Delcam - PowerMILL 8.0 Whats New en - 2007

What's New in
PowerMILL 8.0
By Delcam plc
Release Issue 1
Disclaimer
Delcam plc has no control over the use made of the software described in
this manual and cannot accept responsibility for any loss or damage
howsoever caused as a result of using the software. Users are advised that
all the results from the software should be checked by a competent
person, in accordance with good quality control procedures.
Information contained in this manual is subject to change without notice
and does not represent a commitment by Delcam plc. The software
described in this manual is furnished under licence agreement and may be
used or copied in accordance with the terms of such licence. No part of
this manual may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying and recording,
for any purpose without the express permission of Delcam plc.
Copyright 1996-2007 Delcam plc. All rights reserved.
Acknowledgements
This documentation references a number of registered trademarks and
these are the property of their respective owners. For example, Microsoft
and Windows are either registered trademarks or trademarks of
Microsoft Corporation in the United States and/or other countries.
Patents
The Raceline smoothing functionality is subject to patent applications.
Patent pending: GB 2374562 Improvements Relating to Machine
Tools
Patent granted: US 6,832,876 Machine Tools
Some of the functionality of the ViewMill and Simulation modules of
PowerMILL is subject to patent applications.
Patent granted: GB 2 423 592 Surface Finish Prediction
PowerMILL Version: 8.0 Date: 29/08/2007 16:17
Contents
Introduction
Toolpath preparation......................................................................................1
Toolpath generation .......................................................................................3
Toolpath verification......................................................................................4
Toolpath output..............................................................................................4
User interface .................................................................................................5
General ...........................................................................................................5
Toolpath preparation
Undoing patterns and boundaries ..................................................................7

Boolean boundaries........................................................................................8
Example of Boolean operations on two boundaries ............................10
Tool axis.......................................................................................................12
Tool database ...............................................................................................14
Search settings .....................................................................................15
Stock material ......................................................................................16
Search results .......................................................................................17
Creating tools from the tool database ..................................................18
Tool enhancements ......................................................................................20
Export a tool to the tool database ........................................................20
Cutting Data tab ...................................................................................22
Description tab.....................................................................................27
Feeds and speeds enhancements ..................................................................29
Using the Feeds and Speeds dialog .....................................................35
Leads and links ............................................................................................41
Along Radial option.............................................................................41
Automatically Extend option...............................................................42
Add Leads at Tool Axis Discontinuities fields....................................44
Workplane....................................................................................................45
Workplane undo example ....................................................................46
Sets ...............................................................................................................48
Feature sets...................................................................................................49
Create holes from toolpath plunge points............................................50
Create holes from contact normals ......................................................51
What's New in PowerMILL 8.0
Contents i
Editing feature components .................................................................53

Editing automatically identified holes.................................................55
Setup sheets..................................................................................................59
Toolpath generation
62
Tool axis editing ..........................................................................................62

Select Regions tab................................................................................63
Edit Tool Axis tab................................................................................65
Example of tool axis editing ................................................................67
Area clearance improvements......................................................................84
Trochoidal moves ................................................................................85
Horseshoe moves .................................................................................86
Swarf machining enhancements ..................................................................88
Blisk machining ...........................................................................................89
Blisk area clearance .............................................................................91
Blade finishing.....................................................................................99
Hub finishing .................................................................................... 102
Example of Blisk machining ............................................................ 103
Parametric Offset finishing enhancements ............................................... 111
Port machining preview ............................................................................ 113
Disc Profile finishing ................................................................................ 114
Drilling enhancements .............................................................................. 117
General toolpath enhancements ................................................................ 117
Draw Contact Track option .............................................................. 120
Toolpath verification
121
Changes to simulation............................................................................... 121

Simulation......................................................................................... 122
ViewMill........................................................................................... 123
Machine ............................................................................................ 132
Simulation examples......................................................................... 133
Toolpath output
140
Text block enhancements.......................................................................... 140

Text Block toolbar ............................................................................ 141
ii Contents
NC program notes ..................................................................................... 141

Coolant ...................................................................................................... 142
Arc fitting.................................................................................................. 143
Drilling cycle output ................................................................................. 143
User interface
144
View toolbar.............................................................................................. 144

Options dialog........................................................................................... 145
Background image ............................................................................ 146
Tool tab ............................................................................................. 149
Tool context menus................................................................................... 150
General enhancements
152
Index
153
Contents iii
Introduction
PowerMILL 8.0 offers all of the original features of PowerMILL 7.0, but
with numerous improvements. The most significant improvements are:
There is a new set of options on the individual Boundary and Pattern
context menu, which allows you to undo and redo boundary edits (see
"Undoing patterns and boundaries" on page 7).
You can now perform Boolean operations on boundaries (see "Boolean
boundaries" on page 8).
There are a few enhancements to
Tool Axis (on page 12):
Tilting - when tilting in a Fixed Direction, PowerMILL first

searches in the direction specified, and if that fails, searches in the
opposite direction.
Automatic Collision Avoidance has two new Tilt Tool Axis
options.
There are several Tool enhancements (on page 20):
A new Tool Database (on page 14)
Tool toolbar.
button is available on the
The Tool dialog has an additional option to Export a tool to the

tool database (on page 20).
The Cutting Data tab (on page 22) of the Tool dialog has a new
set of parameters which complement those in the tool database.
A new Description tab (on page 27) on the Tool dialog allows
you to add your own parameters to the tool.
Introduction 1
There is a new
Feeds and Speeds dialog (see "Feeds and speeds
enhancements" on page 29).
There are a couple of enhancements to
41).
Leads and Links (on page
The Links tab now has the Along Radial option (on page 41) and
Automatically Extend option (on page 42).
The Lead In and Lead Out tabs have additional Add Leads at
Tool Axis Discontinuities fields (on page 44).
You can now Undo and Redo Workplane Transformations (see
"Workplane" on page 45).
There is a new Sets (on page 48) entity in the Explorer. Sets are
particularly useful when Blisk machining. Sets are very similar to Levels.
There are several Feature Sets (on page 49) enhancements including:
Two additional ways of creating holes:
Create holes from toolpath plunge points (on page 50).
Create holes from contact normals (on page 51).
Holes generated automatically from the Recognise Holes in
Model option on the Feature Sets context menu can now be
edited. For more information, see Editing automatically identified
holes (on page 55).
Individual components of a Feature can be edited from the
Component tab on the Feature dialog. For more information,
see Editing feature components (on page 53).
There are a few enhancements to Setup Sheets (on page 59).
The Setup Sheets User Guide is available for download. It
contains step-by-step instructions on how to create and customise
setup sheets.
2 Introduction
Toolpath generation
Tool Axis Editing (on page 62) is a new option, which allows you
to edit the tool axis of selected (partial) segments of a toolpath whilst
preserving the toolpath contact positions.
There are several Area Clearance improvements (on page 84)
including:
You can now create a toolpath with trochoidal moves (on page
85) along the whole toolpath.
Offset Area Clearance now uses horseshoe moves (on page
86), which maintain cutter direction, rather than circular loops on
external corners.
Swarf Machining enhancements (on page 88) include an option of
Follow Surface Laterals.
There are three new Blisk Machining strategies available:
Blisk area clearance (on page 91).
Blade finishing (on page 99).
Hub finishing (on page 102).
Parametric Offset Finishing enhancements (on page 111)
include a new option of Edge Tolerance.
The Port Machining strategy dialogs now include a Port Machining
Preview (on page 113) button, to improve consistency with other
machining strategies.
A new Disc Profile Finishing (on page 114) strategy uses a tipped disc
tool to create profile toolpaths. The edge of the tool, rather than the tool
tip, is driven along the surface. This strategy will not cut at sharp angles,
but will retract, re-position and then plunge before continuing machining.
There are a couple of Drilling enhancements (on page 117).
There are several General toolpath enhancements (on page 117)
including:
A new
Draw Contact Track option (on page 120). This
draws the trace of the toolpath contact points in red.
Introduction 3
There is a change in the way that simulation works in PowerMILL.
There are now three simulation toolbars:
Simulation (on page 122) - controls the playing of the simulation.
ViewMill (on page 123) - controls the visualisation of the
simulation.
Machine (on page 132) - controls the visualisation of the machine
tool.
For information on to how to use the new simulation toolbars, see the
Simulation examples (on page 133).
Toolpath output
The Text Block enhancements (on page 140) include:
The Text Block toolbar (on page 141) aiding text block creation.
The Rotation option in the Type field.
NC Program Notes (on page 141) allow you to add notes to NC
programs, and record the programmer's name and date.
The Coolant (on page 142) can be set using a new Coolant option;
changing the coolant type in different dialogs has different impacts.
Arc Fitting (on page 143) a toolpath is now only available using the
Output Type of Fit Arcs in the Point Distribution
than when outputting an NC program.
dialog rather
If you want to set a preference for Drilling Cycle Output (on page
143), then you can set it in the template, or when you are about to write
the NC program.
4 Introduction
User interface
The PowerMILL 8.0 View toolbar (on page 144) contains the same
buttons as in PowerMILL 7.0, but they are reorganised into several pullout toolbars.
There are three changes to the Tools - Options dialog:
You can now choose a background image (on page 146) for the
graphics area.
There is a new Tool tab (on page 149).
If you don't want your output file to have an extension type '.' in the
extension field of the NC Program tab.
There are additions to the Tool context menus (on page 150).
General
There are several general enhancements (on page 152).
PowerMILL is much faster at deleting multiple entities in the
Explorer.
Graphics performance (such as dynamic pan, rotate and zoom) is
faster than it was in PowerMILL 7.0.
There is now support for 3DConnexion SpacePilot.
Template objects now support folders.
Significant improvements in the time taken to shade a model.
PowerMILL can now read both surface and triangle information
from third party CAD model file formats that support dual data
(such as Rhino).
Introduction 5
Only new features available in PowerMILL 8.0 are documented here. For
information on bug fixes, corrections and compatibility issues, refer to the
Release Notes. These can be found from the Windows Start menu:
Start - Delcam - PowerMILL - PowerMILL800x - Release Notes 8.0x.
For information on known bugs found since the release of the software,
see the Known Bugs list. It can be found in the product tree at
\dcam\pmilldoc8000\file\help\ppp.htm.
For information about all other features, consult the on-line reference
documentation.
6 Introduction
Undoing patterns and boundaries

There is a new set of options on the individual Boundary and Pattern
context menus which allows you to undo and redo edits.
Undo Last Edit - reverts the boundary to what it was before the edit.
Redo Last Undone Edit - reinstates the edit you have just undone.
Clear History Buffers - empties the undo buffer, so that you can no
longer undo an edit.
Toolpath preparation 7
Boolean boundaries
You can now perform Boolean operations on boundaries.
You can use:
the Boundaries context menu:
button on the
the Create a Boolean Operation Boundary
Create Boundary pull-out list on the Boundary toolbar.
8 Toolpath preparation
In either case, the Boolean Operation Boundary dialog is displayed.

This option allows you to perform Boolean operations (such as add,
subtract and intersect) on two existing boundaries.
Reference Boundaries - defines the two boundaries you want to work

on.
Boundary A - select, from the drop-down list, the first boundary
you want to use.
Boundary B - select, from the drop-down list, the second
boundary you want to use.
Boundary A must be different from Boundary B.
If you choose a Type of Subtraction, Boundary B is subtracted
from Boundary A. So the order of selection of the A and B
boundaries is important.
If you choose a Type of Addition or Intersection then the order
of selection is irrelevant. The result is the same whichever order the
A and B boundaries are selected.
Boolean Operation
Type - defines which Boolean operation to perform.
Addition - creates a boundary which is the addition of the two

boundaries (Boundary A + Boundary B).
Subtraction - creates a boundary which is the subtraction of
Boundary B from Boundary A (Boundary A - Boundary B).
Intersection - creates a boundary which is the intersection of
Boundary A with Boundary B.
For more information, see Example of Boolean operations on two
boundaries (on page 10).
Example of Boolean operations on two boundaries

This example shows the effect of Boolean operations on two boundaries.
- Boundary A
- Boundary B
Addition gives:
Subtraction:
as Boundary A and
If you selected
subtraction gives:
as Boundary B then
as Boundary A and
If you selected
subtraction gives:
as Boundary B then
Intersection gives:
Tool axis
There are a couple of enhancements to the Tilt Tool Axis option on the
Collision Avoidance tab on the Tool Axis Direction
dialog:
When tilting in a Fixed Direction, PowerMILL first searches in

the direction specified, and if that fails, searches in the opposite
direction.
There are two new Tilt Tool Axis options.
Towards Curve - if a collision is detected, the tool will tilt such

that the tool tip tries to point towards the curve, until the collision
is avoided, to become a Toward Curve Tool Axis.
From Curve - if a collision is detected, the tool will tilt such that
the tool tip tries to point away from the curve, until the collision is
avoided, to become a From Line Curve Axis.
The curve must be a pattern with a single segment.
Tool database
A new Tool Database
The Tool Database
defined database.
button is now available on the tool toolbar.

dialog allows you to select tools from a pre-
The dialog splits into three areas:

Search Settings (on page 15) - allows you to select the criteria
to find the required tools.
Stock Material (on page 16) - allows you to specify the stock
material type.
Search Results (on page 17) - shows the tools in the database
that meet your search criteria.
Options for Tool Database - displays the Tool tab (on page 149)
in the Tools - Options dialog. This enables you to specify the location
of the tool database and how the tools are created.
Hovering the mouse over the Tool Database dialog header

displays the database file path in the Status bar.
Search settings
You can select a tool by entering search criteria in any number of the
fields (or, entering no search criteria, to display the whole database for
the selected tool type), and then clicking the Search button.
Name - allows you to search by the name of the tool.
Search String - enter the characters you are looking for in the
Tool Name.
Search Mode - defines how characters in the Name field are

searched.
Equals - the Tool Name only contains the characters in the
Name field.
Like - the Tool Name contains the characters in the Name
field, but may contain additional characters.
Diameter - allows you to search by the diameter range of the tool
specified by the Minimum and Maximum fields.
Length - allows you to search by the length range of the tool specified
by the Minimum and Maximum fields.
Tip Radius - allows you to search by the tip radius range of the tool
specified by the Minimum and Maximum fields.
Type - allows you to search by the tool type specified.
Flutes - allows you to search by the number of tool flutes.
Tool Family - allows you to search by the tool family specified.
Search - searches the database for all the tools that meet your criteria.
Reset - resets the search criteria to those displayed at start up.
Stock material
The stock material displayed here is the material that will be associated
with any new tool created in PowerMILL, whether it be from the tool
database or otherwise. If the tool is created from the database, it inherits
any cutting data that exists for that tool and stock material combination in
the database.
- displays the stock material to which the cutting
data refers. This drop-down list contains all the available stock material
types.
Define a new Stock Material - defines a new stock material for
use with the tool database. This displays the New Stock Material
Name dialog:
Enter a name for the new stock material, and then click
Spaces are not allowed in stock material names, but numbers are.
So Mild Steel isn't allowed, but Mild_Steel or Mild_Steel_1 are.
Search results
Tool List - displays all tools that meet the search criteria. It also gives
details of the tool's dimensions.
The size of each column can be moved in a standard Windows way by
placing the cursor over the end of a column and dragging it to a new
location. This works in the same way as the Toolpath List in the NC
Program dialog.
- shows the number of records found.
Select All Search Results - selects all listed tools.
Deselect All Search Results - deselects all selected tools.
Delete - deletes the selected records.
Create Tools - creates the selected tools in your project, and adds them
to the Explorer.
You can select tools by either using the Select All
any of the standard Windows selection methods.
button or by
Creating tools from the tool database

This example shows you how to create tools from the tool database.
1. Click the Tool Database
button on the Tool toolbar.
2. Enter the search criteria you are interested in. For example, to list
all end mills with a diameter between 4mm and 5mm.
Enter a Type of End Mill.
Select the Diameter option, and select a Min of 4.0 and a Max
of 5.0.
3. Click the Search button to find the tools that meet your criteria.
4. Select the tools you want to add to your project.
5. Click the Create Tools button. PowerMILL creates the specified

tools in your project, and adds them to the Explorer.
6. Click Close to close the dialog.
Tool enhancements
There are several tool enhancements:
A new Tool Database (on page 14)
Tool toolbar.
The Tool dialog has an additional option to Export a tool to the

tool database (on page 20).
The Cutting Data tab (on page 22) of the Tool dialog has a new
set of parameters which complement those in the tool database.
A new Description tab (on page 27) on the Tool dialog allows
you to add your own parameters to the tool.
Export a tool to the tool database

The Tool Tip dialog has an extra
button, which displays the Tool
Database Export dialog where you can add this tool to the tool
database.
This dialog is also available from the Add All Tools to Database
option on the Tools context menu, and Add Tool to Database option
on the individual Tools context menu.
The Tool Database Export dialog controls how tools created in

PowerMILL are exported to the database.
Export Options
Tool Geometry - exports the tool tip geometry to the tool database.
Cutting Data - exports the cutting data to the tool database.
Stock Material - allows you to change the stock material of the tool
being exported.
- lists all the stock material types. If the material
specified doesn't exist, then it is added to the tool database when
exported.
Define a New Stock Material - adds a new stock material to the
list. On export any new materials are added to the tool database.
Tool Family - indicates to which tool family (if any) the tool belongs.
Tools with the same family and with the same stock material share
cutting data.
Export Details
Summarises what will be exported to the tool database.
If you want to export several tools to the tool database, the simplest
way is to select the tools you want to add, and then choose the Add
Selected Tools to Database option from the right-click menu.
Cutting Data tab

This tab has changed dramatically.
The Cutting Data records are synchronised and shared for all tools with
the same Family Name and Stock Material.
If you have a blank Stock Material, then the cutting data is

synchronised and shared for all tools with the same Family Name,
blank Stock Material and Cutting Data records.
They are not shared for tools with blank Family Name, and the
same Stock Material and Cutting Data records.
The Cutting Data tab displays parameters related to the cutting
behaviour of the tool. Typically, cutting data values will depend on the
material being cut.
Tool Family - provides a way to group tools together, so that they can
share cutting data in the database. For example, you can enter the tool
material name as the Tool Family, then all tools with the same Tool
Family and Stock Material will share cutting data.
If you change the Tool Family, the Cutting Data from other tools with
the same Tool Family and Stock Material will be applied to this tool.
If no tools in the project or tool database share the same Tool Family
and Stock Material, the Cutting Data remains unchanged.
- adds a new tool family. The Enter the new family name dialog
is displayed.
Enter a name (which cannot contain any spaces). Click on

accept the new name, or
to
to cancel.
Tool ID - the user-defined name allocated to the tool, and added to the
cut file. By default, this is the same as the Name.
Coolant (on page 142) - allows you to specify the coolant:
None - no coolant output.
Standard - coolant turned on.
Flood - coolant on flood.
Mist - coolant on mist.
Tap - tap coolant on.
Air - air blast.
Through - coolant through spindle.
Double - two coolant codes are allowed.
The coolant is always turned off at the end of a toolpath.
Cutting Data table

This table summarises the information in the Edit Cutting Data dialog
(on page 24). To edit any of the values, double-click on one of the rows in
the list.
Clear - clears the cutting data for the selected row.
Delete - clears all the cutting data and the tool family.
Edit - edits the cutting data for the selected row.
Display Feed/Tooth in TDU - displays the feed/tooth and depth of cut
values in tool diameter units rather than actual values.
Tool Diameter Units - is the distance relative to the tool
diameter. So with a 10mm tool and a TDU of 0.5, this gives
an actual value of 5mm.
Hide Empty Rows - hides all empty rows. This makes it easier to use if
you want only one or two feed and speed sets for a tool. A single row of
data is always shown. If there is no cutting data then the default
Finishing/General empty row is shown. This row can be used for all
your cutting data if you don't want to differentiate between the different
toolpath types.
Edit Cutting Data dialog
Toolpath Type - specifies the type of toolpath cut with this tool. This is
either Roughing or Finishing.
Operation - specifies the cutting mode of the tool.
Tool Properties - summarises information from the Tip and Cutting
Data tabs.
Tool ID - the name of the tool. This is the same as the Tool ID on
the Cutting Data tab.
Diameter - the diameter of the tool. This is the same as the
Diameter on the Tip tab.
Tool Family - the tool family to which the tool belongs.
Number of Flutes - the number of flutes on the tool.
Tool/Material Properties
Axial Depth of Cut - the depth of cut measured along the tool axis in
mm or inches depending on the Units setting.
In calculations, this value is represented by the symbol ap.
The maximum value is limited by the flute length of a solid cutter
or by the inserts fitted.
Typically, this value is used to set the maximum Stepdown for
Area Clearance and Constant Z machining.
Radial Depth of Cut - the depth of cut measured normal to the tool
axis, measured in mm or inches depending on the Units setting.
In calculations, this value is represented by the symbol ae.
Typically, this value is used to set the Stepover for machining.
Surface Speed - the speed of the tool when material is being removed,
measured in metres (or inches) per minute depending on the Units
setting.
In calculations, this value is represented by the symbol vc.
The surface speed represents the rate at which the cutting edges of
the tool can be driven through the material.
This values is used to calculate the Spindle Speed.
Feed/Tooth - the cutting feed per tooth, measured in mm or inches
depending on the Units setting.
In calculations, this value is represented by the symbol fz.
The feed per tooth is determined by the construction of the tool,

and may be limited by the strength of the cutting edges or the
capacity of the tool to remove swarf.
This value is used to calculate the Cutting Feed Rate.
If only one flute is specified for the tool, then Feed/Tooth is the
same as Feed/Rev.
- loads the Surface Speed and Feed/Tooth from the active
toolpath (from the Feeds and Speeds
dialog).
Edit Feed/Tooth and Depth of Cut in TDU - displays the

Feed/Tooth and Depth of Cut values in tool diameter units rather than
actual values.
Tool Diameter Units - is the distance relative to the tool
diameter. So with a 10mm tool and a TDU of 0.5, this gives
an actual value of 5mm.
Cutting Conditions
Spindle Speed - the rotation of the spindle, measured in revolutions per
minute.
In calculations, this value is represented by the symbol n.
This value is calculated automatically from the Surface Speed
value.
If you edit this value then the Surface Speed value is also
updated to reflect your change.
Cutting Feed Rate - the cutting feed rate, measured in mm or inches
per minute depending on the Units setting.
In calculations, this value is represented by the symbol fv.
This value is calculated automatically from the Feed/Tooth value.
If you edit this value then the Feed/Tooth value is also updated to
reflect your change.
Description tab
A new Description tab is available. It contains two major areas:
Description frame that was located on the Cutting Data tab in
previous versions.
User Defined Settings frame which is new. It allows you to add
your own parameters to the tool.
Description - any text entered here is written as a 29000 record in the

cut file, and can be displayed in setup sheets.
User Defined Settings - adds user-defined parameters to the tool.
Name - enter the name of the new setting. Setting names must
start with a letter and can only contain letters (A-Z, a-z), numbers
(0-9) or the underscore character (_).
- adds the new Name to the list.
List - displays a list of all user-defined parameters.
Edit Selected Setting - enables you to edit the selected setting.

Selecting a setting in the list displays the Name and Value here.
Name - displays the name of the setting selected in the list. You
can edit this name.
Value - displays the value of the setting selected in the list. You
can edit this value.
- deletes the setting.
Tool Assembly - displays the defined tool tip, tool shank and tool
holder components which are controlled using the Tool Assembly
toolbar
Feeds and speeds enhancements

The old Feed Rate dialog has been updated to a Feeds and Speeds
dialog, which defines the machine feeds and spindle speeds.
Toolpath Properties - loads the appropriate values when the tool is

activated.
Toolpath: Corner Finishing - displays the name of the active toolpath

whose feeds and speeds are described.
Type - specifies the type of toolpath cut with this tool. This is either
Roughing or Finishing.
Currently, this parameter only used to output a record in the
cut file for the postprocessor, where it can be used, for
example, to select different smoothing tolerances on the CNC.
Operation - specifies the cutting mode of the tool.
This allows you to set the tool/material properties for different

toolpath operations. This is not a parameter, and so it does not set
the actual toolpath operation.
Selecting the Type and Operation allows PowerMILL to load the
appropriate values from the tool definition when the tool is
activated.
Tool Properties - displays information about the tool used to create the
toolpath.
Displays information about the tool used to create the toolpath.

Tool/Material Properties - specifies cutting conditions of the tool and
material.
Surface Speed - the speed of the tool when material is being removed,
measured in metres (or inches) per minute depending on the Units
setting.
In calculations, this value is represented by the symbol vc.
The surface speed represents the rate at which the cutting edges of
the tool can be driven through the material.
This values is used to calculate the Spindle Speed.
Feed/Tooth - the cutting feed per tooth, measured in mm or inches

depending on the Units setting.
In calculations, this value is represented by the symbol fz.
The feed per tooth is determined by the construction of the tool,
and may be limited by the strength of the cutting edges or the
capacity of the tool to remove swarf.
This value is used to calculate the Cutting Feed Rate.
If only one flute is specified for the tool, then Feed/Tooth is the
same as Feed/Rev.
Axial Depth of Cut - the depth of cut measured along the tool axis in
mm or inches depending on the Units setting.
In calculations, this value is represented by the symbol ap.
The maximum value is limited by the flute length of a solid cutter
or by the inserts fitted.
Typically, this value is used to set the maximum Stepdown for
Area Clearance and Constant Z machining.
Radial Depth of Cut - the depth of cut measured normal to the tool
axis, measured in mm or inches depending on the Units setting.
In calculations, this value is represented by the symbol ae.
Typically, this value is used to set the Stepover for machining.
All of these fields are preceded by an icon (either
or
).
Calculated - the values are calculated automatically by

PowerMILL.
Edited - the values are edited by you (or another user).
This value will not change when a new tool is activated.
Recommended: 200.00 mm/min - the recommended values. If you
have specified values in the Tool - Cutting Data dialog, then the values
entered there are displayed as recommended values here.
Cutting Conditions - specifies machine tool cutting conditions.
Spindle Speed - the rotation of the spindle, measured in revolutions per

minute.
In calculations, this value is represented by the symbol n.
This value is calculated automatically from the Surface Speed
value.
If you edit this value then the Surface Speed value is also
updated to reflect your change.
PowerMILL can automatically calculate this value from the
Surface Speed field on the Tool Cutting Data tab by clicking
on the Feeds and Speeds
dialog.
Cutting Feed Rate - the cutting feed rate, measured in mm or inches

per minute depending on the Units setting.
In calculations, this value is represented by the symbol fv.
This value is calculated automatically from the Feed/Tooth value.
If you edit this value then the Feed/Tooth value is also updated to
reflect your change.
PowerMILL can automatically calculate this value from the
Feed/Tooth field on the Tool Cutting Data tab by clicking
on the Feeds and Speeds
dialog.
Plunging Feed Rate - the speed of the tool when it is entering the
material ready for its cutting moves, measured in mm or inches per
minute depending on the Units setting. These are vertical moves.
In calculations, this value is represented by the symbol Vp.
By default this value is Feed Rate Plunge Factor * Cutting

Feed (Vp = Vf*fv). For more information, see Feed rate plunge
factor.
Skim Feed Rate - the skim feed rate, measured in mm or inches per
minute depending on the Units setting.
Coolant (on page 142) - allows you to specify the coolant:
None - no coolant output.
Standard - coolant turned on.
Flood - coolant on flood.
Mist - coolant on mist.
Tap - tap coolant on.
Air - air blast.
Through - coolant through spindle.
Double - two coolant codes are allowed.
The coolant is always turned off at the end of a toolpath.
All of these fields are preceded by an icon (either
or
).
Calculated - the values are calculated automatically by

PowerMILL.
Edited - the values are edited by you (or another user).
This value will not change when a new tool is activated.
Recommended: 200.00 mm/min - the recommended values. If you
have specified values in the Tool - Cutting Data dialog, then the values
entered there are displayed as recommended values here.
Working Diameter - specifies the effective tool diameter.
This frame enables you to make corrections for the working diameter of
the tool. For example, when surface milling with anything other than a
square-ended cutter with a small depth of cut, the full diameter of the
cutter is never engaged in the material. If the spindle speed is calculated
using the tool diameter, the surface speed of the part of the tool in the cut
will be less than it should be.
Depth off Cut - depth of cut of the strategy ap.
Surface Slope - inclination from the horizontal of the surface being

machined. The inclination of the surface being machined has an influence
on the effective tool diameter.
Overhang Compensation - specifies the correction required when
extensions are fitted.
The distance a tool projects out of the tool holder can have a huge impact
on tool life, especially for solid carbide cutters. Excessive overhang
increases both tool deflection and vibration, both of which increase the
rate of wear. Most tool manufacturers make specific recommendations
similar to the following:
ap' = ap * (4Dc/1)2, where
ap' - revised depth of cut
ap - depth of cut
Dc - cutting diameter
Typically, this correction is not made for indexable insert cutters since the
length is predetermined by the holder construction. However, if
extensions are fitted, some kind of reduction should be made.
Reset - loads the values from the active tool's Cutting Data tab into
this dialog.
Apply - loads the values in this dialog to the active toolpath.
Accept - accepts the values on the dialog, and closes it.
Cancel - closes the dialog without updating the feed rates.
For more information, see Using the Feeds and Speeds dialog (on
page 35).
Using the Feeds and Speeds dialog

1. If you create a Tool
, but don't define any Cutting Data,
then you will see the Feeds and Speeds
All fields are preceded by

values.
2. Create a new Tool
Cutting Data.
dialog.
, and have no recommended
(with a valid diameter), and add in some
3. Double-click on the relevant item in the list.
4. The Edit Cutting Data dialog is displayed. Enter appropriate

cutting data.
5. Look at the Feeds and Speeds

dialog again, and you will
see that the values are the same as before, except that there are now
Recommended values for the fields for which you entered
values in the Tool - Cutting Data dialog.
6. Click Reset to update the values in the Feeds and Speeds

dialog with those from the Tool - Cutting Data dialog.
7. To manually edit a field, type the required value in the relevant

field of the Feeds and Speeds dialog.
In this case, the Cutting Feed Rate was edited and is now
preceded by
to show that it has been edited manually. The
Plunging Feed Rate and Feed/Tooth have also changed, as the
values have been calculated (Plunging Feed Rate = Cutting
Feed Rate * Feed Rate Plunge Factor).
The Feed Rate Plunge Factor is defined on the Tool tab
of the Tools - Options dialog.
8. Clicking
changes it to
, and updates the value in the Feeds
and Speeds dialog to the recommended value.
In this case, clicking Reset would have had the same result.
The difference is that Reset updates all values with those in
the Tool - Cutting Data dialog, whereas clicking
only
updates that particular field (and any fields calculated from
that field).
Any field on the Cutting Feed dialog with a value of 0.0, or
no value, is not fed through to the Feeds and Speeds
dialog.
Leads and links

There are a couple of enhancements to Leads and Links
The Links tab now has the Along Radial option (on page 41) and
Automatically Extend option (on page 42).
The Lead In and Lead Out tabs have additional Add Leads at
Tool Axis Discontinuities fields (on page 44).
Along Radial option

The Links tab has an additional option of Along - Radial.
Along Radial
Enables retract and approach moves perpendicular to both the tool
axis and the tangent direction of the toolpath.
To use this option contact normals must be stored with the

toolpath.
Automatically Extend option

The Links tab has an additional field of Automatically Extend.
Automatically Extend - lengthens the retract and approach moves

made within links so that they retract to/approach from the safe area/skim
surface over which the intervening moves are made. This lengthens the
initial move at the start, and the final move at the end.
Maximum Length - the maximum length of the extension.
Retract Distance - defines the length of the Retract move.
Approach Distance - defines the length of the Approach move.
This toolpath has Retract and Approach Moves set to 0:
This toolpath has Automatically Extended selected:
This toolpath has Automatically Extended deselected and a Retract

and Approach Distance of 10:
- retract along tool axis.

- retract normal to the safe plane.
Add Leads at Tool Axis Discontinuities fields

The Lead In and Lead Out tabs have an additional field of Add leads
at tool axis discontinuities.
Add Leads at Tool discontinuities - enables you to insert leads and

links between continuous segments where there is an angular change in
tool axis between neighbouring segments. This ensures that any
reorientation of the tool axis at a specific point takes place away from the
part.
Angular Threshold - the minimum angle required before leads and
links are inserted. The angle is the change in the tool axis between
neighbouring segments.
Workplane
There are three new options on the individual workplane context menu.
Undo Last Edit - undoes the last transformation. For example, if you
rotate the workplane by 30 then Undo Last Edit returns the workplane
to what it was before the edit.
This is also available from the Undo
dialog.
button on the Workplane
Redo Last Undone Edit - redoes the transformation you have just
undone. In the above scenario, it reinstates the rotation of 30 .
This is also available from the Redo
dialog.
button on the Workplane
Clear History Buffers - clears the history of the workplane

transformations. This means that you can't undo or redo any previous
workplane transformations. You can undo or redo any subsequent
workplane transformations.
For more information, see the Workplane undo example (on page 46).
Workplane undo example

This example looks at how to Undo, Redo and Clear workplane
transformations.
1. Start by creating a workplane (select Create Workplane on the
Workplane context menu). In this case, it is 20mm in Z above the
global transform:
2. Edit the workplane (select Edit - Workplane on the individual

Workplane context menu). In this case, it is 30mm in X (by
keying in a Distance of 30 and then clicking
You will now see that the Undo

Workplane dialog.
).
3. Edit the workplane (select Edit - Workplane on the individual

Workplane context menu). In this case, it is 45 in Y (by keying
in an Angle of 45 and then clicking
4. Click Undo
).
to remove the last transformation.
You will now see that the Redo

Workplane dialog.
5. Click Undo
to remove the first transformation.
6. Click Redo
to add in the first transformation.
7. From the individual Workplane context menu, select Clear

History Buffers option. The Undo
now cease to be available.
and Redo
button
Sets
There is a new Sets entity in the Explorer. Sets are particularly useful
when Blisk machining.
Sets are similar to levels. However, there are some crucial differences:
Each entity must be on one (and only one) level. You can't have the
same entity on two different levels, or in no level.
Each entity can be on more than one set, or in no set. You can have
the same entity in two or more different sets, in a set (or sets) and
in a level or just in one level.
Deleting a project deletes all the levels and sets.
Deleting all the levels and sets deletes the model.
Sets and levels cannot have the same name. For example, you
cannot have a set called Hub and level called Hub.
The individual Levels and Sets context menu is the same as the
individual Levels context menu in previous versions.
The Levels and Sets context menu is similar to the Levels context
menu in previous versions. Only the new items are described here.
Create Set - creates a new set

same way as Create Level .
in the Explorer. This works in the
Delete All Except Non-Empty Levels - deletes all the sets (whether
they contain entities or not) and deletes all the levels which contain no
entities. Only levels containing entities remain.
For more information on how to use levels and sets, see Example of Blisk
machining (on page 103).
Feature sets
There are several Feature Sets enhancements:
Two additional ways of creating holes:
Create holes from toolpath plunge points (on page 50).
Create holes from contact normals (on page 51).
Holes generated automatically from the Recognise Holes in
Model option on the Feature Sets context menu can now be
edited. For more information, see Editing automatically identified
holes (on page 55).
Individual components of a Feature can be edited from the
Component tab on the Feature dialog. For more information,
see Editing feature components (on page 53).
You can now select multiple features within one feature set in the
same way that you multi-select entities such as feature sets,
toolpaths or tools.
Improved hole recognition when using the Recognise Holes in
Model option.
User-created workplanes are now used when the workplane is
parallel to the one that PowerMILL would create automatically.
Holes are no longer created from aspects of the model, such as
fillets, which are not true holes.
When Compound Holes and Create from Partial Holes are
selected, compound holes are created as a single feature. In
previous versions compound holes were created as multiple
features.
Tapered Holes are now correctly oriented.
Create holes from toolpath plunge points

Holes can be created from toolpath plunge points. Taking the following
Offset Area Clearance toolpath:
1. Make sure that the relevant toolpath is active.

2. From the Feature Sets context menu, select Create Feature
Set.
Select Hole in the Type field, and Plunges in the Use field.
Enter an appropriate
, in this case 20.
Click Apply to create the holes at all the active toolpath's plunge
points.
3. If you look in the Explorer, you can see three holes you have just
created.
Create holes from contact normals

Holes can be created normal to the contact point of pattern's points.
Taking the following model and pattern:
1. Select the relevant pattern.

2. From the Feature Sets context menu, select Create Feature
Set.
Select Hole in the Type field, and Normals in the Use field.
Choose an appropriate depth using the Define top by and Define
bottom by fields.
Enter an appropriate
, in this case 20.
Select Multi-Axis. This ensures that all holes are created in one
feature set.
Click Apply to create the holes at all active toolpath's plunge
points.
3. If you look in the Explorer, you can see three holes you have just
created.
Editing feature components

Individual components of a feature can be edited from the Component
tab on the Feature dialog.
Edits a component of a feature.
shows the component that you are editing. For compound

holes, the component that is edited is pale yellow. To edit a different
component, select the graphic.
Dimension - allows you to define the shape of the active (pale yellow)
component.
Upper diameter - the diameter at the top of the current
component. This must be greater than or equal to the Lower
Diameter.
Depth - the vertical height of the component.
Draft Angle - allows you to create features with draft angles.
Lower diameter - the diameter at the bottom of the current
component. This must be less than or equal to the Upper
Diameter.
Coordinates - the location of the hole.
Axis - the orientation of the Z axis of the hole.
This is only editable if the holes are created as Multi-Axis.
If you edit any of these fields you must click Apply for them to take
effect.
For an example on using this dialog, see Editing automatically identified
holes (on page 55).
Editing automatically identified holes

Holes generated automatically from the Recognise Holes in Model
option on the Feature Sets context menu can now be edited.
This example uses RetainerPlate.dgk from the Examples folder:
1. Select part of the model, including some of the holes.

2. From the Feature Sets context menu, select Recognise Holes
in Model. This displays the Feature dialog.
3. Select the Multi-Axis and Compound Holes check boxes, and

then click Apply.
PowerMILL recognises the specified holes, which can all be

edited.
- standard holes with the Z axis of the hole aligned with the
workplane Z axis.
- compound holes with the Z axis of the hole aligned with the
workplane Z axis.
- standard holes with the Z axis of the hole not aligned with the
workplane Z axis.
4. Select the hole that you want to edit.
This can either be edited graphically, or from dialogs.

5. From the graphics context menu, select Feature - Select and
Edit, or from the individual Feature menu select Select and
Edit to display the Feature dialog.
or
6. Select the Component tab.
7. Edit the required fields, in this case, the Upper Diameter, and X
and Y coordinates.
Altering the Upper Diameter automatically updates the

Lower Diameter.
8. Click Apply for these changes to take effect.
If you edit a compound hole, select the relevant component in the
graphical area of the dialog (it turns pale yellow), and then edit the
appropriate values.
When you select a hole where the Z axis of the hole is not aligned
with the workplane Z axis, the Coordinates frame cannot be
edited.
Setup sheets
The following enhancements have been made to the setup sheets
functionality in PowerMILL 8.0:
The default export location for setup sheets has changed from:
%[project.path]/ncprograms/SetupSheets.html
to
%[project.path]/ncprograms/%[project].html,
where the variable {project} is now used to generate the default
name of the export root file.
A project summary page is created by default irrespective of the
number of NC programs that exist in your project.
When you regenerate setup sheets, PowerMILL no longer displays
the Overwrite Bitmap? message for every toolpath in the current
NC program.
It has been replaced with two queries. The first one asks if you
want to overwrite the first snapshot, and the second one gives you
an option to overwrite all remaining snapshots.
Trailing zeros are now suppressed so, for example, a feedrade of

5500.00 appears as 5500.3.
The total machine time (including lead and link times) and the
cutting time values are now displayed on setup sheets.
For NC programs, the following variables have been added to the
Header.html template:
{ncprogram.statistics.totaltime}
{ncprogram.statistics.cut_time}
For individual toolpaths, the following variables have been added
to the Toolpath.html template:
{totaltime}
{CutTime}
You can choose the Current View or ISO View for toolpath
snapshots when you take snapshots of all toolpaths.
The following new variables are available for setup sheet

templates:
{ncprogram.notes} - notes related to an NC program;
{project.notes} - notes related to an entire project;
{Tool.Holder[n].Length} - length of a holder component;
{Tool.Holder[n].LowerDiameter} - lower diameter of a holder
component;
{Tool.Holder[n].UpperDiameter} - upper diameter of a holder
component;
{Tool.Shank[n].Length} - length of a shank component;
{Tool.Shank[n].LowerDiameter} - lower diameter of a shank
component;
{Tool.Shank[n].UpperDiameter} - upper diameter of a shank

component,
where n is the component number starting from 0 (that is, for
the first tool component n=0, for the second component n=1
and so on).
You can now print all setup sheets for a single NC program or
selected NC programs. Previously, it was only possible to print the
setup sheet currently showing in the browser, together with the
index file.
The Setup Sheets User Guide is available for download. It contains
step-by-step instructions on how to create and customise setup sheets.
Toolpath generation
Tool axis editing

A new Edit Tool Axis
toolbar.
button is now available on the Toolpath
dialog allows you to edit the tool axis of

The Tool Axis Editing
selected (partial) segments of a toolpath whilst preserving the toolpath
contact positions. This can be used to:
Manually redistribute toolpath points and calculate the tool axis in
any region of the toolpath in order to improve (smooth) the
machine tool movement at the start of each toolpath pass. The
Point Distribution example (on page 72) illustrates how this
functionality might be applied to the start of each toolpath segment.
Locally modify the specified tool axis to achieve extra clearance.
Modify the whole toolpath when the job is moved from one
machine tool to another, with different tool axis limits.
Initially, you must define the region you want to edit in the Select
Regions tab (on page 63). Then you define how you want edit the tool
axis in the Edit Tool Axis tab (on page 65).
62 Toolpath generation
Select Regions tab

The Select Regions tab enables you to define the area of the toolpath
you want to edit.
Define Region By - controls how to select the region of the toolpath

you want to edit. Most of the Tool Axis Editing dialog is similar to the
Limit Toolpath dialog:
Plane - selects the region of the toolpath to one side of the
specified plane. This works in exactly the same way as Limit
Toolpath to Plane.
Polygon - selects the region of the toolpath to one side of the
specified polygon. This works in exactly the same way as Limit
Toolpath to Polygon. For more information, see steps 2-5 in the
Point Distribution example (on page 72).
Boundary - selects the region of the toolpath to one side of the
specified boundary. This works in exactly the same way as Limit
Toolpath to Boundary.
Whole segments - selects complete segments of the toolpath.
For more information, see the Multiple selection example (on
page 80).
Pairs of Points - selects the region of the toolpath between two
points. For more information, see steps 3-5 in the Tool axis
editing example (on page 76).
Toolpath generation 63
Plane
Type - defines the limiting plane. These options are only available
if you have a Define Region By of Plane:
Plane X - defines the YZ plane. Either pick a point on the
screen using the left mouse button, or enter the X coordinate in
the Point frame of the dialog.
Plane Y - defines the XZ plane. Either pick a point on the
screen using the left mouse button, or enter the Y coordinate in
Plane Z - defines the XY plane. Either pick a point on the
screen using the left mouse button, or enter the Z coordinate in
Arbitrary - either pick two points on the screen using the left
mouse button to define the normal to the required plane, or enter
X, Y and Z coordinates in the Point and Normal frames of the
dialog.
Point - defines the origin of the plane.
Normal - defines the direction of the normal of the plane.
Boundary
Boundary - determines which boundary is used to limit the
toolpath. You can select the required boundary from the dropdown list. This option is only available if you have a Define
Region By of Boundary.
Projection Plane - determines in which plane the toolpath is
limited. Select one of the following from the drop-down list:
Workplane, View Plane or Best Fit Plane. This option is
only available if you select the Limit to Boundary option.
Side - determines which side of the plane, polygon or boundary
is selected:
Inner
Outer
For a closed polygon or boundary it is obvious what is inside or
outside. However, this is not the case for a plane. So, each plane
has an arrow, normal to the plane, at each corner, to indicate which
side of the plane will be selected. The boundary or polygon must
be a closed, non-intersecting contour.
Save Selection - saves the currently selected portions of the toolpath,

and adds it to any other portions of the toolpath that have already been
saved. For more information, see Multiple selection example (on page
80).
Clear Selection - removes all portions of the toolpath from the Saved
Selection.
Edit Tool Axis tab

The Edit Tool Axis tab enables you to define how you want to edit the
toolpath. You must define the area of the toolpath you want to edit on the
Select Regions tab (on page 63), before you can edit it.
Type of Editing - determines whether you want to make local changes

by defining a new tool axis, changing the existing tool axis at a constant
rate or manipulating the point distribution:
New Axis Definition - defines a new Tool Axis, and can also
manipulate the existing Point Distribution.
Axis Interpolation - causes the Tool Axis to change at a
constant rate over the selected region, and it can manipulate the
Point Distribution.
Tool Axis - displays the tool axis that will be used in the selected
toolpath region.
- displays the Tool Axis Direction dialog, which enables you to

edit the tool axis.
This option is available only if you have a Type of Editing as
New Axis Definition.
Point Distribution - when selected, displays the point distribution used
to create the toolpath, for example:
- displays the Point Distribution dialog, which enables you to edit

the point distribution of the toolpath.
Blend Distance - distance over which the tool axis will change from
the new orientation to the original. This minimises marks on the model
caused by a sudden change in tool axis. For more information, see Blend
Distance example (on page 83).
Undo - undoes any changes that you have made.
This option is not available until you have selected Apply.
The Undo option becomes unavailable if you:
Deactivate the current toolpath.
Edit the toolpath using something other than the Tool Axis
Editing dialog.
Close the dialog.
Apply - applies the edits defined in the dialog.
Cancel - closes the dialog without making any additional edits.
Example of tool axis editing

This example looks at the different options available for tool axis editing
using the Impeller.dgk model available from the Examples folder.
Calculate a Block from the Model Limits and create a 10mm Ball Nosed
tool.
Before you can edit the toolpath you must create one. In this case, a
surface machining toolpath, which is then trimmed so that the nearvertical end fillet of the blade remains unmachined.
1. Select the splitter blade
2. Click the Toolpath Strategies

button, select the Finishing
tab, and choose the Surface Finishing option.
3. In the Surface Finishing dialog, select the Max U Max V option

in the Start Corner field, and then press the Tool Axis
button.
Select:
Lead/Lean in the Tool Axis field
Enter -70 in the Lean field
4. Click Accept to close the Surface Finishing dialog.
5. Click Apply to calculate the toolpath, then click Cancel.
6. Limit this toolpath, so that the end fillet is not machined. From the
individual Toolpath context menu, select Edit - Limit.
Select:
Limit to - polygon
Delete Original - deselected
Save - Outer
7. Create a polygon by selecting points similar to points
and
below:
8. Click Apply, then click Cancel to trim the toolpath and close the
dialog.
dialog, change the Lead In to
9. From the Leads and Links
Extended Move with a Distance of 30.
10.Click the Copy to Lead Out button to apply the Extended

Move to the Lead Out.
11.Click Apply, then click Accept.
The next few examples look at editing this toolpath in a variety of ways:
The Point Distribution example (on page 72) looks at tool axis
interpolation to smooth the machine tool movement in a specified
region of the toolpath.
The Tool Axis editing example (on page 76) shows how to
modify the toolpath tool axis locally to gain extra clearance.
The Multiple Selection example (on page 80) shows how to
multi-select regions of a toolpath before editing the tool axis.
The Blend Distance example (on page 83) shows how to the
smooth transition between the original and the edited tool axis.
Point distribution example
This example looks at tool axis interpolation and point redistribution
within a selected region. The machine tool movement at the start of each
toolpath segment is smoothed by making the tool axis change more
gradual.
This example uses the impeller.dgk model available in the Examples
folder, and assumes that you have completed the procedure in the
Example of tool axis editing (on page 67).
1. Look at the fillet of the blade toolpath, and select Draw Toolpath
Points
2. Open the Tool Axis Editing dialog by clicking

Toolpath toolbar.
on the
Select:
Define by Region - Polygon
Side - Inner
3. Create a polygon by selecting points similar to points

and
below:
4. Click the Save Selection button. The selected portions of the

toolpath turn white.
5. If you want to add additional portions of toolpath, select them first,
and then click the Save Selection button to add them to the
current selection. In this case, you have already selected the
required portion.
6. Open the Edit Tool Axis tab.
Select:
Type of Editing - Axis Interpolation.

7. Click the Point distribution
button.
Select:
Output Type - Redistribute
Tolerance Factor - 0.5
Limit Point Separation - selected
Maximum Point Separation - 0.5
Mesh Factor - 0.1
Limit Maximum Triangle Length - selected
Maximum Triangle length - 1.0
8. Click Accept to close the Point distribution dialog.
9. Click Apply to create the additional points.
Tool axis editing example

This example looks at modifying the specified tool axis to achieve extra
clearance around the fillet area.
This example uses the impeller.dgk model available in the Examples
folder, and assumes that you have completed the procedure in the
Example of tool axis editing (on page 67).
1. Look at the fillet of the blade toolpath, and select Draw Toolpath
Points
2. Animate the toolpath to see the clearance issue. From the

individual Toolpath context menu, select the Attach Active
Tool to Start option, and then move the tool. There are many
ways of achieving this; using CTRL+End key and then pressing
works well.
3. Select
on the Toolpath toolbar to open the Tool Axis
Editing dialog.
Select:
Define by Region - Pairs of Points
4. Select two points on the bottom toolpath segment in a similar
position to those shown below.
5. Click the Save Selection button. The selected portions of the

toolpath turn white.
6. If you want to add additional portions of toolpath, select them first,

and then click the Save Selection button to add them to the
current selection. In this case, you have already selected the
required portion.
7. Open the Edit Tool Axis tab.
Select:
Type of Editing - New Axis definition
Blend Distance - 5
8. Click the Tool Axis

button. Change the Lean Angle to -10,
and then click Accept.
9. Click Apply on the Tool Axis Editing dialog.

10.If you animate the toolpath again (see step 2) you can see the
difference in the tool clearance in this region of the toolpath.
11.Zoom in on the edited part of the toolpath to see the difference that
the change of tool axis has made.
- original toolpath.
- edited toolpath.
The Blend Distance was added so that the Lean Angle of the
tool is changed from -70 to -10 over a period of 5mm rather than
instantaneously. The same also occurs at the end of the region,
where Lean Angle of the tool is changed from -10 to -70 over a
period of 5mm rather than instantaneously. For more information,
see the Blend Distance example (on page 83).
Multiple selection example
This example demonstrates how to multi-select regions of a toolpath
before editing the tool axis. This example uses the impeller.dgk model
available in the Examples folder, and assumes that you have completed
the procedure in the Example of tool axis editing (on page 67).
1. Select
on the Toolpath toolbar to open the Tool Axis
Editing dialog.
Select:
Define by Region - Whole Segments
2. In this case, it's easier to select the segments without having the
model visible. Click the Shade
undraw the model.
and Wireframe
buttons to
3. Select a couple of toolpath segments using a drag box.
4. Click the Save Selection button. The selected segments turn

white (shown in black below).
5. Select another couple of toolpath segments using a drag box.
6. Click the Save Selection button. The selected segments are

added to the previous ones.
7. Click the Clear Selection button to deselect all the selected

segments.
Blend distance example

When a Blend of 5mm is used, you can see the smooth transition
between the original and the edited tool axis:
When a Blend of 0 is used, you can see the discontinuity between the
original and the edited tool axis:
Area clearance improvements

There are a few enhancements to Area Clearance:
Enhanced rest roughing ordering reduces machining times and air
time by minimising jumps to different parts of the model.
You can now create a toolpath with trochoidal moves (on page
85) along the whole toolpath.
Allow Tool Outside Block (on the Expert Area Clearance
dialog) now works for Feature Set machining.
Approach Outside moves have been improved for slot features.
Reduced air cutting when using a Stock Model or a Block

Defined by Triangles.
Cusp removal with Links of Smooth during Offset Area
Clearance now uses horseshoe moves (on page 86) which
maintain cutter direction, rather than circular loops on external
corners.
Trochoidal moves
The Trochoidal Moves area of the Offset Area Clearance dialog

replaces the Restrict Tool Overload in previous versions. The only
new option is Full.
Trochoidal Moves - controls the creation of trochoidal moves. There
are three options:
None - no trochoidal moves are created.
Full - trochoidal moves are created all along the toolpath. For
more information, see Tool Loading.
Restrict Overload - as the tool approaches overload,
PowerMILL automatically puts in a trochoidal path to remove
the overload. This happens in corners, narrow channels, slots,
and the first cut of an offset toolpath (which is, in effect, a
narrow channel).
Since some tool overload may be acceptable, it can be
controlled by the slider. The default setting for the allowable
overload is 10% of existing stepover. So, if you use a stepover
of 10 and an allowable overload of 10%, trochoidal moves will
not start appearing until an overload condition of 10% is
exceeded. For more information, see Tool Loading.
The Trochoidal Moves options only become available if, at the
bottom of the dialog, you have a Type of Model or a Preference
of Maintain Cut Direction.
If you select Full in the Trochoidal Moves field, the generated toolpath
contains only trochoidal moves.
Horseshoe moves
Cusp removal with Links of Smooth during Offset Area Clearance

now uses horseshoe moves, which maintain cutter direction.
Previous versions used circular loops on external corners.
Swarf machining enhancements

A new option, Follow Surface Laterals, is available on the
Advanced Swarf Finishing dialog, which is opened by clicking the
Advanced button on the Swarf Finishing
dialog.
Follow Surface Laterals - when selected, the swarf toolpath follows

the underlying surface rulings.
When deselected, this is not necessarily the case.
Blisk machining
A new Blisks tab is available on the Toolpath Strategies New
dialog.
The following blisk machining strategies are available:
Blisk area clearance (on page 91).
Blade finishing (on page 99).
Hub finishing (on page 102).
The Blisks tab on the Toolpath Strategy New
dialog contains the
area clearance and finishing strategies required to machine a blisk or
impeller.
Blisk machining strategies only work with:

Spherical tools (ball nosed, tapered spherical, and spherical tipped
disc tools).
A cylindrical symmetric hub containing one untrimmed surface of
revolution.
A cylindrical symmetric shroud containing one untrimmed surface
of revolution that must match the blade (and splitter) profile.
At least 2 blades.
If there is a splitter blade, it must extend as far radially as the left
and right blade.
The fillet must be in the same level (or set) as the blade.
Selecting one of the options from this dialog and then clicking OK
creates a batch toolpath and displays the Blisk Area Clearance dialog.
The left side of the dialog contains the standard options for all toolpaths.
For blisks, you can only specify a general Thickness value; this is
why the Thickness
button is greyed out.
Blisk area clearance

Blisk Area Clearance enables rapid removal of material when
machining a blisk or impeller. Blisk area clearance only machines down
to a level that it can machine completely.
Blisk Definition - defines the different parts of the blisk or impeller,

and how many blades you want to machine. Initially, you must define the
geometry that makes up the individual components of a blisk. Each of the
blisk components must be grouped together into a single Level or Set.
A blisk such as:
which contains no splitter blades or fillets, can be represented as:
- hub
- shroud
- left blade
- right blade
An impeller such as:
Can be represented as:
- hub
- left blade
- right blade
- splitter blade
- fillet for left blade
- fillet for splitter blade
- fillet for right blade
The shroud isn't displayed, but is required.

When defining your levels/sets they must contain the following surfaces:
Hub level/set must contain surfaces
Shroud level/set must contain surfaces

Fillets level/set must contain surfaces
.
,
and
Left Blade level/set must contain surfaces
and
Right Blade level/set must contain surfaces
and
Splitter Blade level/set must contain surfaces
and
.
.
Hub - select the Level or Set that defines the hub geometry from
the drop-down list.
Shroud - select the Level or Set that defines the initial
unmachined stock geometry from the drop-down list.
Fillets - select the Level or Set that defines the fillet geometry
from the drop-down list. All the fillets must also be in the Level or
Set that defines the blade.
Since entities can be in only one level (but can belong to
many sets) if levels are used to define the blade, then a set
must be used to define the fillets. The fillet surface must
belong to both the level defining the blade and the set
defining the fillet.
Left Blade - select the Level or Set that defines the left blade
(and any fillet) geometry from the drop-down list.
The left blade must be positioned clockwise from the right
blade. So the left blade is the blade on the left when viewed
looking into the gap that will be machined, in the direction of
the central axis, with the Z axis of the active workplane
pointing upwards.
Right Blade - select the Level or Set that defines the right blade
(and any fillet) geometry from the drop-down list.
The right blade must be positioned counter-clockwise from
the left blade.
Splitter Blade - select the Level or Set that defines the splitter
blade (and any fillet) geometry from the drop-down list.
Hub - select the Level or Set that defines the hub geometry from
the drop-down list.
Machine - the number of blades you want to machine.
One Blade - area clears between the two selected blades.
All Blades - area clears the whole blisk.
Total Number - the total number of blades on the blisk. This

option is only available if you select a Machine option of All
Blades.
Calculate - automatically calculates the Number of blades on the
blisk.
Tool Axis Elevation - these options are only available if you select a
Tool Axis of Automatic.
From - defines the initial target tool axis.
Radial Vector - a radial tool axis normal to the Z axis.

Hub Normal - a tool axis normal to the hub. This gives a
continuously changing elevation angle.
Shroud Normal - a tool axis normal to the shroud. This gives
a continuously changing elevation angle.
Offset Normal - a tool axis normal to the current toolpath
offset. This gives a continuously changing elevation angle.
Average Hub Normal - a tool axis which is the average angle
if Hub Normal was selected. This gives a constant target
elevation angle. If possible, PowerMILL will keep to this angle;
otherwise PowerMILL deviates as necessary.
Average Hub Normal - a tool axis which is the average angle
if Hub Normal was selected. This gives a constant target
elevation angle. If possible, PowerMILL will keep to this angle;
otherwise PowerMILL deviates as necessary.
Average Shroud Normal - a tool axis which is the average
angle if Shroud Normal was selected. This gives a constant
target elevation angle. If possible, PowerMILL will keep to this
angle; otherwise PowerMILL deviates as necessary.
Average Offset Normal - a tool axis which is the average
angle if Offset Normal was selected. This gives a constant
target elevation angle. If possible, PowerMILL will keep to this
angle; otherwise PowerMILL deviates as necessary.
Angle - elevation angle. This option is only available with a From
of Radial Vector.
Machining - defines the offset profile, order and direction for
machining.
Offset - defines how to offset from the hub profile to the shroud
profile.
Off - only machines the last slice, closest to the hub. This is
equivalent to selecting the Hub Finishing (on page 102)
strategy.
Offset Down - offsets the shroud profile. The offsets continue
as an offset of the shroud until the hub profile is reached, at
which point the hub profile is followed.
Offset Up - offsets the hub profile.
Merge - starts by offsetting the shroud profile and slowly

migrates the offset so that at the end it's offsetting the hub
profile.
An offset of Merge gives this result:
- shows the first offset which follows the shroud profile.

- shows the last offset which follows the hub profile.
- shows the hub.
- shows the shroud.
The profiles between the first and last offsets gradually change
from the shroud profile to the hub profile.
Pocket machine - when selected, PowerMILL machines one
pocket at a time. When unselected, PowerMILL machines one
level at a time. This option is only available if you select a
Machine of All Blades.
Pocket machine is selected:
Pocket machine is unselected:
Direction - determines the milling strategy.

Climb - creates toolpaths using only climb milling.
Conventional - creates toolpaths using only conventional or
'upcut' milling.
Any - creates toolpaths using both conventional and climb
milling, as appropriate.
Blisk Area Clearance will not machine below a level that it has
not machined completely.
Blade finishing
Blade Finishing finish machines the blades of a blisk or impeller.
Whether this is done one blade at a time or one pocket at a time depends
on the Machining Operation selected.
This diagram shows Machine - One Blade and an Operation of

Machine All Faces.
The majority of this dialog works in exactly the same way as the Blisk
Area Clearance (on page 91) dialog.
and how many blades you want to machine.
Tool Axis Elevation - defines the initial target tool axis.

machining. The only additional option here is Operation.
Operation - defines which faces of the blades are machined.
Machine Left Blade - all the faces of the left hand blade are
machined. This option minimises the number of lifts. If this
option is combined with Machine of All Blades, then all the
blades are machined completely.
Machine All Faces - machines all the faces in the pocket.

Machine Splitter - machines all the faces of the splitter.
Left and Splitter Blades - machines all the faces of the left
blade, and all the faces of the splitter.
Right and Splitter Blades - machines all the faces of the
right blade, and all the faces of the splitter.
Machine Left Blade and Machine All Faces produce
toolpaths encompassing the whole blisk (assuming the blisk
has no splitter blades) if a Machine option of All Blades is
selected. However, the actual toolpaths and leads and links
will look different.
When finishing single blades, the blades on either side of the

blade being machined must be modelled (though they don't
have to be on any particular level or set).
- blade to be machined.
,
- blades which must be modelled, but don't need to
be on any specific level or set.
Hub finishing
Hub Finishing finish machines the hub between two blades.
The majority of this dialog works in the same way as the Blisk Area
Clearance (on page 91) dialog.
and how many blades you want to machine.
Tool Axis Elevation - defines the initial target tool axis.
machining.
The only difference is that Machine gives you the option of One
Pocket or All Pockets.
Example of Blisk machining

This example looks at how to set up and machine a simple blisk. It uses
Blisk_Simple.dgk in the Examples folder.
1. Create the Levels and Sets (on page 103).

2. Define the Block and Tool (on page 105).
3. Define Surface default thickness (on page 106).
4. Create the Blisk Area Clearance toolpath (on page 107).
5. Define appropriate Leads and Links (on page 108).
Create the levels and sets
To machine a blisk, each blisk components must be grouped into a series
of levels or sets. The model in this example contains the necessary levels
and sets.
There is no reason why Whole Blisk is a set and the rest are levels.
Whole Blisk could have been a level, with all the rest being sets. They
can't all be levels as Whole Blisk contains entities which are in the other
levels/sets. What is important is that the hub, shroud, left blade, right
blade and splitter blade (if they exist) are all in individual levels/sets.
- hub
- shroud
- left blade
- right blade
These four sets/levels are the only surfaces that are required to machine
the whole blisk.
Define the block and tool

The block is a simple cylindrical block.
1. Create a cylindrical Block
2. Create a 25mm diameter Ball Nosed Tool
On the Tip tab, enter:

Diameter - 25
Length - 80
On the Shank tab, click on the Add a Shank component
button, and enter:
Upper diameter - 25
Length - 80
Define surface default thickness
For all Blisk Machining strategies, you must have a Shroud defined as
a Level or Set. However, this surface must be ignored when creating the
toolpath, otherwise it would be impossible for the tool to access the
material to be removed.
1. In the Thickness Preferences
Defaults tab.
2. Select the first thickness set in the list

Mode of Ignore.
dialog, open the Surface
, and a Machining
3. Select the Shroud in the graphics window, and click the Acquire
Component
button.
4. Click Accept.
Create the Blisk area clearance toolpath
You have now completed the setup, and can create the toolpath.
button, open the Blisks tab,
1. Click the Toolpath Strategies
and then select the Blisk AreaClear Model strategy.
This example uses a coarse Tolerance, Stepover and

Stepdown.
The Tool Axis is set to Automatic.
2. Select the appropriate levels (or sets) to define the Hub, Shroud,
Left Blade and Right Blade. Leave the Splitter Blade field
blank.
3. Select a machine of One Blade if you want to minimise
machining time. Otherwise, select a Machine of All Blades, and
click the Calculate button to area clear the whole blisk.
4. Select an Elevation From of Hub Normal, and an Offset of
Offset Up.
5. Click Calculate to compute the toolpath.
Define appropriate leads and links

The cutting moves of the toolpath created in Create the Blisk area
clearance toolpath (on page 107) are correct, but the links need to be
defined appropriately. One of possible solutions is offered below:
1. In the Leads and Links
dialog, click the Lead In tab.
Select:
1st Choice - Extended Move
Distance - 10
Click Copy to Lead Out to copy these valued to the Lead Out
tab.
2. Open the Links tab.
Select:
Short/long Threshold - 100
Short - Circular Arc
Along - Tool Axis
Automatically - selected
Maximum Length - 250
3. Click Apply to apply the changes to the active toolpath.
When the Allow Start Points to be Moved on the Lead In tab

of the Leads and Links dialog is selected, then the lead in and
lead out moves of closed toolpath segments are placed in the middle
of the concave part of the main blade. This can leave witness marks
on the part. If you deselect this option, the closed toolpath segments
start and end at the Z minimum of each blade.
Parametric Offset finishing

enhancements
A new option, Edge Tolerance, is available on the Parametric
Offset Finishing
dialog.
In PowerMILL 7.0, the edge tolerance was calculated automatically. This

worked well in many instances, but occasionally ripples would appear
when an incorrect tolerance was used. Now you have the ability to
specify your own edge tolerance to avoid such problems.
Using a finer tolerance doesn't necessarily improve the result.
Sometimes using a coarser tolerance can improve the toolpath.
Edge Tolerance - defines the tolerance between the tool contact point
and the Start Curve and End Curve. This tolerance has an effect on
the quality of the resulting toolpath. An Edge Tolerance of 0 uses the
automatic tolerance. This option is only available if you have a Limiting
Method of Contact Position.
The automatic value works well in most cases. However, when using
a very small machining tolerance, specifying an Edge Tolerance
can dramatically improve toolpath quality.
It is recommended that the Edge Tolerance is larger than the
input tolerance.
Appropriate Edge Tolerance converts this toolpath:
To this:
Port machining preview

The Port Machining strategy dialogs now include a Preview button, to
improve consistency with other machining strategies.
For Port Area Clearance toolpaths two slices,
at each end of the port together with the pattern
For Port Plunge or Spiral Finishing, a slice

point with two arrows, and the pattern
and
, are drawn
is drawn at the merge
Disc Profile finishing

A new strategy of Disc Profiling is available.
Disc Profile Finishing uses a tipped disc tool to create profile
toolpaths. The edge of the tool, rather than the tool tip, is driven along the
surface. This strategy does not cut at sharp angles, but retracts,
repositions and then plunges before continuing machining.
Drive Curve - when selected, an embedded pattern determines the

machining profile rather than the selected surface.
Embedded Pattern - determines which curve is used to create
the cutting moves. This allows you to profile a specific part of the
model, rather than all of it.
Tool Axis - the orientation of the tool axis.
The toolpath always cuts the outside.
The standard Tool Axis frame on the left side of the dialog is
always set to Automatic.
Orientation - determines the tool shank orientation.
Inside:
Outside:
Elevation - the angle of the disc axis, from the horizontal.

An elevation angle of 30
Profile
Total depth of Cut - the total depth that is required.
The Depth of Cut,

, is measured in the plane of the disc.
This means that the depth of cut is not necessarily along the Z
axis.
Min Curvature Radius - the minimum machineable curvature

radius. When the curvature is sharper than this, the tool will retract,
reposition and then plunge before continuing machining.
Multiple Cuts allows multiple profiling paths. The first pass is at a
depth determined by the Stepdown value, the last pass is at Total
Depth of Cut.
Stepdown - defines the distance between different machining
levels.
Direction - determines the milling strategy.
Any - creates toolpaths using both conventional and climb milling,
as appropriate.
Climb - creates toolpaths using only climb milling.
Conventional - creates toolpaths using only conventional or
'upcut' milling.
Pocket machine - when selected, PowerMILL machines one pocket at
a time. When unselected, PowerMILL machines one level at a time.
Drilling enhancements
There are a few drilling enhancements:
You can now use the Thickness parameter with an Operation of
Pre Drill and Full Diameter, as well as Drill to Hole Depth.
The Retract Factor on the Expert Drilling page now works for
Deep Drill as well as for Break Chip.
General toolpath enhancements

There are several general toolpath enhancements.
There is an improved algorithm used in toolpath calculations
involving surface models, producing faster calculation times.
The improved speeds happen at small tolerances (such as
0.001mm).
Some strategies (especially 5-Axis) are speeded up more than
others.
Larger tools have greater improvements than smaller tools.
Models with highly curved surfaces have greater improvements
than 'flat' models.
Finishing toolpaths now respect cylindrical blocks when
calculating the toolpath outside a boundary.
The ordering of Interleaved Constant Z toolpaths has been
changed. When machining the bottom of a pocket, PowerMILL
machines from out to in (as before). However, when machining the
top of a boss (an area with no steep regions above it), PowerMILL
now machines from inside to out.
The Allow Tool Outside Block option is now available for most
finishing strategies.
The Output Type of Redistribute on the Point Distribution

dialog
produces fewer points in concave corners. This improves
the surface finish.
Draw Contact Track option (on page 120). This
A new
draws the trace of the toolpath contact points in red.
Toolpath Templates save all parameters in the Incremental
Heights frame of the Rapid Move Heights
dialog.
Improved stepdown calculations (speed and quality) when

creating a Constant Z Finishing toolpath using the Calculate
Using Cusp option in conjunction with a Workplane.
There is a new option of Set Coolant on the individual Toolpath

Edit context menu. This defines the coolant as the value currently
set in the Feed Rates
dialog.
The Sorting buttons have been updated to make them easier to

understand.
Version 8.0
Version 7.0
Draw Contact Track option

There is a new Draw Contact Track
toolbar.
option on the Toolpath
Draw Contact Track - draws the trace of the toolpath contact

points in red.
This option is available only if you select Contact Normals in the
Calculation area of the Toolpath tab of the Options dialog on
the Tools menu. The contact normals are the I, J, K vectors.
- standard toolpath trace in green.

- toolpath contact point trace in red.
Changes to simulation
The operation of the simulator (or player) is controlled by the
Simulation (on page 122) toolbar.
The visualisation of the simulation is controlled by the ViewMill (on
page 123) toolbar.
The visualisation of the machine tool is controlled by the Machine (on
page 132) toolbar.
For more information on to how to use the new Simulation toolbars, see
Simulation examples (on page 133).
The toolpath or NC program no longer has to be active, or drawn to
carry out a ViewMill or Machine Tool simulation. To see the
animation, the toolpath must be drawn , but not necessarily
active.
Toolpath verification 121
Simulation
The simulation controls have been split across two toolbars:
Simulation toolbar - enables you to visualise cutting the part,
using any of the cutting tools and toolpaths you have generated, or
using a complete NC program:
Machine (on page 132) toolbar - enables you to visualise the
machine tool cutting the part:
The Play buttons on the right of the Simulation toolbar remain
unchanged, but the initial part of the Simulation toolbar has changed as
follows:
Switch on Display - now displays only the Position and
Collision tabs. The ViewMill tab is now available from the ViewMill
(on page 123) toolbar.
The remainder of the toolbar allows you to define whether you want to
simulate a toolpath or an NC program, and which tool you want to use for
the simulation.
Toolpath and NC Program Toggle - toggles between the
selection of a toolpath
or an NC program
Toolpath/NC Program - allows you to select which

toolpath (or NC program) you want to simulate. The drop-down list
displays all the toolpaths (or NC programs) in your project, and allows
you to reselect one quickly.
Tool - allows you to select which tool you want to
use in the simulation. The tool used by the selected toolpath is chosen by
default, but you can use any other tool in the project. The drop-down list
displays all the available tools in your project, and allows you to select
one quickly.
122 Toolpath verification
ViewMill
The ViewMill toolbar has changed substantially.
You now run toolpath simulations using the Simulation (on page 122)
toolbar, and the ViewMill toolbar allows you to select the graphical
representation of each simulation.
and the Tool Simulation
The View buttons
buttons on the ViewMill toolbar replace the ViewMill tab on

the Simulation Information
dialog .
The other buttons available on the ViewMill toolbar in Version 7.0 are no
longer required, as they are superseded by the options on the Simulation
and ViewMill toolbars in Version 8.0.
The ViewMILL model is now modal; it will remember everything,
including jogging moves.
The ViewMill toolbar enables you to select the graphical representation
of the stock during simulation:
ViewMILL On/Suspend - switches between PowerMILL and
ViewMill.
Clicking the
button, starts the simulator, loading the block.
The button changes to

enabled. Clicking
to show that the tool simulation window is
suspends ViewMill.
- ViewMIll suspended.
- ViewMill on.
- ViewMill Views (on page 126) define the
resolution and shading used for the simulation. By default, the Dynamic
Image
is displayed.
The
button has a small black arrow in the bottom right hand corner
that relates to Tool Simulation Technique. If you hover over this
button, a pull-out toolbar is displayed
. It determines how the
toolpath is represented. Its effects are best visualised with a Shading
Option of Shiny:
Normal (Swept Volume) - represents the tool as a swept
volume.
Advanced (Rotating Flute) - represents the tool more

accurately, and simulates the tool flutes as well as taking into
account the feed rates and spindle speeds.
Save Current State of ViewMill Model - saves the current state

of the simulation as a 'restore point' (you can later rewind the simulation
to the saved state by clicking
).
Restore ViewMill Model to Previously Saved State - rewinds

the simulation to the state previously stored using
Save ViewMill Model - saves the current state of the simulation as

a triangle file, displaying the standard Windows Save dialog. You open a
saved ViewMill model, for example, as an arbitrary block for rest
roughing (by selecting File - Import Model from the menu).
Exit ViewMill - exits the ViewMill model without saving it, and
returns to PowerMILL.
The other buttons that were available on the ViewMill toolbar in Version
7.0 are superseded by the new options on the Simulation and ViewMill
toolbars:
You Reset the block
by clicking the Go to Beginning
button, and then clicking the Refresh

toolbar).
Paint Block
button
is superseded by the Rainbow Shaded Image
on the ViewMill toolbar.
Highlight Conventional Cutting

Cutting
button
button (on the View
and Highlight Climb
is superseded by the Cut Direction Shaded Image

on the ViewMill toolbar.
ViewMill Views
- by default the Dynamic Image
view is used.
No Image - undraws the ViewMill image.
Dynamic Image - simulates the object using a low resolution

image, which can be manipulated using the mouse or the standard View
buttons (on the View toolbar).
If you try to manipulate the view of a high resolution option,

PowerMILL automatically changes the mode to Dynamic
to
allow graphic manipulation. When you have selected the view
orientation, you can revert to a high resolution view. Click
Refresh
on the View toolbar to update the high resolution
view with the new orientation.
Plain Shade - simulation using a high resolution plain-rendered
image. It shades the part in a matt finish.
Shiny - simulates the object using a high resolution shiny-rendered

image. It shades the part in a shiny finish.
Rainbow - simulates the object using a high resolution rainbowrendered image. It shades each successive toolpath in a different colour so
that you can see the effect of each toolpath on the part.
Cut Direction - simulates the object using a high resolution

rainbow-rendered image. It shades the climb and conventional cuts in
different colours.
Kinematic Shaded Image (on page 129) - shows when a machine

tool axis is reversed during a cutting move. It shades the part in one
colour when cutting in a positive direction, and in another colour when
moving in a negative direction. This is useful when multi-axis machining
as axis reversal often leads to surface marks. The axis reversal depends on
the machine tool that is loaded.
Kinematic shaded image

- Kinematic Shaded Image is used in conjunction with a machine
tool, and shows when an axis is reversed during a cutting move. It shades
the part in one colour when cutting in a positive direction, and in another
colour when moving in a negative direction. This is useful when multiaxis machining as axis reversal often leads to surface marks. The axis
reversal depends on the machine tool that is loaded.
The Kinematic Shading dialog is displayed.
This shows the machine tool axes. Click an axis button to display the
positive and negative movements:
X - shades positive and negative movements of the X linear axis in
different colours.
Y - shades positive and negative movements of the Y linear axis in

different colours.
Z - shades positive and negative movements of the Z linear axis in

different colours. This can be used to show where the tool is plunging
into material.
A - shades positive and negative movements of the A rotary axis in

different colours.
E - shades positive and negative movements of the E rotary axis in

different colours.
If a 6-Axis machine is simulated, then an additional axis button with

the appropriate address letter is displayed.
Machine
The Machine toolbar is a subset of the Simulation toolbar available in
PowerMILL 7.0.
The Machine toolbar enables you to visualise the machine tool cutting
the part.
If the toolbar is not already displayed, select View - Toolbar Machine from the menu.
Switch on Display - displays the tool location and collision
positions, allowing you to 'jog' the machine tool. It also allows you to
control the shading of the simulation, and when the cutting tool is drawn.
For more information, see Simulation Information.
This now displays only the Position and Collision tabs. The
ViewMill tab is now available from the ViewMill (on page 123)
toolbar.
Import Machine - specifies a new machine tool. It displays the
Import Machine dialog.
All available machine tools are stored in the
Examples\MachineData folder and have the *.mtd
extension.
Once selected, a machine tool is displayed in the graphics
window. You you can undraw it using the
button.
Active Machine - specifies which machine tool (if

any) you want to include in your simulation. If no machine tool is
displayed, a simple 5-Axis head - head machine is used. The drop-down
list displays the machine tools already been used in the current project,
and allows you to reselect one quickly.
Draw
Undraw Machine - controls whether or not the active
machine tool is displayed on the graphics screen.
Simulation Viewpoint (on page 133) - defines the simulation
viewpoint. The Floor View is selected by default.
Output Workplane - defines which workplane in the

PowerMILL project aligns with the machine tool coordinate system. The
drop-down list displays the workplanes already defined in this project.
Selecting one of these specifies the orientation of the part relative to the
machine tool.
An example of Gauge Distance Offset shows how to use the
Overhang field on the Tool - Holder dialog as a Gauge
Distance Offset value in machine tool simulation.
Simulation viewpoint
There is a pull-out toolbar to define the simulation viewpoint. By default,
is displayed. It has a small black arrow in the
the Floor View
bottom-right corner. If you hover on this button a pull-out toolbar is
displayed:
There are three viewpoints available:

Floor View - defines the simulation from the floor viewpoint, as if
you are standing looking at the machine tool.
Model View - defines the simulation from the model viewpoint. The
model remains stationary while the cutting tool and machine tool move
relative to it.
Tool View - defines the simulation from the viewpoint of the cutting
tool. The tool remains stationary while the model and machine tool move
relative to it.
Simulation examples
Simulation now offers greater flexibility. It uses a combination of the
three simulation toolbars to produce the simulated results:
Toolpath animation (on page 134) uses the Simulation toolbar.
ViewMill simulation (on page 135) uses the ViewMill and
Simulation toolbars.
Machine tool simulation (on page 138) uses the Machine and
You can also combine ViewMill and Machine simulation using all
three simulation toolbars. For more information, see Combining
simulations (on page 138).
Toolpath animation
To animate a toolpath, use the Simulation toolbar.
1. To simulate an individual toolpath, select it from the drop-down
.
list
2. Alternatively, to simulate an NC program, click
to change it to
, and then select it from the drop-down list
When you select the toolpath you want to simulate, the tool
used to create the toolpath is selected in the tool
field by default. However, you can change this
tool. This allows you to create a simulation with a different
tool to the one originally used to create the toolpath. For
example, the tool could have the same tip as the one used to
create the toolpath, but with a shank and holder defined.
You can also select the toolpath or NC program by selecting
Simulate from Start menu option on the individual
Toolpath or NC Program context menu.
3. Click Play
to display the animated toolpath.
To replay a simulation, click
followed by
ViewMill simulation
To simulate something in ViewMill, you need to access the ViewMill
and Simulation toolbars.
The following steps do not need to be carried out in the order given, but
the order is the most logical and efficient for simulating multiple
toolpaths.
1. If the ViewMill and Simulation toolbars are not displayed, select
them from the menu using View - Toolbar - ViewMill and View
- Toolbar - Simulation.
2. On the Simulation toolbar, select the Toolpath

Program
) and the Tool
(or NC
you want to simulate.
3. Click the Switch ViewMill On

display the shaded block.
button to turn it green
, and
4. To see a different representation of the simulation, select a

different option from the View buttons on the ViewMill toolbar
. Dynamic Image
is selected by default.
If you simulate a toolpath or NC program using one view,

once the simulation is complete you can change the view to
another one. Typically, for speed you would simulate using
the Dynamic Image
Rainbow
5. Click Play
view and, on completion, change to
view.
on the Simulation toolbar to start the simulation.
Click Pause
to pause the simulation.
If you want to simulate more than one toolpath, try selecting

Rainbow
6. Repeat steps 2-5 to simulate additional toolpaths.

7. To replay a simulation, either:
Rewind to the beginning by clicking
again
, and then click Play
or:
From the individual NC Program or Toolpath context menu,

select Simulate from Start.
to unload the simulation

8. When the simulation is complete, click
model and dim the buttons on the Simulation toolbar.
Speeding up ViewMILL simulations
This procedure describes a method of speeding up a ViewMill
simulation:
Program
) and the Tool
(or NC
If the Simulation toolbar is not displayed, select View Toolbar - Simulation from the menu.
select Undraw Image
3. Click the Play
, and select a tool of Normal
,
.
button to run the simulation.
4. When the simulation is complete, select an appropriate view, such

as Shiny Shaded Image
You can change between the ViewMill views (on page 126) during
a simulation, provided that the ViewMill simulation remains On
.
Machine tool simulation
To simulate something on a machine tool, use the Machine and

Program
) and the Tool
(or NC
on the Machine toolbar to
2. Click Import Machine Tool
select the machine tool you require.
3. Use the Simulation Play buttons
run the simulation.
to
Combining simulations
It is possible to combine the different modes of simulation:
Program
) and the Tool
(or NC
display the shaded block.
3. Accept the default of Dynamic Image
4. Select the machine tool from Import Machine

Machine toolbar.
5. Click the Play
, and
on the
button to run the simulation.
Toolpath output
Text block enhancements

Text Block (under the individual NC Program context menu) has two
new options:
The Text Block toolbar (on page 141) aiding text block creation.
The Rotation option in the Type field.
Rotation - forces a C axis rotation in the postprocessor. If you
enter 180 you will see C180 in the tape file and the postprocessor
moving from C180. This enables you to rotate around the tool axis.
The difference between this and using ppfun Rotate 180 is that the
postprocessor takes account of the movement, so if the next move
could be C10 or C170, C170 is chosen.
140 Toolpath output
Text Block toolbar

New Text Block - creates a text block, but doesn't add it to an NC
program.
Add Text Block - adds the current text block to the current NC
program.
Remove Text Block - removes the current text block from the NC
program.
Copy Text Block - copies the current text block, but doesn't add it
to an NC program.
Delete Text Block - deletes the current text block.
Import - opens an existing text block. The Import Text Objects
dialog is displayed. This is a standard Windows Open dialog.
Export - saves an existing text block. The Export Text Objects
dialog is displayed. This is a standard Windows Save dialog.
NC program notes
The individual NC Program context menu has an option of Edit Notes. This is similar to toolpath notes and setup sheets project notes.
Toolpath output 141
Notes - allows you to add notes to an NC program. Displays the Notes

for NC Program dialog. In this case, the NC Program is called 2.
Date - defaults to today's date, but can be edited.

Programmer - defaults to the programmer for the NC program,
but can be edited.
Notes - area where you record NC program notes.
Coolant
The Coolant can be applied in several places:
The Cutting Data tab of the Tool
The Feeds and Speeds
dialog.
dialog.
The Toolpath tab on the Edit Selected NC Programs dialog

(available from the individual NC Program context menu).
The NC Programs dialog (available from the Settings option on
the individual NC Program context menu).
Changing the coolant type in different dialogs has different impacts.
If you change the coolant type on the Tool dialog, any new toolpath or
NC program using this tool picks up this new coolant type.
If you change the coolant type on the Edit Selected NC Programs
dialog:
Any new NC program using this toolpath picks up this new coolant
type.
This value overrides the value entered in the Tool dialog.
142 Toolpath output
If you change the coolant type on the NC Programs dialog:

This NC program picks up this new coolant type.
This value overrides the value entered in the Tool dialog or the
Edit Selected NC Programs dialog.
Arc fitting
It is recommended that you Arc Fit a toolpath on creation using the
Output Type of Fit Arcs in the Point Distribution
than when writing an NC program.
dialog rather
When you arc fit an existing toolpath, the arc fitting is carried out so that
the toolpath is as close as possible to the original toolpath, and within
tolerance. However, because the toolpath was also created to tolerance, it
is possible that both tolerances could make the actual tolerance larger
than expected.
For this reason, Arc Fit has been removed from the NC Program and
NC Preferences dialogs.
Drilling cycle output

Drilling Cycle Output has been removed from the Toolpath tab on
the NC Preferences dialog. If you want to set a preference for drilling
cycle output, then you can set it in the template. However, you can still
set the drilling cycle output when you are about to write the NC program
on the Toolpath tab in the Edit Selected or the NC Program dialogs.
Toolpath output 143
User interface
View toolbar
The PowerMILL 8.0 View toolbar contains the same buttons as in
PowerMILL 7.0, but they are reorganised into several pull-out toolbars.
This rearrangement has several advantages:
It is easier to see which options are currently selected.
The toolbar is shorter. If you don't run PowerMILL maximised, it
means you are less likely to 'lose' the shading options at the bottom
of the toolbar.
It is consistent with the PowerSHAPE View toolbar.
Six of these buttons have a small black arrow in the bottom right hand
corner. If you hover on one of these buttons, a pull-out toolbar is
displayed:
View Z toolbar
View X toolbar
View Y toolbar
View ISO toolbar
Zoom toolbar
Shade toolbar
144 User interface
Options dialog
There are three changes to the Tools - Options dialog:
You can now choose a background image (on page 146) for the
graphics area.
There is a new Tool tab (on page 149).
If you don't want your output file to have an extension type '.' in the
extension field of the NC Program tab.
User interface 145
Background image
You can now customise the background of the graphics area. This is
available from the View tab in the Options dialog (available from the
Tools menu).
View Background Image - allows you to choose an image (rather than

a colour) as a background to PowerMILL.
or
background image.
- displays the name of the selected
Load Background Image from File - displays the View

Background Image dialog, which allows you to open an existing
image file.
Remove Background Image - removes the currently selected
image, and reverts to colour defined in Tools - Customise Colours View Background.
Fit - controls how the image fits into the background:
146 User interface
Clip - the image is clipped in one direction so that it fits in the

other. In the picture below the top and bottom of the image are
clipped. The scaling is preserved.
Whole - shows the whole of the image, with borders in the

background colour. The scaling is preserved.
User interface 147
Stretch - the image is stretched to fit thee graphics area. In the

picture below the width of the image is stretched. The scaling is
NOT preserved.
Tile - duplicate instances of the image make up the background.
148 User interface
Tool tab
A new Tool tab is now available on the Options dialog.
It has two frames:

Feeds and Speeds - in previous versions these options were on
the Toolpath tab.
Database - sets options for your tool database.
Feeds and Speeds
Feed Rate Plunge Factor - specifies the plunge rate as a
percentage of the cutting rate when loaded from the active tool.
The default value is 0.1. This is remembered for future
PowerMILL sessions.
Auto Load Feed Rates - automatically loads the Feed Rates
stored in the Cutting Data tab on the Tools dialog when the tool
is activated. This is remembered for future PowerMILL sessions.
Auto Load Depth of Cut - automatically loads the Axial
Depth of Cut and Radial Depth of Cut stored in the Cutting
Data tab on the Tools dialog when the tool is activated. This is
remembered for future PowerMILL sessions.
User interface 149
Database
Database File path - specifies the location of the tool database.
- allows you to find the required directory and filename.
- displays the name of the selected tool
database.
A sample tool database is available in the Examples folder.
Load Shank with Tool - when selected, loads the shank as well
as the cutter from the database. When deselected, only loads the
cutter from the database.
Double Click to Create Tools - when selected, double clicking
on a tool displayed in the Search Results of the Tool
Database creates that tool. When deselected, tools are only
created by using the Select All, Select None and Create Tools
buttons.
Tool context menus

There are two additions to the Tools context menu and the individual
Tool context menu.
Add All Tools to Database - adds the tools in this project to the active
tool database. The Tool Database Export dialog is displayed.
150 User interface
Change Stock Material for All Tools - defines a new stock material
(on page 16) for all the tools in this project. The Enter Stock Material
dialog is displayed.
User interface 151
General
enhancements
There are several general enhancements.
PowerMILL is much faster at deleting multiple entities in the
Explorer. This includes toolpaths, patterns, workplanes, and so on.
Graphics performance (such as dynamic pan, rotate and zoom) is
faster than in PowerMILL 7.0. This is most noticeable when
drawing toolpaths containing arc/line combinations.
There is now support for 3DConnexion SpacePilot.
Template objects now support folders. This means you can use the
folder functionality when creating template objects. This can be
useful for structuring tooling templates, toolpaths, workplanes and
so on.
There are significant improvements in the time taken to shade a
model. Only surfaces which are displayed are shaded. So, using
levels and only having certain levels visible can greatly reduce
shading times. This is most noticeable when shading large models
(models containing hundreds of surfaces).
PowerMILL can now read both surface and triangle information
from third party CAD model file formats that support dual data
(such as Rhino). You must install PS-Exchange version 510502 or
later to enable this feature.
152 General enhancements
Index
A
Add leads at tool axis discontinuities
41, 44
Allow tool outside block 84, 117
Along radial 41
Animation of toolpath 134
Arc fit 143
Area clearance 84, 85
Blisk area clearance 89, 91
Horseshoe moves 86
Improved ordering 84
Trochoidal moves 85
Automatic collision avoidance 12
Tilt tool axis 12
Axial depth of cut 22
B
Background image 146
Ball nosed tool 67
Blade 91
Blade finishing 99
Blend distance for smooth tool axis
transition 83
Blisk machining 89
Blade 91
Blade finishing 99
Hub 91
Hub finishing 102

Impellor 91
Shroud 91
Splitter blade 91
Block enhancements
Boolean operations on boundaries 8
Boundary
Boolean operations on boundaries
8
Redo boundary edits 7
Undo boundary edits 7
Empty history buffer 7
C
Clear transformation history 45
Collision avoidance
Automatic collision avoidance 12
Tilt tool axis 12
Coolant 142
Customising background image 146
Cut direction simulation 126
Cutting data 20, 22
D
Disc profile finishing 113
Draw contact track 120
Drilling
Retract factor 117
Index 153
Break chip 117

Deep drill 117
Dynamic image simulation 126
E
Edge tolerance 111
Edit tool axis 67
F
Feature set machining
Feature sets 49
Editing feature components 53
Feeds and speeds 29, 35, 149
Finishing
Blade finishing 99
Hub finishing 102
Interleaved constant Z toolpath
117
Parametric offset finishing 111
Surface finishing 67
Swarf machining 88
Follow surface laterals 88
Floor view 133
H
Holes
Editing automatically identified
holes 55
From contact normals 51
From toolpath plunge points 50
Horseshoe moves 86
Hub finishing 102
I
Impellor 91
Improved ordering 84
154 Index
Interleaved constant Z toolpath 117

Ordering 117
K
Kinematic shaded image 129
L
Leads and links 41
Lead in and lead out
Add leads at tool axis
discontinuities 41, 44
Links tab
Along radial 41
Automatically extend 42
Levels
Sets 48, 103
Load shank with cutter from database
149
M
Machine toolbar 121, 122, 132, 133,
138
Model view 133
Multiple selection of toolpath regions
80
N
NC program
Notes 141
Text block 140, 141
Notes 141
O
Options dialog 145
Tool tab 149
P
Edge tolerance 111

Pattern
Plain shade simulation 126
Point distribution 72
Arc fit 143
Tool axis editing example 72
Port machining 113
R
Rainbow simulation 126
Redo last transform 45
Retract factor 117
Break chip 117
Deep drill 117
S
Search results 17
Search settings 15
Select regions 63
Sets 48, 103
Setup sheets 59
Shank 149
Shiny simulation 126
Shroud 91
Simulation 121
Combination of toolpath and
machine 138
Machine tool 138
Simulation toolbar 121, 122, 123,
132, 133, 134, 138
Speed up 137
ViewMill views 126, 129
Viewpoint 132, 133
Floor view 133
Model view 133
Splitter blade 91
Surface
Swarf machining 88
T
Text block 140, 141
Tilt tool axis 12
Tool
Ball nosed tool 67
Cutting data 20, 22
Database 14, 15, 17, 18, 20, 149
Description 27
Dialog 20
Tool toolbar 20
Tool axis
Editing 62, 63, 65, 67, 72, 80, 83
Select regions 63
Tool context menus 150
Tool database 14
Creating tools 17
Search results 17
Search settings 15
Stock material 16
Tool tab 149
Toolbars
Machine toolbar 121, 122, 132,
133, 138
Simulation toolbar 121, 122, 123,
132, 133, 134, 138
Tool toolbar 20
Database 14, 15, 17, 18, 20,
149
View toolbar 144
ViewMill toolbar 121, 122, 123,
126, 129, 133, 135
Toolpath
Animation of toolpath 134
Blade finishing 99
Blisk machining 89
Draw contact track 120
Hub finishing 102
Index 155
Interleaved constant Z toolpath

117
Simulation 121
Toolpath strategy buttons 67
Type 22
Verification 121
Trace 120
Track 120
Trochoidal moves 85
U
Undo last transform 45, 46
V
Verification 121
View toolbar 144
ViewMill toolbar 121, 122, 123,
126, 129, 133, 135
W
Workplane 45, 46
Clear transformation history 45
Redo last transform 45
Undo last transform 45, 46
156 Index

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What's New in

Undoing patterns and boundaries ..................................................................7

What's New in PowerMILL 8.0

Editing feature components .................................................................53

Tool axis editing ..........................................................................................62

Changes to simulation............................................................................... 121

Text block enhancements.......................................................................... 140

What's New in PowerMILL 8.0

NC program notes ..................................................................................... 141

View toolbar.............................................................................................. 144

What's New in PowerMILL 8.0

Tool Axis (on page 12):

Tilting - when tilting in a Fixed Direction, PowerMILL first

button is available on the

The Tool dialog has an additional option to Export a tool to the

What's New in PowerMILL 8.0

Leads and Links (on page

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

Undoing patterns and boundaries

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

In either case, the Boolean Operation Boundary dialog is displayed.

Reference Boundaries - defines the two boundaries you want to work

What's New in PowerMILL 8.0

Addition - creates a boundary which is the addition of the two

Example of Boolean operations on two boundaries

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

When tilting in a Fixed Direction, PowerMILL first searches in

What's New in PowerMILL 8.0

Towards Curve - if a collision is detected, the tool will tilt such

The curve must be a pattern with a single segment.

What's New in PowerMILL 8.0

button is now available on the tool toolbar.

The dialog splits into three areas:

What's New in PowerMILL 8.0

Hovering the mouse over the Tool Database dialog header

What's New in PowerMILL 8.0

Search Mode - defines how characters in the Name field are

What's New in PowerMILL 8.0

What's New in PowerMILL 8.0

Creating tools from the tool database

button on the Tool toolbar.

What's New in PowerMILL 8.0

4. Select the tools you want to add to your project.

5. Click the Create Tools button. PowerMILL creates the specified

6. Click Close to close the dialog.

What's New in PowerMILL 8.0

button is available on the

The Tool dialog has an additional option to Export a tool to the

Export a tool to the tool database

What's New in PowerMILL 8.0

The Tool Database Export dialog controls how tools created in

What's New in PowerMILL 8.0

Cutting Data tab

What's New in PowerMILL 8.0

If you have a blank Stock Material, then the cutting data is

Enter a name (which cannot contain any spaces). Click on

What's New in PowerMILL 8.0

Cutting Data table