PowerMill Starter Pack

Process & Technology Guide

1. Introduction
Autodesk® PowerMill® is a robust CAM software for manufacturers of molds, dies and
complex components to achieve better quality control and efficiency from CNC machining.

Access a vast library of toolpath strategies and combine with advanced optimization tools
to generate the NC code needed to produce exceptional quality parts. Use powerful
simulation tools to validate and enhance the motion of 5-axis machines.

By learning to use PowerMill, users can:

 Work with 2D and 3D CAD data in a CAM workspace.
 Explore manufacturing options with rapid visual results.
 Get familiar with efficient roughing strategies.
 Discover a large variety of different finishing strategies and their usage.
 Make use of toolpath parameters to customize the results.
 Learn about the power of toolpath editing.
 Define strategies for the accurate manufacture of Electrodes
 Create toolpath strategies for Wire and Arc and Powder Based Additive
Manufacturing methods
 Drive and control Robot arms with various end effectors
 Verify the resulting toolpath with 2D, 3D and machine simulation.
 Create the resulting NC-Program together with supportive setup sheets.

The goal of the PowerMill Technology & Process Guide is to outline best practices and
business use cases for an implementation of PowerMill.

The PowerMill Starter Pack covers the following topics:

● Workflow 1: Standard 3D and 5-axis Machining
● Workflow 2: Electrode Solution Milling
● Workflow 3: Robot Programming
● Workflow 4: Additive Manufacture

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2. Use Cases

2.1. Use Case 1: Mold Manufacture

Description: Accurate and high-quality machining of large mold and die tools.

2.1.1. Use Case Objectives

Typical Goals for manufacture of mold tools:
• Reliable roughing to increase cutting tool life
• High-quality surface finishing
• Minimize errors to reduce the amount of scrappage of expensive parts
• Improved toolpath safety to reduce risk of expensive machine tool collisions and
machine downtime.

2.1.2. Recommended Workflows

Workflow 1 – Standard 3D and 5 Axis

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2.2. Use Case 2: Aerospace Components
Description: High-quality, fast, and repeatable manufacture of complex aerospace
components.

2.2.1. Use Case Objectives

Typical Goals for manufacture of aerospace components:
• Fast and repeatable cycle programming times
• Automated 5-axis toolpath creation to make complex part programming
easier
• Make difficult-to-machine materials easier to cut
• Reduced time for manual polishing

2.2.2. Recommended Workflows

Workflow 1 – Standard 3D and 5 Axis
Workflow 3 – Robot Programming

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2.3. Use Case 3: Electrode Manufacture

Description: Automated manufacture of electrodes for EDM.

2.3.1. Use Case Objectives

Typical Goals for Electrode Manufacture:
• Reduce time for electrode programming using toolpath templates
• Reduce human errors on electrode programming
• Automate the electrode machining

2.3.2. Recommended Workflows

Workflow 2 – Electrode Solution Milling

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2.4. Use Case 4: Part Repair using Blown Powder Additive

Manufacturing
Description: Using blown powder Additive processes to rebuild or repair damaged
components.

2.4.1. Use Case Objectives

Typical Goals for part repair or rebuild using blown powder Additive Manufacturing:
• Reduce the need for damaged expensive components to be scraped
• Create small batches of complex components efficiently
• Save material when compared to traditional subtractive manufacturing
methods
• Minimize lead time by repairing components when compared to
manufacturing a new component from scratch.

2.4.2. Recommended Workflows

Workflow 4 – Additive Manufacture
Workflow 1 – Standard 3D and 5 Axis

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2.5. Use Case 5: Part Build using Robotic Wire Arc Additive
Manufacture
Description: Using Wire Arc Additive Manufacture to build a propellers or other complex
components.

2.5.1. Use Case Objectives

Typical Goals for creating parts using Robotic Wire Arc Additive Manufacturing:
• Optimization of component geometry that would not be possible with
traditional subtractive techniques.
• Creation of parts too large for Additive Manufacturing machines.
• Creation of components on demand negate the need for storing many large-
scale spares.

2.5.2. Recommended Workflows

Workflow 4 – Additive Manufacture
Workflow 3 – Robot Programming
Workflow 1 – Standard 3D and 5 Axis

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2.6. Use Case 6: Robot Polishing

Description: Automated polishing of components using a Robot arm.

2.6.1. Use Case Objectives

Typical Goals for automating the polishing of components using robots:
• Improve the accuracy and repeatability of polishing operations
• Improve polishing throughput when compared to hand polishing
• Reduce the need for inspection and manual rework

2.6.2. Recommended Workflows

Workflow 3 – Robot Programming
Workflow 1 – Standard 3D and 5 Axis

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3. Workflows
By applying workflows to use cases we can simulate what happens in a real project work to
achieve results. To avoid any pitfalls within computational design, make sure to do things in
the correct order:

1. 3D and 5-axis Manufacture

2. Electrode Solution Milling
3. Robot Programming
4. Additive Manufacture

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3.1. Workflow 1 – Standard 3D and 5 Axis

Recommended workflow for 3 or 5-axis Machining.

To manufacture a part using 3 or 5-axis and PowerMill, these are the typical steps taken:
● CAD data: Import and arrange part CAD geometry
● Part Setup: Define work-holding and stock material
● Toolpath Creation:
○ Roughing, rest roughing
○ Semi-finishing, finishing
● Toolpath Editing: Manipulate toolpaths to exact requirements
● Simulation: Simulate toolpaths with full machine tool simulation to ensure safety
● Create NC code: Post NC code ready for use on machine tool

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PowerMill 3/5-axis User Interface

3.1.1. Key Considerations

 When modelling cutting tools, it is advised to model the entire cylindrical part of the tool
as cutting flutes. This provides more accurate collision checking, especially on vertical
walls.
 When programming in 3+2 or 5-axes, it is recommended to use an *.mtd (machine tool)
file to enable accurate collision checking.
 When creating roughing strategies for mold tools, it is recommended that the part is
roughed down to a thickness of less than the diameter of next (rest roughing) tool.
 Avoid full diameter cuts with small milling tools where to possible, this is to preserve the
life of the tool.

3.1.2. Recommendations
 Once a toolpath has been created, creating a clone of it makes subsequent toolpath
creation much easier. All parameters from the original toolpath are retained.
 Using a stock model for each operations enables a greater accuracy of toolpath
calculation and verification.

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3.2. Workflow 2 – Electrode Solution Milling

Recommended Workflow for Electrode Milling:

To manufacture electrodes using PowerMill Electrode Solution, these are the typical steps
taken:
● Import .trode file: Import electrode CAD geometry, block and undersizes
● Select Electrode type and template.
● Run automated toolpath creation.
● Toolpath Editing: Manipulate toolpaths to exact requirements
● Simulation: Simulate toolpaths with full machine tool simulation to ensure safety
● Create NC code: Post NC code ready for use on machine tool

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PowerMill Electrode User Interface

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3.2.1. Key Considerations

 Most problems in electrode manufacture are due to human error.
 Undersizes will be automatically considered by the electrode wizard.
 The electrode wizard is only as good as the templates created.
 The calculation of the electrode NC-Programs can be automated
using the PowerMill Project Server

3.2.2. Recommendations
 Prepare templates which include tools and toolpaths that can be applied to a wide
variety of different electrodes to save time when programming.
 Consider creation of templates for different electrode types.
 Check the created toolpaths after the wizard finished.
 Macros can be used to automate the creation of boundaries for use with toolpath
templates.

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3.3. Workflow 3 – Robot Programming

Recommended Workflow for Robot Programming:

PowerMill Robot is used to supplement either a 5-axis machining workflow or additive

workflow in order to create complex components using a robot arm with various end
effectors. The following steps are the typical ones taken:

● Set up Robot Cell:

○ Choosing the correct Robot from the library
○ Position the part in the robot cell
● Robot Simulation:
○ Pre-positioning of the robot
○ Set robot axis priorities and simulation constraints
○ Run and record simulation
● Robot Program:
○ Add toolpaths recordings to the NC program
○ Check the NC Program settings
○ Write NC program

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PowerMill Robot User Interface

3.3.1. Key Considerations

 Robots are not as accurate as machine tools but have more tool options.
 The part size must fit the robot working envelope and positioned correctly.

3.3.2. Recommendations
 For a large part, users might consider using a linear axis or rotary table with the robot.
 Never use a simulation that produced errors in a robot NC-Program.
 It is essential that the Position and Orientation of workplanes created on the robot
correspond to those created in PowerMill.

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3.4. Workflow 4 – Additive Manufacture

Recommended workflow for Wire/Arc or Powder Based Additive Manufacture:

The below steps are the typical to be followed when following a workflow for Powder Based
or Arc/Wire Additive Manufacture:

● Preparing CAD for Additive:

○ Defeaturing the part
○ Offsetting surfaces to print Near Net Shape components
● Additive Strategies:
○ 2.5D Netfabb Strategies
○ Surface Coating
○ Feature Creation
○ Converting Subtractive toolpaths to Additive Strategies
● Special Properties of Additive Toolpaths:
○ Layer definition
○ Process Parameters
○ Ordering and combining segments
● Additive Simulation: Visualization of material build up
● Posting Additive NC Programs

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PowerMill Additive User Interface

3.4.1. Key Considerations

 Printing parameters will differ depending on part geometry and material settings
 Keep in mind that PowerMill Additive simulation is only a simple visualization tool, many
other factors (below) affect the deposition of material.
 Consider the orientation of a part and the angle at which it’s deposited onto the base.
The orientation of deposition can affect number of part overhangs and thus strength of
component.
 Due to the heat involved in Direct Energy Deposition and Wire Arc Additive Manufacture,
there will likely be some deformation of the component during deposition. This will affect
deposition parameters such as speed and bead width.
 Adding a wait time between the deposition of layers will prevent heat build-up, and thus
deformation, of the part.
 The build sequencing (i.e. the order in which features are built) can have an effect on the
final part geometry.
 Toolpath strategy has a large effect on how long it takes to build a part and the heat
dissipation of that part.

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3.4.2. Recommendations
 It is best to modify CAD geometry before creating Additive Strategies. Offsetting
surfaces outwards and defeaturing a component makes it simpler and easier to create a
Near Net Shape component leaving material for subtractive finishing.
 For Wire Arc Additive Manufacturing, it is recommended to combine it with PowerMill
Robot. Thus, robot limits and movement can be considered for the build sequencing,
choice of toolpaths and part orientation.

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4. References
 If a project gets locked, claim it back using the typed command ‘project claim’.
It is recommended to add it to the ribbon or user menu.
 To add a user defined ribbon, see: User defined Ribbons
 To add a user menu, see: Creating custom menus

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and pricing at any time without notice, and is not responsible for typographical or graphical
errors contained in these materials. Autodesk assumes no liability as a result of the use or
application of these materials which are provided on an “As Is” basis.

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