MFG225409-L

Advanced Toolpath Editing in PowerMill 2019

Christopher Marion - Speaker
Autodesk

Todd Steele – Lab Assistant

Autodesk

Learning Objectives
• Go through some of PowerMill’s basic editing options as well as some of the more advanced
toopath options that even a 3-axis programmer can take advantage of
• Learn how to run a full machine simulator and detect collisions or near collisions
• Learn how to find potential problematic areas during the simulation and correct them before
sending the file to the machine
• Gain a basic overview of PowerMill software's different types of tool axis options for
simultaneous programming
• Learn how to manipulate specific regions of a toolpath and override the behavior of the
machine tool

Description
This class will venture into some of basic editing tools that are offered with PowerMill.

We will them apply these to some of the advanced editing tools, like the Dynamic Machine
Control and Editing Within a Region. We will demonstrate these editing tools live.

Speaker(s)
Christopher Marion is Product Specialist with the Advanced Manufacturing group of products
that are offered by Autodesk. He is based out of the Windsor, Ontario, Canada office. He offers
support, training and technical consultation in PowerMill, PowerShape, FeatureCAM & Fusion
Production across North America.
His 20+ years of direct industry related experience in subtractive manufacturing has given him
the ability to convey his knowledge to others during conversation about these products. Before
coming to Autodesk, Christopher worked as a CAM programmer, a Designer (plastic injection
molds and fixturing) and as a continuous improver in process planning and development.
In Christopher’s free time, he enjoys spending time with his wife, son, daughter and dog Jasper.
He loves to spend time on the ice coaching and playing hockey (He’s Canadian, what did you
expect?) as well as root for his favorite inept sports teams (Detroit Tigers, Lions and Red
Wings).

Page 1
 Table of Contents

PowerMill Introduction……………………………………………………………………………...….3
Screen Layout…………………………………………………………………………...………...…….4
Mouse Manipulation……………………………………………………………………………..……..5
Interactive Mouse Examples……………………………………………………….…………..6
Toolpath Editing………………………………………………………………………………..……….7
Basic & Intermediate Editing…………………………………………………………………...……..8
Ramp Moves……………………………………………………………………………….…….9
Speeds & Feeds………………………………………………………………………………..11
Leads & Links………………………………………………………………………….………..13
Reorder Segments……………………………………………………………………………..18
Toolpath Transformations……………………………………………………………………..19
Editing Feeds on Surfaces…………………………………………………………………….22
Moving Start Points…………………………………………………………………………….23
Edit History Replay……………………………………………………………………………..24
Edit Named Parameter…………………………………………………………………...……26
Dynamic Machine Control…………………………………………………………………………....28
Collision Checking…………………………………………………………………………...…29
Colliding Sections……………………………………………………………………...……….30
Replace Tool………………………………………………………………………...………….31
DMC - Swap Configuration…………………………………………………………...……….32
DMC – Change Tool Axis One Region……………………………………………...……….33
DMC – Change Tool Axis Multiple Regions………………………………………...……….35
DMC – Creating Workplanes………………………………………………………...………..37
Edit Within Region…………………………………………………………………………………….39
Tool Axis to Lean……………………………………………………………………………….40
Tool Axis to Fixed Direction……………………………………………………………...……42
Axis Interpolation…………………………………………………………….................……..45

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 PowerMill Introduction

PowerMill is a stand-alone CAM system that quickly produces additive toolpaths, inspection
probe paths, and gouge-free NC toolpaths from CAD models using 2.5D machining, 3-axis
machining, or multi-axis simultaneous machining. These toolpaths can then be checked for
collisions against other models (for example, clamps) and the tool holder before being output
to cutter location and tape files.
PowerMill has a wide variety of direct interfaces. It supports IGES, VDA, and STL data
formats, which enables you to import data from any CAD system that supports these neutral
formats.
Using PowerMill's simulation, you can load entire machine tools to verify toolpaths and
visualise machine and cutting tool actions from different perspectives.

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 Screen Layout
The following window is displayed when starting up PowerMill

1 Quick Access Toolbar - Enables you to quickly access frequently used ribbon commands, such as Save,
without having to navigate the ribbon.

2 Ribbon - A collection of tabs and groups that organise PowerMill functionality.

3 Explorer - Provides control over all PowerMill entities.

4 Graphics Window - The working area of the screen.

5 View toolbar - Provides quick access to common views and shading options in PowerMill. The full range of viewing
options are available on the view tab.

6 ViewCube - Enables you to interactively orientate the contents of the graphics window.

7 Status and Information toolbar - Enables you to create and activate workplanes, display various preset and user-
defined settings. If you hover the cursor over a button, help is displayed. The help can be, for example, a brief description
of the item beneath the cursor, or information about the calculation that is in progress

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 Mouse Manipulation

The View Cube - used to manipulate the view orientation, either

dynamically, or by using the fixed views.

Left Mouse Button - Clicking the left mouse button on an entity in

the graphics window allows you to select it.
Holding down the left mouse button and dragging it to the left and
upwards or to the right and downwards, allows for selection of
entities inside of a box.
Double clicking on an item in the Explorer allows the user to quickly
activate it.

Center Mouse Button - Clicking and holding down the middle

mouse button down and moving the mouse around the graphics
area allows you to rotate the model.
Scrolling the mouse wheel (if equipped) back and forth does allow
for zooming towards the model or zooming away from the model
too.

Right Mouse Button - Right clicking on an entity will open up menu's.

Right clicking on an item in the Explorer, will produce a different menu
and right clicking on the model in the Graphics Window.

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 Interactive Manipulation Examples
Let’s get familiar with PowerMill’s mouse and interface controls.

Go to the browser the is located at the top of the Explorer on the left-hand side of the UI. Clicking on the
browser tab will display the home page of where we will be working during this lab.

Then click on the Autodesk University Las Vegas 2018 link to go to the next page. From here, click on
the Model Manipulation link to get to the interactive examples on basic mouse functions needed to
progress further in this course.

These examples should only take approximately 10 minutes. Please read through everything carefully

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 Toolpath Editing

A huge advantage PowerMill has over its competitors, is that a lot of changes that the programmer needs to
make to a calculated toolpath can be done afterwards. PowerMill allows quick Modification to non-cutting
segments items like speeds and feeds, change entry and exit moves (leads and links) as well as intuitive
toolpath editing functionality which enables you to easily reorder or remove segments of a toolpath, and to
modify the properties of toolpath segments such as start and end points.

Toolpath editing allows for quick tidy up unwanted toolpath segments, which leads to more efficient toolpaths.
Additionally, toolpath editing is used to improve the safety of your toolpaths by avoiding collisions or alleviating
problems on specific machine tools. For example, editing the tool axis across a segment to avoid a collision
with the machine spindle or table.

You can access many of the functions you need to edit toolpaths from the Toolpath Edit tab on the ribbon.

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 Basic & Intermediate Toolpath Editing
Let’s get familiar with some of PowerMill’s basic and intermediate toolpath editing options.

Go back to the browser and navigate to the Advanced Toolpath Editing page.

Click on the Toolpath editing link (shown above), then click on the image in the Basic &
Intermediate Editing section to load in the project.

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 Ramp Moves
PowerMill has the intelligence to warn the user about movements into the stock that need some attention
during roughing operations. In this first example, expand the Toolpaths branch that is located in the Explorer
and expand the 1_Ramp Moves folder. In this folder is the uncalculated toolpath Plunge Warning.

We need to activate this toolpath before we can calculate it. Right click on the toolpath to open up the menu of
options available on this toolpath. Select Activate from the menu. You will notice that the toolpath in the
folder has now been bolded.

Now:

1. Go to the Toolpath tab, located on the ribbon at the top of the UI

2. In the Calculate group, select the calculator icon to drop down a list of choices
3. Click on the Calculate icon

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After the toolpath calculates, the following warning will display.

Reading the warning, PowerMill is letting the user know that there are areas within the roughing toolpath that
are potentially plunging into stock. Depending on the material that is being machined, the toolpath should be
edited to adjust to these movements. Press OK to proceed.

Since PowerMill’s cutting segments and non-cutting segments are independent from each other, we can simply
add ramp moves after the calculation.

1. Click on the Toolpath Edit tab

2. Click on the Toolpath Connections icon to open the Toolpath connections form
3. Go to the Lead ins tab
4. In the 1st choice pull down menu, select the ramp option
5. Now click on the Ramp options icon
6. In the Max zig angle field, place a value of 3
7. Press the Accept button
8. Press the Apply button, followed by Accept

The non-cutting segments update quick to allow the user to move onto programming their part instead of
waiting for the entire toolpath to recalculate itself.

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 Speeds and Feeds
Simply changing the speeds and feeds of a particular toolpath can be a daunting task for some CAM systems.
With PowerMill, this is relatively simple process.

In the folder 2_Speeds and Feeds there are (2) toolpaths that have the default speeds and feeds values of
1500 RPM and 70 IPM. Since these are drilling toolpaths, these feeds could potentially cause damage to the
tool.

To fix this:

1. Active toolpath Centerdrill_Holes

2. Go to the Toolpath Edit tab
3. Click on the Feeds & Speeds icon to open up the Feeds and Speeds form

4. In the Spindle speed field, enter 1200

5. In the Cutting feed rate field, enter 5
6. In the Plunging feed rate field, enter 10
7. Press Apply

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Again, this was a very simple process to change the speeds and feeds for the active toolpath without having to
recalculate the toolpath.

There is another toolpath in the same folder. Activate Peckdrill_Holes and enter in the following values:

▪ 650 RPM
▪ 4 IPM cutting
▪ 20 IPM plunge
▪ 1200 IPM skim

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 Leads & Links
Entry moves and exit moves are easily driven and modified after the calculation of the toolpath. Allowing the
ability to make these changes freely can save lots of time since there is no waiting for calculation times. This
also allows drastic time savings because of improved efficiencies.

Look at the image below, this is an image of Raster Top that is located in folder 3_Vertical Arc Leads

If we activate the toolpath in the folder and then right

click to show the menu, we can check the estimated
run time of this toolpath if we select the Statistics
option.

The dialog shows towards the bottom that there are

205 lift moves and the run time is just over 9 minutes
Let’s go back into the Toolpath Connections in the
Toolpath Edit tab.

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1. Go to the Lead ins tab
2. In the 1st choice option, select Vertical arc and enter in the following values:

Angle - 90
Radius - 0.125

3. Press Apply

Notice that the lead in moves (orange segments) updated instantly. Now place the same values in the
leads outs tab.

The movement into each segment and the movement out of each segment looks much smoother. However,
we are still left with retract moves that are unnecessary.

Go into Toolpath Connections and go to the Links page. Change the 1st choice option to Skim and
uncheck the Apply constraints checkbox. Then press the Apply button.

Look how the retract moves have changed.

Still not very efficient. Change the 1st choice option to On surface. Try using Circular arc. Observe the
differences.

Notice the large arc moves.

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While these arc moves may not pose any issues on the machine tool. Let fix this to utilize the rapid travel
feedrates.

1. Go back into Toolpath

Connections

2. Go to the Links tab

3. Check the Apply constraints back

on

4. Leave Distance as the default

option

5. Chance the value to 0.25

6. Chance the 2nd choice option to

Skim

7. Press Apply

Now look at the statistics on the toolpath (Right click on the toolpath, select Statistics)

Notice the number of lifts and the runtime.

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Let’s look at a different toolpath. Active toolpath Swarf Pocket in folder 4_Pocket Center Leads

Notice that the toolpath starts on the wall of this vertical pocket.

Activate the toolpath and go to Toolpath Connections

1. Go to the Lead ins tab

2. In 1st choice, select pocket centre
3. Press Apply
4. Make the lead out the same. Instead of going to the lead outs page, press the Make lead outs
the same as lead ins button

The lead out page will adopt all the settings that were placed into the
lead ins page. This saves time manually placing this information in if
you want them to be the same.

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Open up folder 5_Horizontal Arc Leads and activate toolpath Swarf Corner No Leads

1. Apply horizontal arc moves to the leads ins and lead outs
2. Apply appropriate link moves

Try to mimic the image below

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 Reorder
The reorder function allows the user to take selected segments or all segments associated with the
toolpath and change the placement as to where these segments occur or change the segment
direction.

Activate toolpath Reorder-Alternate Directions that is in folder 6_Toolpath Reorder

1. Add vertical arc lead in and lead outs of 90 degrees and 0.125 radius
2. Change the links to circular links with a constraint value of 0.25

Notice that the toolpath is still very inefficient. This is because the program did not have the direction set to
both (climb and conventional directions) before calculating the toolpath.

This can be modified by going to the Toolpath Edit tab and selecting the Reorder icon. This will open up a
form with all of the cutting segments listed. Select the alternate directions icon on the left hand side of the box.

Without recalculating the toolpath, we can changed the cut direction from climb only, to both directions.

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 Toolpath Transformations
Transforming options like copying, moving, rotating and mirroring can all be applied to toolpaths.

Activate the toolpath Multiple Passes that is inside the folder Copy Multiple. Then go to the Toolpath Edit
tab and select the Transform icon.

Select the Move icon

Then, in the floating toolbar, select the copy option and place a value of 10 in the field.

At the bottom of the interface in the green field (in the status bar), place a value of 0 0 0.125 and hit enter.

Close the toolbar and press the green check mark on the ribbon to accept the change. PowerMill will keep the
original toolpath and create a copy Multiple Passes_1

Activate this toolpath and right click on it. Select the very first item Simulate from Start. The Simulation tab
will activate automatically. Press the Play button.

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Notice how the toolpath, starts and the bottom and cuts upwards.

Let’s fix this:

1. Go to the Toolpath Edit tab

2. Select the Reorder icon

3. Click on the Reverse order icon

on the left side

4. Rerun the simulation

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Let’s try a different type of transformation. Open folder 8_Mirror Toolpath and activate toolpath
Multiple Passes Copied.

This part is symmetrical about the X axis. We will mirror this toolpath to the other side of the part to save some
time.

Go to the Toolpath Edit tab and select the Transform icon. Select the Mirror icon. When the floating toolbar
pops up, select the ZX button. You see the preview of the new toolpath in purple.

Run the simulation.

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 Editing Feedrate on Selected Surfaces
In some cases, we may want to control how the tool cuts at certain locations in the toolpath. We can select
certain surfaces and change the feedrates independently from the rest of the programmed toolpath.

Open folder 9_Edit Feed On Surfaces and activate toolpath Swarf Corner With Leads

Right click on the toolpath in the explorer and search for the sub menu Edit. Another menu will fly out. Select
the option Update Feed Rate On Chosen Surfaces…

A pop-up dialog box will appear. In the graphics window, select the large interior fillet where the toolpath is
cutting and then press the icon on the dialog box to create a set (left). Then select the acquire icon (right) to
add this surface to the set. Leave the cutting parameters the same.

Press Apply and Cancel

To view the change. Go to the Toolpath tab and select the Feeds within the Draw group.

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 Moving start Points
PowerMill allows the movement of start and end points on a closed toolpath.

Open folder 10_Moving_Start_Points and activate toolpath Moving Start Points.

Go the Toolpath Edit tab in the ribbon and apply some appropriate leads and links to avoid the toolpath lifting
and plunging on the wall of the circular pocket. Once finished, select the Move Start Points icon.

The ribbon interface will alter to give only the options available in this editing tool, there are two options for
moving start points. The default option is to move all the start points at one time. Draw a line to where the
new start points should take place.

Try using the Single option. Drag the control points individually. Notice how the leads and links adjust
automatically.

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 Edit History Replay
Some applied edits will replay themselves if the toolpath needs to be recalculated for items that cannot be
edited outside the calculation (ie, thickness, tolerance, stepovers………)

Open folder 11_Edit Reply in the Explorer and activate toolpath Toolpath_Limiting. Let’s make some
changes to the toolpath.

1. Go to the Toolpath Edit, and select the Reorder

option

2. Click the Alternate direction icon to make

toolpath cut in a climb cut fashion

3. Click on the Limit icon in the Toolpath Edit tab

4. Go to a top view

5. Leave the Limit to option to Plane and Type to

Plane X

6. Enter -4 in the open field

7. Press Apply

8. Leaving the Toolpath Limit form open, change the

Limit to option to Polygon

9. Create a freeform polygon in the center of the

toolpath

10. Change the Save option to Outer and press Apply

11. Press Cancel

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12. Right click on toolpath Toolpath_Limiting_1_1 and press Select Surfaces
13. Right click on the toolpath again and select settings
14. Press the recycle icon to open the parameters of the toolpath
15. Change the Thickness to 0.02 and hit Calculate

Notice that the toolpath re-generated itself to the new thickness value that was applied and then it replayed the
edits back to it that we just applied earlier.

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 Edit Named Parameters
There are times where you may want to change a certain parameter in multiple toolpaths.

Go to folder 12_Edit_Named_Parameter.

There are seven toolpaths in this folder. The toolpaths labelled Swarf_Wall _1 thru Swarf_Wall_6 all have a Z
maximum height value of -1.5. This value was a mistaken left in during the calculation.

Toolpath Swarf_Master has the appropriate value of 0, which allows the toolpath to machine from the top of
the walls down to the bottom. We want to apply this value to the others in this folder.

1. Activate toolpath Swarf_Master

2. Now, select toolpath Swarf_Wall_1 thru Swarf_Wall_6 by holding down the CTRL button when
selecting them.
3. Once selected, right click on any one of the toolpaths and go to Edit, then Set Named Parameter

Page 26
4.In the Enter Parameter Name field, type in ZRange.Maximum.Active and press the green checkmark.

5.These toolpaths will be set back to an invalidated state (uncalculated)

6. Right click on the Toolpaths branch
7. Click on Batch Process

All of the toolpaths in the Explorer re-calculate themselves

Notice now that each one of those toolpaths now cuts from the top of the wall down to the bottom of the wall
like the Swarf_Master does.

This concludes the portion of this first exercise.

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 Dynamic Machine Control

When programming parts with 4th and 5th axes movements, a large benefit in programming is being able to use
a simulation file to check the behavior of the toolpath in the machining environment before outputting code and
finding faults before it is too late.

Another large benefit is being able to use the machine simulation file (MTD) to correct these faults either before
or after the toolpath has been calculated.

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 Collision Checking

During the toolpath calculation, generally PowerMill gouge checks against the model with the cutting portion of
the tool assembly. After the calculation, a colored status light is displayed. These status lights give
information about the safety of the toolpath. A white check mark, means that the toolpath is gouge free.

It is up to the user to take this safety to the next level. They have the option to check for collisions against the
tool assembly after the toolpath calculation or during the toolpath calculation.

Go up to the Browser and select on the image in the Dynamic Machine Control section. Expand the
Toolpaths branch and expand the Collision Checking folder & activate toolpath Finish Locks.

The toolpath indicates that is has been calculated as gouge free. Let’s make sure that the whole tool assembly
is safe before it gets sent out to the machine.

1. Go to the Toolpath Edit tab and select the

Verification

2. Make sure the Toolpath Verification form looks

like the image to the left and hit Apply

3. The simulation should come back with a message

that states, “No collisions were found”

4. Press OK

5. Press Accept to close the form

Notice that the status light has changed from white to blue.
This indicates that the entire tool assembly is safe to within
0.05 to the model.

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 Colliding Segments
Toolpath segments can be selected and deleted to suit the program needs.

Open folder Colliding Segments and activate toolpath Finish_Pocket_Delete

Go to the Toolpath edit tab and select the Verification icon. Leave the parameters and press Apply.

The following warning is issued…..

Press OK

Notice that the segments that are unsafe are

highlighted in red.

Un-shade the model by pressing the F3 key or pressing the icon on View toolbar

1. Go to the Home tab and select the Colliding

Sections icon in the Verification group.

2. Once the dialog box opens, select the first line (1),
hold the shift button and select the last line (30).
Then press the red X in the top left corner.

3. Selecting the X will delete the colliding segments of

the toolpath and set the safety status to blue.

Alternate method: Re-run the verification on the other

toolpath in this folder. Instead of selecting the X, select the
icon right below. This will split the toolpath in a safe
toolpath and an unsafe toolpath.

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 Replace Tool
Open folder Replace Tool and activate toolpath Finish_Pocket_Replace

Run the same verification as we did in the last two examples. Once the PowerMill box warns the user about
the collision, press OK.

1. Go to the Replace tool menu.

2. Notice that there are (2) tools that can be

selected. Select tool 1 1/4in Button Slim
Holder.

3. Press Apply

PowerMill will now replace the original tool with this new
tool and update the collision status. Since there are still
collisions involved, repeat the process, but select tool
1 1/4in Button Ultra Slim Long.

4. Press Apply

PowerMill should now return a message that there were

no collisions found and the status light will change to
blue.

5. Press OK

6. Press Accept to close out of the verification

page.

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 DMC – Swap Configuration

This editing tool can be used to easily modify a 3 axis, 3+1 axis or 3+2 axis toolpath to avoid potential near collisions
or actual collisions using a replica of the machine tool (MTD file).

Open folder DMC – Fix and activate toolpath Raster_Flats_Safe. Run the verification with the same parameters.
PowerMill indicates a collision at a depth of 0.12, minimum tool over hang is 3.12

Open the Tools branch in the Explorer. The tool that is associated with this toolpath is already active.

Right click on 1in Button HeatShrink Long and select Settings. Go to the holder tab and adjust the overhang to
3.125 and press Close

Notice the status light on that toolpath changed from red to blue, indicating that it is now a safe toolpath.

Normally we would be satisfied with sending this off to the machine, however since we have a machine simulation
file (MTD), we can run a full machine simulation to verify this.

Right click on the toolpath and select Simulate from Start

The machine file will attach itself to the tool holder and the Simulation tab will open. Press the play button.

The simulation plays through without any issues.

Activate toolpath Raster_Flats_Unsafe and run the verification. This time there were no collisions because we
already fixed the overhang on the previous toolpath.

Run the machine simulation.

The simulation found a collision with the

machine tool and stops to show the user.

This toolpath will need to be modified

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 1. Go to the Toolpath Edit tab and select the Dynamic Machine Control icon

2. Press the Swap Configuration icon (this flips the machine tool to the alternate solution)

3. Press the Update Toolpath icon to accept the change

4. Press the green checkmark to finish editing the toolpath

5. Rerun the simulation.

Everything looks good.

Here is a video of this example…. https://autode.sk/2CL5aM2

Page 33
 DMC – Change Tool Axis in One Region

Let’s look at another example. Activate toolpath Raster_Wall_One_Solution and simulate. The simulation should
stop once PowerMill detects the collision between the toolholder and the model.

Press OK to continue

Let’s correct the issue by using the Dynamic Machine Control.

1. Go to the Toolpath Edit tab and select the Dynamic Machine

Control icon.

2. Click on the Machine Tool Position option.

3. Enter 20 in the B axis field

4. Enter -90 in the C axis field

5. Press Close

6. Press the Update Toolpath icon

7. Press the green checkmark

8. Rerun the simulation

Watch this video of this example https://autode.sk/2Cj9zoC

Page 34
 DMC – Change Tool Axis In Multiple Regions

The Dynamic Machine Control now also allows us to select different regions in the toolpath to make edits.

Activate toolpath Corner_Multiple_Solutions in folder DMC – Fix. Running a simulation will surely cause a
collision to the toolholder. But since this toolpath wraps around both walls, a single solution is not possible.

Go to the Toolpath Edit tab and select the Dynamic Machine Control icon

Press the Select Regions icon opens the following dialog box, then:

1. In the Define Region By menu, select Plane

2. Make sure Plane X is enabled

3. Leave the point at 0

4. Press the Save button

The segments that we are editing will turn white

5. Grab the tool and snap it to one of the white segments.

6. Press the Machine Tool Position icon on the ribbon and

type in the following values. C -45 & B -30

7. Press the Update Selected Regions icon to set these

values

8. In the Select Edit Region box, change the Define

Region By option to Whole Segments

9. Box select the other segments that have not been

edited yet and Press the Save button

10. Drag the tool to the opposite side and enter the values
in the position form C -135 & B -30

11. Press the Update Selected Regions icon

12. Close the forms if any are open, then press the green
checkmark

13. Simulate the toolpath

Page 35
You will notice how the machine jumps from one angle to the next angle as it cuts from one segment to the next.
This is because the ordering of the toolpath has not been affected.

Let’s fix this by going to the Toolpath Edit tab and selecting the Reorder icon

Manually select the first half of the toolpath by selecting with a box

Press the Move to start icon

Close the form

Perform a gouge check and collision check

Simulate the toolpath

Here is a video demonstration of the example https://autode.sk/2O02b3v

Page 36
 DMC – Creating Workplanes

The DMC also allows the user to preplan their next toolpath by creating the tip with the machine tool and then
applying it to a new toolpath.

1. Activate tool 1/2in Ball Long

2. Activate folder DMC - Create

3. Go to the Toolpath Edit tab and select the

Dynamic Machine Control icon.

4. Grab the tool and drag it to the following corner

in the large orange pocket (lighter surfaces)

5. Select the Machine Tool Position icon

6. Place values of C 45 & B 20 (Depending on

the corner selected, these values may differ)

7. In the Utilities group, select the Create

Workplane menu and select at Tool tip

8. Press the green checkmark

A new workplane will be created on the model at the

tool location. Now,

9. Go to the Toolpath tab and select the

Toolpath icon in the Create group

10. Select Constant Z Finishing in the

Finishing page

11. Change the toolpath name to DMC WP

12. Change the Stepdown to 0.1

Page 37
 13. Go to the Workplane page and select
workplane 1 from the dropdown menu

14. Then go the Limit page

15. Change the boundary to corner and uncheck

both Maximum and Minimum Z limits

16. Press the Calculate button

17. Update the leads and links moves

18. Simulate the toolpath

Watch the video demonstration here

https://autode.sk/2D2zbHh

This concludes the portion on the second exercise.

Page 38
Editing Within A Region

Page 39
 Tool Axis to Lean

Using the Edit Within Region tool allows the ability to edit the tool axis of selected (partial) segments of a toolpath
while preserving the toolpath contact positions.

Go up to the Browser and select on the image in the Edit Within Region section. Expand the Toolpaths
branch and expand the Apply Lean folder. Activate toolpath Corner_Finishing_Lean.

Change the leads and links to appropriate moves then simulate it. The toolpath will stop simulating because of
a collision between the holder and the model.

At this point, we could re-calculate the toolpath with an appropriate tool axis movement to utilize some live five
capabilities. However, we can take advantage of a powerful editing tool that PowerMill provides to the user.

Go to the Toolpath Edit tab and select the Edit Within Region icon.

1. In the Define Region By select Whole

Segments in the dropdown menu

2. Left mouse drag a selection box across the entire

toolpath

3. Select Save Selection

Page 40
Click on the Specify Changes tab, then:

1. Click on the Icon next to Tool Axis box

2. Change the Tool axis from Vertical to Lead/Lean
3. Enter a 20 value in the Lean field
4. Change the Mode option from Contact Normal to Vertical
5. Press Accept

6. Then press the Apply button

7. Then re-simulate the toolpath

Watch the video demonstation here…….https://autode.sk/2SimKvG

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 Tool Axis to Fixed Direction
During the simulation, you may have noticed that there was quite a bit of movement in the rotary axis when the
toolpath cut on the side of the model that has the wavy cut outs. Since we applied a lean to the entire toolpath,
the tool axis by default stays perpendicular to the toolpath segment.

Let’s use the same tool, but this time we will only edit the portion of this toolpath to eliminate the unnecessary
table movement.

Open up folder Fixed Direction and activate toolpath Corner_Finishing_Lean_Fixed_Direction

Right click on the toolpath and simulate from start. This time pause the simualtion in the area we are trying to
fix, but try to pause it close to the A20 C180 mark (turn on the Machine Tool position to view the angles). Once
paused, type in these values into the A & C axis fields.

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Go to the Toolpath Edit tab and select the Edit Within Region icon. Change the Define Region By option to
Polygon.

Select a box around the portion we are going to modify and press Save Selection

Go to the Specify Changes tab and select the icon next to the Tool Axis.

Change the Tool Axis to Fixed Direction.

Select the icon in the Direction section to input the new vector.

Click on the Align with tool icon to change the new vector to how we have the tool aligned currently in the
simulation.

Press Accept twice to get back to the Specify Changes area

Enter 0.125 in the Blend Distance field

Press Apply, but do not hit cancel. Leaving the tab open allows the option to undo the changes. Just simply
move the box out of the way by dragging it.

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Run the simulation on the toolpath. The tool axis it that region now stays fixed to the new vector we applied.
However, the interior corner in the opposing side of the part is causing a large violent change of direction.

Pause the simulation near A20 B315. Place these value in the Machine Tool Position form

Go back to the Select Regions tab and keep the selection on Polygon. Create a polygon in the corner and
press Save Selection.

Go to:

1. Specify Changes

2. Click on the Tool Axis icon

3. Click on Direction Input icon

4. Click on the Align to tool icon

5. Press Accept twice

6. Place a 0.5 value in the Blend

Distance field

7. Press Apply

Do not close the Edit Within Region tool, but simply drag it out of the way.

Run the simulation

Run a gouge check

Run a collision check

Watch the video demonstation here……..https://autode.sk/2O7jy2m

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 Axis Interpolation
In the previous example, we changed the behavior of the tool axis by creating a new vector from the placement
of the tool. Let’s us the same editing tool in this next example, but choose an alternitive method instead.

Open folder Axis Interpolation and active toolpath Corner_Finishing_Axis Interpolation. This toolpath
already has the lean tool axis applied to it, but the rotary table swings in the back of machine during the cycle.

Go to a top view (CTRL + 5) or select the option from the Viewcube

Turn off the MTD and zoom into the part

We can draw the tool axes at each point in the toolpath by going to the Toolpath tab and selecting the Tool
Axes icon in the Draw group.

Zooming into the same area as the previous example, we can clearly see how the tool would behave at each
point in the toolpath in the wavy section of the model.

We will use an option in PowerMill to smooth these tool axis combs within a area that we will define.

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Go to the Toolpath Edit tab and select the Edit Within Region icon

Use the Polygon method to select a box around the wavy section in the back of the model

Tip: When creating the polygon, look for axes that are vertical in both the lefthand and righthand sides
of the bounding box. This will make all of the tool axes in between straighten towards these on the outside.

1. Press the Save Selection button

2. Go the Specify Changes tab

3. In the Type of Editing dropdown, select Axis

Interpolation

4. Press Apply

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Do not close the Edit Within Region tool, just drag it out of the way for now.

Turn the MTD file back on and run a simulation

Notice how the tool axis behave in the wavy portion of the model

Press Cancel to close the editing tool.

Now follow these steps from above and do the same operation in the interior corner on the opposing side of
the part.

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Another minor issue that we can correct is the orientation of the table during the simualtion. You may or may
not have noticed, but the table tips towards the back of the machine. The angle isn’t that great, but it may be
difficult for the operation to see what is happening.

Let’s modify this so the table tips towards the front of the machine.

1. Go to the Toolpath Edit tab, and select the Edit Within

Region icon

2. Change the Define Region By to Whole Segments

3. Box select the entire toolpath and Save Selection

4. Go to the Specify Changes tab and change the Type of

Editing to Orientation Vector Only

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 Click on the icon next to
Orientation vector

Fill the Machine axis control form as

shown in the image to the left.
Press Accept
Press Apply but do not close the
editing tool, drag it out of the way for
now

Run the simulation and view the results. The table should tip towards to operator.

Watch a video demonstration of this example here…………….https://autode.sk/2SiArdZ

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 Extra Time?
Feeling good about what you’ve learned here?

Open up folder Challenges

Try and use some of the options we went through today, and fix the following toolpaths.

Yellow Pocket:

1. Apply Appropriate Leads and Links

2. Re-order toolpath to cut any direction
3. Make sure the status light is blue
4. Move start/end points to a safe location (not in the corner)

Raster Wall:

1. Remove the collsion(s)

2. Change the tool axis to C-45 & A25
3. Swap the table towards the operator
4. Make sure the status light is blue

Tip: Look at the tools available & use the DMC

Autodesk Scribe:

1. Change the tool axis to a fixed direction

2. Table toward the operator
3. Reorder the toolpath to cut from theAutodesk logo towards the letter K
4. Make (4) multiple passes as 0.01, cutting from the top down
5. Be sure the status light is blue

Tip: Use a combination of machine simulation and Edit Within Region to establish the fixed direction. Using
the reordering function to bypass the cutting behavior (use the move to end option).

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 Thank You!
I’d like to thank you all for attending my lab here at Autodesk University 2018. Hopefully you gained some
knowledge and understanding of how a great product like PowerMill provides amazing toolpath editing options
for its users.

Even if you are a beginner or an well versed programmer, you can see for yourself how much control the
software allows with little ease.

If you’d like to find out more about what PowerMill can provide for you or your company, go visit
https://www.autodesk.com/products/powermill/overview. You can download a free 30 day trial there and review
some great information listed there.

Here is another great link on the complete catalogue of manufacturing software Autodesk provides
https://www.autodesk.com/solutions/manufacturing

Lastly, if you’d like some free introductory training, visit https://learn.manufacturing.autodesk.com

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