axis tool movement and the contact
points between both the base and sidewalls of the pocket as shown below (Leads
and Links not displayed for clarity).
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PowerMILL
Corner Finishing conversion to 5 Axis (continued)
Open the Project Corner_finish from the local directory

PowerMILL_data/five_axis/5axis_Corner_Finish/Corner_finish
The Project contains a single corner finishing toolpath strategy calculated using a 4mm ball
nosed tool assembly referenced against an 8mm ball nosed cutter.
By Attaching the Active Tool it is clearly visible that the bottom of the pocket is unable to be
machined safely using the current tool assembly. This can be confirmed by verifying the
toolpath.
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Right click over the toolpath 4mm_corner finish in the explorer window and
select Verify from the list.
Enter the values into the form exactly as shown and Apply.
PowerMILL will check the toolpath for collisions using the 4bn tool assembly. The toolpath
will be divided into safe and unsafe moves with safe moves machined using the current 4bn
tool and unsafe moves machined with an automatically created tool called 4bn_1. This newly
created tool is a replica of the original tool assembly, with a modified overhang value, to
enable the bottom of the pocket to be machined without collision.
From the Explorer window display the properties of the 4bn and 4bn_1 tools.
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PowerMILL
Therefore to machine the pocket using vertical tool alignment it is necessary to introduce an
additional extended tool. However, using the extended tool raises further issues i.e.
Increased tool deflection, reduced cutting speed etc. all of which may not be acceptable to the
user. Altering the tool alignment will make it possible to machine the pocket with the original
tool. Five Axis tool alignment options are not directly available with the Corner Stitch
Finishing strategy. The 4mm_corner finish_2 3-Axis toolpath can however be used in a
Pattern Finishing strategy set to recreate the original toolpath as a 5-Axis Tool Alignment.

and select the Finishing option located
in the strategies form.

4mm_corner finish_2 Toolpath is
selected as the Pattern, and the Base
Position is set to Automatic for 5-Axis
Tool Alignment to work.
Accept the form.

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The tool can be seen to be leaning away from the walls of the pocket thus avoiding any
collision. This can be confirmed by verifying the toolpath.
Right click over the toolpath 4mm pattern corner finish in the explorer window
and select Verify from the list.
Use the values stored within the form from its previous application and Apply.
PowerMILL will confirm that the toolpath is collision free.
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PowerMILL
Constant Z Finishing - conversion to 5-Axis
Import the model punch2_insert.dgk from the local directory

PowerMILL_data/five_axis/punch2.
Initially a 3-Axis, Constant Z
finishing strategy will be created,
which when checked will be found
to be in collision with the
component form. The strategy will
then be re-machined as a Pattern
finishing strategy along with a
suitable 5-Axis, Tool Alignment. A
full collision check will again be
performed on the final toolpath.

Create a Ball Nosed tool Dia 20, Length 100, Name bn20 as shown in the
following form.
Add a Shank with Upper Dia 30, Lower Dia 20 and Length 50.
Add a Holder with Upper/Lower Dia 50, Length 30 and Overhang as 200..
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Activate the Ball Nosed, bn20.

Select the Sidewall Surface (shown shaded dark below) and Create a Selected
Surface Boundary with the name constZ.

Enter the remaining values into the Constant Z Finishing form exactly as shown
below and Apply.
Toolpath Name is ConstZ_vert.
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PowerMILL
Attach the Active tool, bn20 to a point along the base of the toolpath near to the
highest point of the model to observe the expected Collision condition.

Enter the remaining values into the Pattern Finishing form exactly as shown
below and Apply.
original Toolpath is selected as
the Pattern, and the Base
Position is set to Automatic for
the 5-Axis tool alignment (Lead
0, Lean 30) to work.
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The resultant toolpath (shown below) is a 5-Axis version of the original Constant Z strategy.
Open the Collision checking form by selecting the
icon in the top toolbar.
Select the option Check Collisions.

Set Scope All.
Uncheck Split Toolpath.
Apply the form to receive the following message

confirming that the toolpath is collision safe.
The lower fillet is yet to be machined and again requires a suitable 5-Axis strategy to avoid a
collision situation (This will be covered later in Chapter 9 - Tool Axis Limits).
Save the Project as C:\temp\Punch2 to be continued later during Chapter 10 Tool Axis Limits.
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Issue PMILL 5.5
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5. Profile Finishing
5. Five Axis Profile Machining

Introduction
The Profile Finishing strategy can be applied to Five Axis applications. In the following
example it will provide a Tool Alignment normal to a user defined, surface flowing inwards
at 90 degrees to the base of an angled pocket. Note, the Profile Strategy, controlling surface
is not necessarily the actual base of the pocket.
Import the two models, locnpad.dgk and pocket.dgk (shown shaded) from the
local directory PowerMILL_data/five_axis/locnpad_5axismc.
Delete the locally defined top surface covering the pocket.

Activate the 16mm diameter Ball Nosed cutter.

Enter the remaining values into the Profile Finishing and Tool Axis forms exactly
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PowerMILL
Select the surface defining the base of the pocket, click Apply and after the
toolpath is processed Cancel the form.
The following toolpath is created in which the tool is constantly aligned to the
sidewalls for each profiling pass, the final pass being exactly on the base.
Note:- the Reference Surface has been specially designed to create a Tool Alignment that is
always parallel with the sidewalls of the pocket with Lead/Lean 0.
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Animate the toolpath and observe the Tool Alignment normal to the Reference
Surface (as well as parallel to the sidewalls).
Import the additional model flat_pktbase from the same directory as before.
Right mouse click the toolpath and select Settings to reopen the Profile Finishing
form.
Select the icon to Create a new toolpath based on this one
.
Ensure that the original base surface still selected as the Reference Surface.
Click Apply and after the toolpath is processed Cancel the form.
The tool is still aligned to the lower (selected) Reference

Surface but this time the profile tooltracks are limited by the
upper base surface.
The next example shows how Profile can be used to swarf machine the sidewalls of the
component. After the calculation of the tool tracks additional limiting will be required to
leave just a single track around the base.
Right mouse click the latest toolpath and select Settings to reopen the Profile
Finishing form.
Select the icon to Create a new toolpath based on this one
.
Select the outer sidewall surface of the component (shown shaded below), right
click over it to open the local menu and select the option Reverse Selected.
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PowerMILL
Update the remaining values in the Profile Finishing and Tool Axis forms to be
exactly as shown below and Apply and after the toolpath is processed Cancel the
form.
Gouge Avoidance:Multiple Cuts :Lead/Lean:-
Strategy Trace
Mode Off
Lead 0
Upper Limit box unticked

Lean -90
Apply Leads/Links as follows:Zheights:

--- Skim 15 Plunge 5
Lead In/Out: --- Horizontal Arc
Angle 90
Links:
--- Short/Long/Safe: Skim
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Radius 10
PowerMILL
The resultant toolpath must now be modified to leave the single track around the base.
Select the unwanted, upper tool tracks (arrowed) using the left mouse key and then
right mouse click to open the specific, toolpath menu.
Select Edit -> Delete Selected to retain only the single lower tool track.
Animate the toolpath and observe the Tool Alignment following the variable
angle around the component sidewall.
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Issue PMILL 5.5
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6. Embedded Pattern
6. Embedded Pattern Finishing

Introduction
This strategy allows the user to produce an Embedded Pattern Finishing Toolpath using an
Embedded Pattern to define the contact points of the toolpath. An Embedded Pattern is a
curve lying on the model linked to its associated surface (or surfaces).
An Embedded Pattern Finishing toolpath can be used to specify the exact position of
contact point or to use information about the underlying surface (for example surface normal)
to determine the Tool Axis orientation when engraving.
Embedded Pattern Finishing Engraving
Import the model Embedded.dgk from the local directory

PowerMILL_data/five_axis/ 5axis_Embedded_Pattern.

Create a Taper Tipped Form tool Dia 5 Tip rad 0.5, Length 25, Taper height
15, Taper Angle 7.5,Name TTR 0.5
Add a Shank with Upper/Lower Dia 5 and Length 10.
Add a Holder with Upper Dia 30, Lower Dia 20 and Length 5.
Add a Holder with Upper Dia 30, Lower Dia 30 and Length 20.
Right click over Patterns in the Exporer Window and select Toolbar to display
the Pattern toolbar at the top of the screen.
Create a Pattern
and Insert from File the Delcam_Pattern.dgk from the
local directory PowerMILL_data/five_axis/ 5axis_Embedded_Pattern.
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6. Embedded Pattern
PowerMILL
The Pattern contains the Text DELCAM positioned above the component surfaces. It then
needs to be embedded before it can be used.
Rename the Pattern Text

Right click the Patterns menu in the explorer window and select Edit Embed.
The Embedded Pattern dialog is displayed.
Select Drop as the method and Apply.
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6. Embedded Pattern
An Embedded Pattern called Text_1 is created marked by

the explorer. The original pattern is also kept.
in
and select the Embedded Pattern

Finishing option located in the strategies form.
Enter the values into the Embedded Pattern Finishing form exactly as shown and
Apply.
Select the Embedded Pattern

Text_1
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6. Embedded Pattern
PowerMILL

The embedded toolpath has been produced normal to the surface but the toolpath has been
highlighted in the explorer window with a warning.
This is because the
lowest toolpath segments intentionally cut into the surface to produce the engraving. To
remove the warning the toolpath would have to be gouge checked. This can be applied from
within the Embedded Pattern Finishing form, however by applying this the lowest toolpath
segments will be removed.
Toolpaths with and without Gouge Check.
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7. Swarf Finishing
7. Five Axis Swarf Machining

Introduction
The Swarf Finishing option creates a toolpath where the selected surfaces are machined with
the side of the tool (Tool Alignment is automatic). A Swarf Finishing toolpath will only
exist where the tool is able to remain in contact with the surfaces for the whole cutting depth.
The surfaces to be machined must be Swarfable (Not Convex or Concave but Linear relative
to the resultant tool alignments)
Import the model swarf_model.dgk (shown shaded) from the local directory
PowerMILL_data/five_axis/swarf_mc.

Create a Dia 12mm x 1tip radiused cutter.
Change the View to ISO 4

(as shown below shaded).
and select the local surfaces to be Swarf machined
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7. Swarf Finishing
PowerMILL

Enter the values into the Swarf Finishing form exactly as shown below and Apply
(Note:- Tool Alignment is automatic for this option).
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7. Swarf Finishing
Open the Leads and links form via the icon

illustrated in the following table:-
, and Apply the settings as
Z Heights:
Skim distance 20.00 -- Plunge distance 5.0
Lead In:
Horizontal Arc Angle 90 Radius 6.0
Lead Out:
Horizontal Arc Angle 90 Radius 6.0
Links:
Short/Long/Safe Skim
Deselect the local surfaces, Animate the resultant toolpath and observe the
changing angle of the tool as it Swarf machines the selected surfaces (Toolpath
shown on previous page).
Using the Right mouse key select the toolpath in the explorer to open the pull
down menu the top half of which is shown below left.
Use the Left mouse key to pick the option Select Surfaces, which will prompt the
actual surfaces used during the toolpath creation to become selected again.
Create a Dia 10mm End Mill

Using the same settings in the Swarf Finishing form create a machining path
aligned to the underside of the recess on the outer sidewall (selection and resultant
toolpath shown on the following page).
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7. Swarf Finishing
PowerMILL
changing angle of the tool as it Swarf machines the selected surfaces.
Select the multiple group of surfaces as shown below and modify the settings as
shown below in the Multiple Cuts area to the lower right of the Swarf Finishing
form and Apply.
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7. Swarf Finishing
changing angle of the tool as it Swarf machines the selected surfaces in a series of
multiple cuts.
Use the Left mouse key to pick the option Select Surfaces, which will prompt the
actual surfaces used during the toolpath creation to become selected again.
Modify the settings as shown below in the Gouge Avoidance and Multiple Cuts
area to the lower right of the Swarf Strategy and Apply.
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7. Swarf Finishing
PowerMILL
Radial and Axial Thickness

In The PowerMILL Explorer - Delete the current Model and all Toolpaths.
Import the models locnpad.dgk and pocket.dgk (shown shaded) from the local
directory PowerMILL_data/five_axis/locnpad_5axismc.
84
Delete the top surface covering the pocket.

Activate the Dia 10 End Mill.
Issue PMILL 5.5
PowerMILL
7. Swarf Finishing

Select the Swarf Finishing form and select Radial/Axial Thickness form via the
icon
(as shown below).
Tick the box Use Axial Thickness and enter the Thickness settings as Radial 0
and Axial 3.
Select the local Surface defining the wall of the pocket (shown below) and
after entering the remaining settings (as shown in the above left) Apply the
Swarf Finishing form.
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7. Swarf Finishing
PowerMILL
3mm Axial Stock

Create another similar Swarf Finishing strategy apart from swapping the
Thickness settings to Radial 3 and Axial 0.
3mm
Radial Stock
View along the Y Axis to Compare the results as shown in the above two
illustrations.
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8. Rotary Machining
8. Four Axis Rotary Machining

Introduction.
This Finishing strategy is designed for machining a component mounted on a fourth,

programmable Rotary Axis. During milling, the component rotates around the rotational Xaxis while the cutter performs simultaneous 3-Axis movements.
The main options available in the above form will be summarised on the following page.
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8. Rotary Machining
PowerMILL
X Limits
The X Limits define the absolute limits of the finishing path along the rotational, X-axis.
These can be manually defined, or automatically set to the limits of the block.
Technique
This enables the cutting method to be specified for rotary milling either Circular, Line, or
Spiral.
Direction
This option determines whether Climb, Conventional, or Any milling directions are used.
Stepover
In the case of Circular and Spiral this is defined as the pitch for each programmed
revolution of the component. For Line this is defined as the angular, stepover between
adjacent tool tracks.
Y Offset
A Y Offset distance can be specified to avoid cutting with the tip of the tool. This view along
the X-axis shows how an offset tool approaches a cylindrical shape:
Angular Limits
The Angular Limits section of the form is only available when using the Circle or Line
technique. The angular limits are defined between a Start and End angle.
S tart an g le
The angular limits are measured in an anti-clockwise

direction when viewed along the positive X-axis. The area
machined is between the start and end angles.
E n d an g le
y
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8. Rotary Machining
Circular Rotary Machining

In this example a model of a bottle with its centre along the X-axis will be used. Using the
Circle technique, the job rotates with the tool aligned to a fixed direction. While the
component rotates, the tool moves back and forth along it's axis to generate the sectional
form. The tool then steps over by the Pitch value and the rotational machining process is
repeated.
Select Delete All and Reset forms.

Import the model Rotary_bottle.dgk from Examples.
Calculate the Block to the model limits and define a Ball nosed tool Dia
10 named bn10.
In the Rapid Move Heights form select Reset to Safe Heights.
In the Start Point form set the values Mode - Fixed to X0 Y0 Z40.
Select the Toolpath Strategies icon and choose the Rotary Finishing
option then OK.
Enter Name
Rotary1_BN10
Click on the Reset
To Block Limits
button from the X
Limits section.
Define a Stepover 5.
Select Technology
Direction - Climb
Apply and Cancel
the form.
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8. Rotary Machining
PowerMILL
Right click over the toolpath Rotary1_BN10 in the explorer and select
Animate -> Start (This will open the Animation Toolbar).
On the Animation Toolbar select the Tool view point icon.
Select the Play button on the Animation toolbar.
By applying Tool view point the rotation of

the component is animated (As if viewing
the actual machine tool).
In the above example each section is machined in the same Climb milling direction. The
entire length of the job is machined since the X Limits are set to the block limits. Selecting
Conventional will produce tool tracks travelling in the reverse direction and Any will
produce alternate Climb and Conventional tool tracks along the job.
Recycle the toolpath, select Any from the Technology Direction pulldown button and click on Apply then Cancel.
Animate the toolpath as before to observe how the tool changes direction
with every new section machined.
Line Rotary Machining
Using the Line technique, the tool feeds in the X direction following the component form. At
the end of each pass the tool retracts and moves above the start of the next pass. At the same
time the rotary axis indexes by the angular stepover and the tool then leads onto the next
machining move.
Recycle the same toolpath again as in the previous example, select the
Line technique using Technology Direction - Climb milling.
For the Angular Limits in Start Angle enter 90, and in End Angle enter
-90.
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8. Rotary Machining
Select the Leads and Links icon, set the Z Heights Skim distance to 20.
Set Links to Skim.
Click on Apply and Close.
Animate the resultant uni-directional toolpath shown below.
Recycle the toolpath and change the Technology Direction to Any.

Apply the form and Animate the resultant bi-directional toolpath.
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8. Rotary Machining
PowerMILL
Spiral Rotary Machining
Using the Spiral technique, a continuous toolpath is generated around the form as the tool
advances along the X-axis. To ensure a clean finish the toolpath starts and finishes with a
constant X position, sectional pass. Due to a Spiral toolpath being a single, continuous track
the cutting direction will be either Climb or Conventional milling. For the same reason the
Angular Limits option is not viable and as a result is blanked out.
Recycle the toolpath again and select the Spiral technique and
Technology Direction - Climb milling.
Click on Apply to produce the toolpath shown below.
Animate the new toolpath.
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9. Positonal Tool Moves
9. Positional Tool Movements

Introduction
5-Axis movement is normally limited to within a specific angular range dependant on the
machine tool type. A toolpath may be created to operate within this range, but a subsequent
move to a new toolpath or toolchange position may cause an off limit movement. To avoid
this situation several options are available to the user:1.
Insertion of Workplanes between toolpaths in the ncprogram list. A Workplane in the

ncprogram list can also be defined as a Toolchange Point if required.
2.
Insertion of a Pattern machining operation, defined in 3d space as an intermediate tool

move.
3.
Limiting of movement in the Start Point form

Safe Z.
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by use of First Point or First Point
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10. Tool Axis Limits

Introduction
It is possible to set the Toolaxis limits of the machine tool within PowerMILL. This enables
the rotary working envelope to be defined and not exceeded when creating multi-axis
toolpaths. Due to differing configurations between different machine tools the angular limits
are translated in terms of Azimuth and Elevation angles in PowerMILL.
Azimuth and Elevation.
The Azimuth is the angle from X 0 anticlockwise around the XY plane. The Elevation is
the angle that is lifted upwards (+90) or downwards (-90) from the XY plane.
.
The Limits form is found within the Tool Axis Direction dialog. Limits can only be applied
if the tool axis is set to anything other than Vertical or Fixed Direction with the Toolaxis
Limits option checked on the definition tab.
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Delete all and Reset Forms.

From the local directory PowerMILL_Data/five_axis/Tool_Limit load in the
model JoyStick.dgk.
Calculate a Block to Min/Max limits.

Create a 10mm Ballnose tool Length 60
Create a Shank with Upper Dia 16 Lower Dia 10 Length 25.
Create a Holder with Upper Dia 50 Lower Dia 30 Length 10
Add a Holder component Upper Dia 50 Lower Dia 50 Length 30
Set Start Point Mode:Automatic and Position:Block Centre safe Z.
Set Leads and Links as follows
Lead in/out
Extensions
Links
Overhang 80
--None
--None
Short
--On Surface
Long
--Skim
Safe
--Skim
Select the Reference Surface (shown shaded above).
From the Toolpath Strategies icon
select the Finishing option from the
form.
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Rename the Toolpath 10bn limits unset and enter the values into the Surface
Projection Finishing and Tool Axis forms exactly as shown below.

Attach Active Tool to the toolpath as illustrated below.
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With this example there is a strong possibility the machine will be outside the rotary limits.
To further illustrate this we will Simulate the process using a DMU50 Evolution machine
tool.
Right click over the newly created Toolpath in the explorer window and select
Attach Active Tool to Start.
This command will raise the Simulation toolbar (if it is not already open) and attach the
active tool to the start of the toolpath.
Select the Import Machine Tool icon.

From the PowerMILL Data/Machine Data directory select the file dmu50v.mtd
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Ensure the Draw/Undraw machine tool icon

is selected to display the
machine tool.
Select View from Front (-Y) and Zoom the machining area.
from the Simulation toolbar.
Select the Tool View Point icon
to observe the virtual machining of the component.
The DMU50 angular limits are X 90 Y 360.This translates to Azimuth angle limits
of 0 to 360 and Elevation angle limits of 0 to 90..When the toolpath attempts to go
beyond this range an error message will be displayed indicating that the Tool axis
limits will be exceeded.
To counter this, suitable limits will be applied to the toolpath on calculation.

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Select the toolpath Settings from the explorer window ,make a Copy
Of the original toolpath and rename 10bn limits set.
From the Tool Axis Direction form
select the Toolaxis limits option
to activate the Limits tab.
Select the Limits tab and enter the values into the form exactly as shown.
Accept the Tool Axis Direction form.

With the original surface selected Apply and Accept the toolpath.
Right click over the Toolpath 10bn limits set in the explorer window and select
Simulate the Toolpath
With Mode set to Remove

Toolpath in the Limits form,
only the portion of the surface
which lies within the limits
range is machined.
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Re-cycle
the 10bn limits set toolpath.
From the Tool Axis Direction form

into the form exactly as shown.
select the Limits tab and enter the values
Accept the Tool Axis Direction form.

With the original surface selected Apply and Accept the toolpath.
Right click over the Toolpath 10bn limits set in the explorer window and select
Simulate the Toolpath
.
With Mode set to

Move Toolpath in the
Limits form,the surface
is fully machined with
the Tool axis staying
within the limits range.
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Defining Limits for a Multi-Axis Machine
The Tool Axis Limits option allows the user to control the angular limits of a tool while
creating a multi-axis toolpath. The specified limits will differ in format depending on the type
of rotary axis configuration. As a result they will have to be translated as universal Azimuth
and Elevation angles to be compatible with PowerMILL.
The configuration of the rotary axes varies widely, however the differences between many of
these are relatively minor and there are really only three fundamentally different machine
configurations:
Table Table
Head Head
Head Table
Both rotary axes move the table.

Both rotary axes move the head.
One rotary axis moves the head, the other moves the table.
The next examples will show how to transpose angular limits of a machine tool into Azimuth
and Elevation angles.

Select the Tool Axis icon
from the main PowerMILL toolbar.
Define Tool Axis as Lead/Lean and set Lead/Lean angles to zero.
Select the Toolaxis Limits option
Open the Limits tab.
Select the Draw Limits option
Select view Iso 1.
to activate the Limits tab.
from the form.
With the Draw Limits option selected

a sphere will be displayed in the
graphics window representing the
angular machining limits available.
Green indicates a machinable portion
and Red a non-machinable portion.
With the default settings selected the
total machining range is covered so the
whole sphere will be Green.
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Table Table
Both rotary axes operate on a table.
With the above Table-Table machine tool the angular limits are specified as:
X 30
Y 360
The machine tool Y limits are equivalent to the Azimuth angle or the angular limits normal
to the XY plane. The Y limit of 360 translates to Azimuth angle limits of 0 to 360.
The machine tool X limits are equivalent to the Elevation angle above the XY plane.
However they are not the same angle. This is best described using the diagram below. The
machine tool measures the angular range relative to the Z Axis and PowerMILL measures it
relative to the XY plane, therefore the angle required for the limit in PowerMILL is the
complementary angle to the one given for the machine tool.
This means that the X limit of 30 translates to Elevation angle limits of 60 to 90.
Retain the default Azimuth Angle and modify the Elevation Angle values in the
form as shown below to update the machining limits.
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The sphere has been updated with the modified values.
An Alternative Table -Table machine tool has the following angular limits:
X 100
Y 360
This translates to Azimuth angle limits of 0 to 360 and Elevation angle limits of 10 to 90.
Modify the Elevation angle values (-10 to 90) in the Angle Limits form to update
the machining limits (as shown).
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Head Head
Both rotary axes move the head.
With the above Head-Head machine tool the angular limits are specified as:
X 60
Z 360
The machine tool Z limits are equivalent to the Azimuth angle or the angular limits normal
to the XY plane. In PowerMILL the Z limit of 360 translates to Azimuth angle limits of 0
to 360.
The machine tool X limits are equivalent to the Elevation angle above the XY plane. The
angular range of the machine tool is relative to the Z Axis, however PowerMILL measures it
relative to the XY plane. Therefore the angle required for the limit in PowerMILL is the
complementary angle to the one given for the machine tool. The X limit of 60 translates to
Elevation angle limits of 30 to 90.
Alternative Head-Head machine tool angular limits:
X 50 to +60
Z 360
This translates to Azimuth angle limits of 0 to 360 and Elevation angle limits of 30 to 90. In
this case the machine tool limits across the XZ plane differ. PowerMILL will use the largest
rotational value (+60). This is allowed by rotating the head 180 about Z to provide access to
the maximum range +60 (which otherwise would be -50).
Modify the Elevation angle values (30 to 90) in the form to update the machining
limits as shown on the following page.
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Head Table
One rotary axis moves the head, and the other moves the table.
With the above Head-Table machine tool the angular limits are specified as:
X 40
Z 360
The machine tool Z limits are equivalent to the Azimuth angle or the angular limits in the
XY plane. The Z limit of 360 translates to Azimuth angle limits of 0 to 360.
The machine tool X limits are equivalent to the Elevation angle above the XY plane. It is the
complementary angle to the Elevation angle. The X limit of 40 translates to Elevation
angle limits of 50 to 90.
Modify the Elevation angle values (50 to 90) in the form to update the machining
limits as shown below.
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Open the Project - C:\temp\punch2 (As Saved in Chapter 4).
Activate the last Pattern finishing strategy listed in the Explorer.
ConstZ_Patt_Lean30 to reinstate the tooling and settings used to create it.
Select the fillet running around the base of the main component form.
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Enter the remaining values into the Projection Surface Finishing form exactly as
During Projection Surface Finishing the tool (bn20) is aligned normal to the Fillet Surface
(if default Lead/Lean 0 is applied). This is creating potential Collision situation with both
the sidewall and the base. Even if the Tool Axis alignment angles are controlled to avoid this
immediate problem further adjustments may be required to keep within permitted rotational
limits of the machine tool.
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In the explorer right click over the previously created Toolpath - SurfProj_nolim
and select Settings to re-open the Surface Projection Finishing form used to
create it.
In the Surface Projection Finishing form select the Icon
to create a copy
and enter the Name - SurfProj_lim60-75.
Use the same values and settings in the Projection Surface Finishing form as
used on the original toolpath with the addition of those shown (below left) in the
Tool Axis form (including the tick box settings) and Apply.
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With the Tool Axis Limits applied the alignment will be restricted to operate between 60 and
75 degrees (Elevation Angle) relative to the XY plane. A sphere (shaded pink) displaying the
Tool Axis alignment limits (shaded green) becomes visible when the box labelled Draw
Limits is ticked. The two illustrations on the following page show the toolpath with the tool
attached on the upper and lower tracks to show the effect of the specified limits.
Compare these with the earlier illustrations of the previous toolpath created with no Tool
Axis Limits applied.
Save the Project.
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11. Toolpath Simulation
Introduction
PowerMILL has the facility to detect Collisions between a machine tool and the model.
By default there are three basic machine configurations that can be imported from the Import
Machine Tool option
on the Simulation toolbar. They are obtainable from the
Examples/MachineData directory
However, additional (more complex) machine configurations are available from the
installation CD in the MachineData directory.

Open the Project Swarf Check from the local directory
PowerMILL_data/five_axis/Collision_Simulation.
Right click over theToolpath Outer Swarf in the explorer window and select
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This command will raise the Simulation toolbar (if it is not already open) and attach the
active tool to the start of the toolpath.
Select the Import Machine Tool icon.

From the PowerMILL Data/Machine Data directory select the file dmu50v.mtd
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Ensure the Draw/Undraw machine tool icon

is selected to display the
machine tool.
Select View from Front (-X) and Zoom the machining area.
Select the Tool View Point icon
Select the option to Open Display

The Simulation Information form will
display information on tool location and
collision positions.
With the Position tab selected machine
tool positions will be displayed. The
values on the left hand side refer to the
Axis Address Letters and their
associated values.
This machine tool has five axes, A and
B are rotary with X,Y and Z as linear.
The values on the right hand side show
the range of travel for each axis
dependant on which toolpaths have been
simulated. These are absolute values
from a specific datum and can be reset
by applying the Zero button.
Select the Collisions tab
on the form.
Any collisions encountered whilst
running, or after the simulation has
been completed, will be displayed in
the Collisions pane.
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to observe the virtual machining of the component.

A collision has been detected and a
warning message displayed.
Select OK to continue the simulation.
The message is only displayed for

the first collision. Any remaining
collisions will be displayed in the
collision pane.
Press Esc to exit the simulation.

Select a Collision position from the list.
The simulation will be moved to the position selected so that the collision can be viewed.
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With a clear view of the collision a better idea is gained as to what needs to be done to avoid
it. In this situation, lengthening the tool will avoid damage to the machine tool and model.
Right click over the tool Tip Rad 10 3 in the explorer window and select Settings.
Select the holder tab on the tool form and modify the Overhang to 50.
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Close the form and Attach Active Tool to Start from the toolpath in the explorer.
Select the option to Open Display

Select the Collisions tab
on the form.
Select the Clear tab
on the form to clear any existing collisions.

.
The Collision pane remains blank indicating that no collisions have been detected.
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12.
12. Appendix
5-Axis Machining
Appendix
5-Axis Leads and Links
Leads and Links are applied in the same way as for 3-Axis applications and will
automatically take into account the applied 5-Axis - Tool Alignment options .
Useful Preview Commands

There are a number of useful commands that may be used to help examine and check the 5Axis toolpaths created in PowerMILL. At present these are typed in via the Command
Window.
EDIT TOOLPATH ; AXIAL_OFFSET
This command allows a new offset 5-Axis toolpath to be created from the Active, 5-Axis
toolpath with an offset. All of the points of the new toolpath are calculated from the old
toolpath but offset along the tool axis vector. The actual toolpath name can be inserted
instead of ; if the toolpath is not Active.
EDIT TOOLPATH SHOW_TOOL_AXIS 30 0
This command displays the tool axis vectors from an existing 5-Axis toolpath. The 30 value
in the command line above is the length of the vector. This value can be altered to any value.
EDIT SURFPROJ AUTORANGE OFF
EDIT SURFPROJ RANGEMIN -6
EDIT SURFPROJ RANGEMAX 6
This command sequence limits the Surface Projection distance range to +/- 6mm.
EDIT SURFPROJ AUTORANGE ON
This command returns to default no limit to the Surface Projection distance range.
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12. Appendix
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Issue PMILL 5.5

Apostila PowerMILL 5.5 - 5 Eixos

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Apostila PowerMILL 5.5 - 5 Eixos

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PowerMILL 5.

PowerMILL5.5 - Five Axis Contents

1. 3+2 Axis Machining and Drilling

2. Five Axis Tool Alignments

3. Surface Projection Finishing

4. Five Axis Pattern Finishing

5. Five Axis Profile Finishing

6. Five Axis Embedded Pattern Finishing

8. Rotary (4th Axis) Machining

9. Positional Tool Movements

10.Tool Axis Limits

Issue PMILL 5.5

1. 3+2 Axis Machining

3 + 2 Axis - Machining Example

Issue PMILL 5.5

1. 3+2 Axis Machining

Create a new Workplane and Rename it as x0el30_B (This will be activated).

Issue PMILL 5.5

1. 3+2 Axis Machining

Issue PMILL 5.5

1. 3+2 Axis Machining

The component is now ready to be machined creating separate strategies relative to

It is advised that the Rapid Move Heights and

The Settings for Rapid Move Heights

Issue PMILL 5.5

1. 3+2 Axis Machining

Suggested Roughing/Semi-Finishing Strategy

3+2 ROUGH RECESSES

DIA 10 Slot Drill

DIA 10 Slot Drill

3+2 SEMIFINISH RECESSES

DIA 6 Ball Nose

DIA 6 Ball Nose

Issue PMILL 5.5

1. 3+2 Axis Machining

3+2 Axis Stock Model Application

Delete all and Reset forms.

Open the Block form and Calculate to Min/Max limits.

Create a 16 ball nosed tool and Rename 16bn.

Issue PMILL 5.5

1. 3+2 Axis Machining

Select the Toolpath Strategies icon

Apply and Accept the form.

1. 3+2 Axis Machining

Animate each toolpath in turn to observe the results.

Issue PMILL 5.5

1. 3+2 Axis Machining

Select a View from Right (X)

Issue PMILL 5.5

1. 3+2 Axis Machining

Activate the work plane Machine_Side.

The Machine_Side workplane enables vertical tool

Activate the tool 16bn.

Select Rest Machining and use Stock

Apply and Accept the form.

Issue PMILL 5.5

1. 3+2 Axis Machining

Selecting the Rest Machining

The Stock Model is re-calculated and displays the remaining material.

Issue PMILL 5.5

1. 3+2 Axis Machining

The Stock Model Rest dialog is displayed.

Select Stock Model 1 and Expand Area By 1.0

Select the tool 6bn.