PowerMill

Lesson 14 – 3+2 Axis Machining

Objectives
• Discriminate 3+2 axis setups using Workplanes.
• Create 3+2 axis Toolpaths.
• Output a selection of Vertical and 3+2 toolpaths in an NCProgram relative
to a single workplane.

Exercise 1 – 3+2 Machining Example

• From the graphics area, local menu select Delete All and then select the
File Tab followed by Options - Reset Forms.

• Import the Model:-

…\PMData\Models\ValveBlock

• Save the Project As:-

…\COURSEWORK\PowerMill_Projects\Basic-3plus2

• Select the whole model, create a Workplane At Top of Selection, and

name it as Top.

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• Create a Workplane At Point, dynamically snap it to the lower, near corner

of the model, and name it as Front.

• Right mouse click on the new workplane, and from the local menu select
Workplane Editor.

• Rotate the workplane 90 degrees about X to create a 3+2 alignment (This

can also be achieved dynamically by dragging the blue handle to a suitable
key point).

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• Create a workplane named Left at the far, lower, left hand end of the
model (as shown above with the Z axis normal to the left face).

• Create a workplane named Rear at the far, lower, back face of the model
(as shown above with the Z axis normal to the rear face).

You now have 4 workplanes ready to create toolpaths relative to a selection of 3+2
set-ups. The final NCProgram output will be relative to the workplane named Top.

• Activate the workplane named Top.

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• From the Home ribbon bar create a Block relative to the Coordinate
System Active Workplane.

• Select Toolpath Connections from the Home tab.

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

• Right-Click on Tools within the PowerMill Explorer and select Create Tool
> From Database.

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

• Select EM16 from the list, and then Create Tools (or simply double click
on EM16).

• Repeat the above procedure and download 2 more tools, EM10 & EM5.

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

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

• Activate the tool EM16.

• From the toolpath strategy selector choose Area clearance followed by

Model Area Clearance and rename it as EM16-TOP1.

• Set Style to Offset model, and in Cut Direction set Profile and Area to
Climb.

• In the Offset page tick Spiral.

• In the Unsafe segment removal page tick Remove segments smaller

than threshold with the default value of 0.95 and untick Only remove
segments from enclosed areas.

• Set Tolerance to 0.1, Thickness to 0.5, Stepover 9, Stepdown 2, and tick

the Constant stepdown box.

• Calculate and then Close the strategy dialog.

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• Activate the tool EM10.

• From the toolpath strategy selector choose Area clearance followed by

Model Rest Area Clearance and rename it as EM10-TOP1.

• Set Tolerance to 0.1, Thickness to 0.5, Stepover 2, Stepdown 1, and tick

the Constant stepdown box.

• In the Rest page use the default Toolpath option, select the toolpath
named EM16TOP1 as the reference item, and input Detect material thicker
than as 0.5.

• Calculate and then Close the strategy dialog.

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• Activate the tool EM5.

• From the toolpath strategy selector choose Area clearance followed by

Model Rest Area Clearance and rename it as EM5-TOP1.

• In the Rest page use the default Toolpath option, select the toolpath
named EM10TOP1 as the reference item, and input Detect material thicker
than as 0.5.

• Calculate and then Close the strategy dialog.

• Activate both the workplane Front, and the tool EM10.

• Select and Blank except the front pocket surfaces.

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• From the Home ribbon bar create a Block relative to the Coordinate
System Active Workplane (while the front, pocket surfaces are selected).

• Select Toolpath Connections from the Home tab.

• In the Lead ins dialog set 1st choice as Ramp, then open the Ramp
options dialog and set Follow Circle, Max zig angle 3, with Circle diameter
0.6, and then Accept.

• In the Safe Area dialog select the Safe area Workplane as Top, and click
Calculate.

• In the Start and end point dialog set Start point to use First point safe
and End point to use Last point safe, and then Accept.

• From the toolpath strategy selector choose Area clearance followed by

Model Area Clearance and rename it as EM10-FRONT1.

• Set Tolerance to 0.1, Thickness to 0.5, Stepover 5, Stepdown 3, and tick

the Constant stepdown box.

• Calculate and then Close the strategy dialog.

• Select Unblank to display the whole model.

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• Right mouse click on the toolpath EM10-FRONT1 and from the local menu
Activate and select Settings to re-open the strategy dialog.

• Select Make a Copy, and rename the new strategy as EM10-REAR1.

• Activate both the workplane Rear, and the tool EM10.

• From the Home ribbon bar create a Block relative to the Coordinate
System Active Workplane (while the rear, pocket surfaces are selected).

• Calculate and then Close the strategy dialog.

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• Activate both the workplane Left, and the tool EM5.

• From the Home ribbon bar create a Block relative to the Coordinate
System Active Workplane.

• Select and then Blank except the left recess surfaces.

• With the above surfaces selected, create a Pattern, rename it as

LeftRecess, and Insert > Model.

• Undraw the model before selecting and deleting the 2 circular pattern
segments.

• Open the Curve Editor (double click on the above segment), cut
where arrowed, and then delete the horizontal parts of the pattern
segment.

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• Finally Merge the pattern to ensure that it contains one open segment.

• Switch on Instrumentation to identify the direction of the pattern segment.

If it is required to climb mill then the above pattern direction will comply with the
default settings of a 2D Curve Profile strategy. Otherwise advanced settings within
the strategy can be applied.

• Select Toolpath Connections from the Home tab.

• In the Safe Area dialog select the Safe area Workplane as Top, and click
Calculate.

• In the Start and end point dialog set Start point to use First point safe
and End point to use Last point safe, and then Accept.

• From the toolpath strategy selector choose Curve Machining followed by

2D Curve Profile and rename it as EM5-LEFT1.

• For the Curves definition input LeftRecess with a Lower Limit of -15.

• Input a Tolerance of 0.01 and a Curve thickness of 0.

• Select the Cut distances page, input a Stock depth of 15, with Stepdown 3
and a Stock width of 2 with Stepover 1.
• Select the Finishing page, Tick Floor finishing, Wall finishing, and Last
pass only.

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• Input a Final stepdown of 1, a Final stepover of 0.5.

• Select the Order page, set Order by Region, and Order as Width first.

• Select the Lead in page, with 1st choice as Horizontal arc, Linear move 2,
Angle 90, and Radius 3, and then copy to Lead out.

• Calculate and then Close the strategy dialog.

• Create an NC Program named 3plus2, input the Machine option file as

select Mazak_Variaxis_5axis_ref.pmoptz.

• For the Output Workplane select Top.

• Add all 6 toolpaths to the NC Program and Apply the settings.

• Select Write to output the NC Program.

All toolpaths listed in the NC Program named 3plus2 will be output relative to the
common datum, workplane Top.

• Activate the toolpath EM16-TOP1 to reinstate the original setup.

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• Select an ISO 1 view.

• In the Simulation ribbon bar connect to a new ViewMILL session, select

Mode Fixed direction, and Shading Plain.

• Select the Entity type as NC Program.

• Right click on the NC Program 3plus2.and from the local menu select
Simulate from start.

• Play the full ViewMill simulation to the end.

Some stock remains at the base of the EM5-LEFT1 toolpath.

• Make a copy of the toolpath EM5-LEFT1, named EM5-LEFT2 and adjust

the settings to remove the remaining stock from the base of the recess
only.

Hints:- In Curve profile use Curve thickness 3, in Cut distances use Vertical
Stepdown 15, Horizontal Stock width 6, and Stepover 3.

• Disconnect the ViewMIll session.

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• Create a Workplane named MC-Datum positioned at 100 below the base

centre, of the model.

• On the main Ribbon bar select Machine Tool and Import:-

…\PMData\MachineData\MAZAK\PMPOST-Mazak_Variaxis_630PSA.mtd.

• In Model Location select the workplane MC-Datum.

• Run a full PowerMill simulation on the NC Program and if any Machine

tool collisions occur make appropriate changes (eg. Move the workplane
MC-Datum further down Z, or increase the length of the Tool Holder
assembly).

• Save the project.

Summary
• Discriminate 3+2 axis setups using Workplanes.
• Create 3+2 axis Toolpaths.
• Output a selection of Vertical and 3+2 toolpaths in an NCProgram relative
to a single workplane.

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