Lesson 2 – 3D Area Clearance & Finishing

Objectives
• Import Models
• Create a Block
• Create Workplanes
• Import cutting Tools from The Database
• Create Safe Area Heights
• Create Roughing Strategies
• Create Finishing Strategies
• Perform Toolpath simulations (ViewMill)
• Create NC output code
• Save Projects

Exercise 1 – Camera Model

• Right mouse click in the graphics area and from the menu select Delete
All, then select File tab > Options > Reset Forms.

• Select the File tab > Import > Model:-

…\PMData\Models\camera.dgk

• Select File & Save As > Project:-

…\COURSEWORK\PMProjects\CameraFinish

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• Select the Home tab > Setup panel > Block .

• In the Block dialog, select Defined by Box, Coordinate System Global

Transform, Type Model, then Calculate & Accept.

• From the Workplane tab > Create panel, select Aligned to Block .

• Select the bottom Left Corner & activate the new Workplane 1 by
selecting it in the Active panel drop-down list.

• Select the Home tab > Setup panel > Toolpath Connections .

• Select the Safe Area tab, and in the Measured from drop-down list ensure
that Block and Model is selected, then Calculate & Accept.

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list, select a Tip Rad tool , then Search.

• Select D20TR3 from the list and then select Create Tools.

• Repeat the above procedure creating both a Tip Rad, D10TR1 & a Ball
Nose, BN10 tool, and then Close the form.

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• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select 3D Area Clearance > Model Area Clearance & OK.

• Change the Toolpath name to AreaClearance, then from the Tool page
select the D20TR3 tool from the drop-down list.

• In the Model area clearance page, select Style Offset Model, both Profile
& Area Climb, input Tolerance 0.1, Thickness 0.5, Stepover 12, Stepdown
3, then Calculate and Close.

• From the PowerMill Explorer > Toolpaths folder turn the light bulb off
next to the Area Clearance toolpath.

We are now going to create various Finishing Strategies on the model.

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Constant Z Finishing Strategy

• From the Tool tab > Active panel select the BN10 tool from the drop-
down list to activate it.

• From the Boundary tab > Create panel, select Shallow .

• In the Boundary dialog input the Name Shallow30, Untick Allow

boundary to be private, Upper Angle 30, Lower Angle 0, Tolerance 0.01,

Thickness 0, Limit (keep tool Centre to edge of block) and then Apply
& Accept.

The boundary is made up of numerous segments which define shallow areas.

Any one of these segments can be selected and deleted if required, with the
exception being that if it is assigned to a toolpath it will be locked.
This Boundary is best suited to steep walled and shallow surface machining
techniques

• Select Toolpath tab > Create panel > Toolpath to open the Strategy
Selector dialog.

• Select Finishing > Constant Z Finishing & OK.

• In the Constant Z finishing page input the Toolpath name ConstantZ,

Order by Region, tick Spiral, Tolerance 0.01, Thickness 0, & Minimum
stepdown 0.5.

• In the Limit page set Trimming to Keep outside.

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• Select Calculate and then Close.

The steep walls have been machined using Keep Outside boundary, next we
will create a toolpath for the shallow regions.

• From the Toolpaths menu within the Explorer window turn the light bulb
off next to the ConstantZ toolpath.

3D Offset Finishing Strategy

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > 3D Offset Finishing & OK.

• In the 3D offset finishing page input the Toolpath name 3DOFF, Set
Offset direction to Outside In, tick both Spiral and Smoothing, input
Tolerance 0.01, Thickness 0, & Stepover 0.5.

• In the Limit page set the Trimming to Keep inside.

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• Select Calculate and then Close.

• From the Toolpaths menu within the Explorer window turn the light bulb
off next to the 3DOFF toolpath.

Steep & Shallowing Finishing Strategy

• Activate both the Workplane 1, and Tool BN10.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > Steep and Shallow Finishing & OK.

• In the dialog enter theToolpath name as SShallow.

• In the Limit page, set Boundary as None.

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• In the Steep and shallow finishing page input Threshold angle 30, Steep
shallow overlap 1, tick both Spiral boxes, and in both Cut direction boxes
select Climb, for both Stepdown & Stepover input 0.5, select Type 3D
offset, tick Smoothing, and input Tolerance 0.01, & Thickness 0.

• Select Calculate and then Close.

• From the Toolpaths menu within the Explorer window turn the light bulb
off next to the Shallow toolpath.

Flat Finishing Strategy

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list, select an End Mill tool then Search.

• Select EM16 from the list and then Create Tools and Close.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > Offset Flat Finishing & OK.

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• In the Offset Flat finishing page, input the Toolpath name OffsetFinish,
input Tolerance 0.01, Thickness 0, Stepover 10, and then select Calculate,
& Close.

The toolpath is only generated on surfaces that are 100% flat, this is
because we had set the Flatness tolerance to 0.0. We would have to alter the
Flatness Tolerance to include any surfaces intended for machining with minor
discrepancies.
Add approaches from outside with an allowance prevents any dwell marks on
surfaces.

• Select the File tab > Save to update the Project.

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

• Create a Block
• Create a Workplane
• Create an Area Clearance strategy
• Create a Shallow Boundary
• Constant Z Finishing strategy
• Create a 3D Offset Finishing strategy
• Create a Steep & Shallow Finishing strategy
• Create a Flat Finishing strategy

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Exercise 2 - ADV Model

• Right mouse click in the graphics area and from the menu select Delete
All, then select File tab > Options > Reset Forms.

• Select the File tab > Import > Model:-

…\PMData\Models\ADV.dgk

In this exercise changing the shallow stepover to a different value within the
Steep and Shallow Finishing form will produce a more efficient toolpath when
using a Tip radiused tool.

• Select the File tab > Save As > Project:-

…\COURSEWORK\PMProjects\ADV-Finish

• From the Home tab > Setup panel select Block .

• In the Block dialog select Defined by Box, Coordinate System Global

Transform, Type Model, then Calculate & Accept.

• From the Workplane tab > Create panel select Aligned to Block .

• Select the bottom Left Corner and then activate the new Workplane 1 by
selecting it in the Active panel drop-down list.

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• Select the Home tab > Setup panel > Toolpath Connections .

• From the Safe Area tab ensure that the Block and Model is selected
within the Measured from drop-down list & select Calculate and then
Accept.

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list, select a Tip Rad tool then Search.

• Select D16TR3 from the list and then Create Tool & Close.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select 3D Area Clearance > Model Area Clearance & OK.

• Rename the Toolpath name as Area Clearance.

• From the Tool page select the D16TR3 tool from the drop-down list.

• From the Model area clearance tab select Style as Offset Model, In
Profile & Area select Climb, Tolerance 0.1, Thickness 0.5, Stepover 8,
Stepdown 3, and then Calculate & Close.

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• From the Toolpaths menu within the Explorer window turn the light bulb
off next to the Area Clearance toolpath.

Steep and shallow Finishing with separate Shallow Stepover

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• From the Strategy Selector dialog box select Finishing > Steep and
Shallow Finishing & OK.

• In the dialog enter theToolpath name as SShallowstep.

• In the Steep and shallow finishing page input Threshold angle 0, Steep
shallow overlap 0, tick both Spiral boxes, set both Cut direction tabs to
Climb, for the stepdown tick Calculate using cusp, input Stepdown 0.002,
Maximum Stepdown 0.5, Cusp 0.02, select ‘Shallow’ Type as 3D offset,
input Stepover 6.5, tick both Smoothing and Centreline, input Tolerance
0.02, & Thickness 0, and then Calculate.

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 The Steep (Constant Z) part of the above toolpath uses a variable Stepdown
(between Min 0.002 & Max 0.5) to maintain a good finish as it tracks around
the upper fillet towards the upper flat area.

• Select the File tab > Save to update the Project.

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

• Create a Block.
• Create a New Workplane.
• Generate an Area Clearance Strategy.
• Create a Steep and Shallow Finishing toolpath with a variable Constant Z
stepdown and a large Shallow Stepover.

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Exercise 3 - Cowling Model

• Right mouse click in the graphics area and from the menu select Delete
All, then select File tab > Options > Reset Forms.

• Select the File tab > Import > Model:-

…\PMData\Models\cowling.dgk

• Select the File tab > Save As > Project:-

…\COURSEWORK\PMProjects\CowlingFinish

• Select the component model and from the Workplane tab > Create panel

select At Top Of Selection .

• Activate the new Workplane 1 by selecting it in the Active panel drop-

down list.

• From the Home tab > Setup panel select Block.

• In the Block dialog select Defined by Box, Coordinate System Active

Workplane, Type Model, then Calculate, before Entering -80 into the
Limits Z box and lock it , followed by Accept.

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• Select the Home tab > Setup panel > Toolpath Connections .

• Select the Safe Area tab and ensure that Measured from Block and
Model is selected and then select Calculate followed by Accept.

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list, select a Tip Rad tool then Search.

• Select D16TR3 from the list and then Create Tools.

• Repeat the above 3 step procedure but this time create a Tip Rad, D12TR1
tool and then Close the form

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select 3D Area Clearance > Model Area Clearance & OK.

• Rename the Toolpath name to AreaClearanceD16.

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• From the Tool page select the D16T3 tool from the drop-down list.
• In the Model area clearance dialog select the Style as Offset Model, in
both Profile & Area select Climb, input Tolerance 0.1, Thickness 0.5,
Stepover 8, Stepdown 12.

• In the Offset page, tick the Spiral box.

• In the Step cutting page, tick Step cutting, input a Stepup 1.5, and input
Detect material thicker than 0.5.

• In the Unsafe segment removal page, tick the box Remove segments
smaller than threshold and leave all other settings as default.

• In the Flat Machining page select Machine flats as Level.

• In the Lead and Links page set Lead In 1st choice Ramp with Ramp
options as Follow Circle, zig angle 4, & then Calculate & Close.

We will now create another roughing strategy using the 12mm Tip Rad tool.

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• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select 3D Area Clearance > Model Rest Area Clearance & OK.

• Rename the Toolpath name to AreaClearanceD12.

• From the Tool tab select the D12T1 tool from the drop-down list.

• From the Model rest area clearance tab select Style as Offset Model,
Climb in Profile & Area, Tolerance 0.1, Thickness 0.5, Stepover 2,
Stepdown 3.

• In the Unsafe segment removal page, Un-Tick the box Remove

segments smaller than threshold and leave all other settings as default.

• In the Rest page select Rest machining as Toolpath AreaClearanceD16,

and in Detect material thicker than input 0.5.

• In the Flat Machining page, set Machine flats to Area & then Calculate &
Close the dialog.

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 We will now create an End Mill and two further Ball Nose tools for the
finishing strategies.

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list, select an End Mill tool then Search.

• Select EM12 from the list and then Create Tools.

• From the Type, drop-down list, select a Ball Nose tool then Search.

• Select BN12 from the list and then Create Tools.

• Select BN5 from the list and Create Tools and then Close.

• From the Tool tab select the EM12 tool from the Active ribbon to activate
the tool.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > Offset Flat Finishing & OK.

• Change the Toolpath name to FlatFinishing.

• In the Limit page, Z limits tick the Maximum box, and input the value -25.0.

• In the Offset flat finishing page untick Add approaches from outside,
untick Rest machining, input Tolerance 0.02, Thickness 0, Stepover 9.

• In the Leads and links > Lead in page select 1st choice Vertical arc, with
Linear move 12, Angle 90, Radius 6, and then Calculate and Close the
dialog.

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 All flat areas below the height limit of Z-25 have been identified and
machined. The flat base of the central pocket has been ignored as it is above
the maximum height limit.

• From the Tool tab select the BN12 tool from the Active ribbon to activate
the tool.

• Shift Select all Flat Surfaces and then Ctrl J to blank (undraw) them.

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• Select all the visually remaining Surfaces.

• From the Boundary tab select Selected Surfaces from the Create
ribbon.

• Ensure that the following settings are applied: Name BN12Boundary,

Tolerance 0.02, Thickness 0, Tool BN12, Un-Tick Allow boundary to be

private, Limit (keep tool Centre to edge of block) then Apply &
Accept.

A boundary has now been created which will used to limit some of the machining
strategies to areas where they are most effective.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > Steep and Shallow Finishing & OK.

• Rename the Toolpath name to BN12-StpShlw.

• From the Tool tab select the BN12 tool from the drop-down list to activate
the ball nose.

• From the Limit page select BN12Boundary, Trimming Keep Inside, Limit

(keep tool Centre to edge of Block), untick the Z limits, Maximum Z

box.

• In the Steep and shallow finishing page input Threshold angle 30, Steep
shallow overlap 0, tick both Spiral boxes, and in both Cut direction boxes
select Climb, for both Stepdown & Stepover input 0.5, select Type 3D
offset, tick Smoothing, and input Tolerance 0.02, & Thickness 0.

• From the Lead and links page, select the Lead in dialog and select 1st
choice Surface normal arc, Angle 90, Radius 6 and select the option to

copy Lead ins to Lead outs , select Calculate & Close.

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 The above displayed toolpath has a stepover of 1 so it can be visualized
more easily.

• From the Tool tab select the BN5 tool from the drop-down list to activate
the ball nose.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > Corner Finishing & OK.

• Rename the Toolpath name to BN5-Cornerfinish.

• From the Limit page, select Boundary as None, Limit (keep tool
Centre to edge of block).

• In the Corner finishing page select Strategy Along, Threshold angle 90,
Cusp 0.02, Tolerance 0.02, Cut direction Climb, Thickness 0.

• In the Corner detection page select Reference tool BN12, and Overlap 1.

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• From the Lead and links > Lead in tab select 1st choice Surface normal

arc, Angle 90, Radius 3, click copy Lead ins to Lead outs , select
Calculate & Close.

Simulation

We will now simulate all the toolpaths.

• Select the NC Program tab > Create panel select NC Program .

• In the PowerMill explorer Shift Select all toolpaths, right click on them,
and from the resultant menu select Add to > NC Program.

• In the PowerMill Explorer expand the NC Programs folder, right click on

NC program 1, and from the local menu select Simulate from start.

• The Simulation tab > Simulation path panel will have automatically been

selected with the Entity type as NC Program and in the Entity box
input 1 (the NC Program name).

• Select the Simulation tab > ViewMill panel and switch the Off

button to On within the ViewMill ribbon.

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• Select Mode from the ViewMill ribbon then Fixed direction .

• From the Shading menu select Rainbow .

• Select Play from the Simulation Controls ribbon.

• Exit the ViewMill session

• Select File > Save to update the Project.

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

• Create both Area Clearance and Model Rest Area Clearance Strategies.
• Create an Offset Flat finishing strategy.
• Create a Steep and Shallow Finishing strategy limited within a Boundary.
• Create a Corner Finishing strategy.
• Create a NC Program.
• Run a ViewMill Simulation.

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Exercise 4 - Phone Model

• Right mouse click in the graphics area and from the menu select Delete
All, then select File tab > Options > Reset Forms.

• Select the File tab > Import > Model:-

…\PMData\Models\phone.dgk

• Select the File tab > Save As > Project:-

…\COURSEWORK\PMProjects\handsetfinish

• Select the CAD Model & from the Workplane tab select At Top Of

Selection from the Create ribbon.

• Activate the new Workplane 1 via the drop-down list from the Active
ribbon.

• From the Home tab create a Block to the default settings.

• Fill in the Block form as follows: Defined by Box, Coordinate System

Active Workplane, Type Model, then Calculate & Accept.

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• Select the Home tab > Setup panel > Toolpath Connections .

• From the Safe Area tab ensure that the Block and Model is selected
within the Measured from drop-down list, then select Calculate & Accept.

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list select a Tip Rad tool then Search.

• Select D20T3 from the list and then Create Tools.

• Repeat the above procedure and create a Dia 12, Ball Nose tool named

BN12 and then Close the form.

• From the Stock Model tab select Stock Model from the Create
ribbon.

• Enter Name Op1, Tolerance 0.05, Stepover 0.3, & Accept.

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• From the Apply ribbon, select Block , then from the Calculate

ribbon, select Stock Model Calculate.

• In the PowerMill explorer right mouse click on Stock Model 1 and from the
local menu select Drawing options and tick both Shaded and Show Rest
Material.

• From the Tool tab select the D20T3 tool from the Active ribbon to activate
the tool.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select 3D Area Clearance > Model Area Clearance & OK.

• Rename the Toolpath name to Area Clearance D20T3.

• From the Tool tab select the D20T3 tool from the drop-down list.

• From the Model area clearance tab select Style as Offset Model, in both
Profile & Area select Climb, input Tolerance 0.1, Thickness 0.5, Stepover
8, Stepdown 3, then Calculate & Close.

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• From the Stock Model tab select Toolpath from the Apply ribbon.

• From the Calculate ribbon select Stock Model Calculate.

You can view the various model states if you would like too by expanding on
the Stock Models > OP1 within the PowerMill Explorer and double
clicking on the state would like to view.

• From the Tool tab select the BN12 tool from the drop-down list.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select Finishing > Raster Finishing & OK.

• Rename the Toolpath name to Raster Finish BN12.

• From the Raster finishing page select Angle 135, Ordering > Style Two
Way, Tolerance 0.02, Thickness 0, Stepover 0.3, then Calculate & Close.

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• From the Stock Model tab select Toolpath from the Apply ribbon.

• Select Stock Model Calculate from the Calculate ribbon.

• Select the Tool tab > Database panel > Tool to open the Tool Database
Search dialog.

• From the Type, drop-down list, select a Ball Nose tool then Search.

• Select BN5 from the list and then Create Tools.

• From the Tool tab select the BN5 tool from the drop-down list to activate
the ball nose.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.
• Select Finishing > Corner Finishing & OK.

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• Rename the Toolpath name to Cornerfinish5.

• From the Limit tab select Boundary None, Limit (keep tool Centre to
edge of block).

• In the Corner finishing page select Strategy Along, Threshold angle 90,
Cusp 0.02, Tolerance 0.02, Cut direction Climb, Thickness 0,

• In the Corner detection page select Reference tool BN12, with Overlap 1.

• From the Lead and links, Lead in tab select 1st choice Surface normal
arc, Angle 90, Radius 3 (radius of tool) & Make the lead outs the same

as the lead ins , select Calculate & Close.

• From the Stock Model tab select Toolpath from the Apply ribbon.

• Select Stock Model Calculate from the Calculate ribbon.

We will now view the various stock model states

• From the PowerMill Explorer expand the Stock Model folder.

• Double click on the various stock model states to view.

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• Select the File tab > Save to update the Project.

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

• Create a Block
• Create a Workplane
• Generate an Area Clearance Strategy
• Create a Raster Finishing strategy
• Create a Stock Model

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Exercise 5 – Vortex (High Speed) Area Clearance

Objectives
• To learn the basics of Vortex Area Clearance.

Vortex machining is an area clearance strategy which rapidly removes

material from a 3D part while accurately controlling the tool loading. Vortex
is best suited to solid carbide tools and is frequently used in combination
with step cutting.
The engagement angle never exceeds that produced by a straight line cut
with a given stepover. This eliminates excessive tool load and all full-width
cuts. This enables you to increase feed rates. As the tool approaches the
maximum engagement angle, the strategy automatically changes to use a
trochoidal path to avoid tool overload.

• Right mouse click in the graphics area and from the menu select Delete
All, then select File tab > Options > Reset Forms.

• Select the File tab > Open > Project:-

…\PMData\Projects\Vortex2-Start

• Select the File tab > Save As > Project:-

…\COURSEWORK\PMProjects\Vortex2

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• Select the Workplane tab > Active panel & from the drop-down list select
TopCentre-Datum.

• From the Home tab > Setup panel select Block.

• In the Block dialog select Defined by Box, Coordinate System Active

Workplane, Type Model, then Calculate & Accept.

• Select the Home tab > Setup panel > Toolpath Connections .

• Select the Safe Area tab and ensure that Measured from Block and
Model is selected and then select Calculate followed by Accept.

• Select Toolpath tab > Create panel > Toolpath to open the
Strategy Selector dialog.

• Select 3D Area Clearance > Model Area Clearance & OK.

• Rename the Toolpath name to D16TR3-Vortex-RGH1.

• From the Tool page select the D16T3 tool from the drop-down list.

• In the Model area clearance dialog select the Style as Vortex, in both
Profile & Area select Climb, input Tolerance 0.1, Thickness 0.5, Stepover
3, Stepdown 12.

• In the Vortex page input Minimum radius (r) as 3.0.

• In the Step cutting page, tick the Step cutting box, and then input a
Stepup value of 1.0.

• In the Flat machining page Machine flats drop-list select Level.

• In the Approach page Move Type drop-list select Helical ramps with Max
zig angle 4, Circle diameter (TDU) 0.7, and Height 5, & then Calculate and
Close.

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• Run a ViewMill simulation on the Toolpath to observe the Vortex area
clearance strategy.

• Select File tab > Save.

Summary
• In the above exercise, you have created a Vortex (high speed) area
clearance strategy.

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