Lesson 10 – 2.

5D Machining

Objectives

• Create extruded features from Pattern segments.

• Create Toolpaths using Feature machining strategy’s.

• Create a Simulation in Viewmill and save the current state of model

Exercise 1 Creating Features from Pattern Segments

• Open Project…\PMData\Projects\2D-Drawing

• Save as …\COURSEWORK\PMProjects\2DPatternExample

• Activate and Draw Pattern 1

• Select an ISO 1 view

• Select Feature Group > Create and then select Feature Group

• Select Feature Editor to display toolbar.

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• Select the outer segment of the pattern followed by selecting

Create 2D Features > Boss then select Rectangular Boss

• In the Position category enter the values Top 0.0 and Bottom -40.0 and
Accept

• Select the Rectangle then select Create 2D Features > Pocket then

select Rectangular Pocket

• In the Position category enter the values Top 0.0 and Bottom -40.0 and
Accept

• Select the Circle then select Create 2D Features > Circular Pocket then

select Circular Pocket

• In the Position category enter the values Top (0.0) and Bottom (-40.0) and
Accept

• Select Accept on the Edit ribbon toolbar

• Select Hole Feature set > Create then Hole Feature Set

An empty hole feature set been created in PowerMill explorer. We now need to
populate it with hole features.

• Select all the Circles on the PCD

• select Holes > Create Holes .

• In the Create from pulldown menu Select Circles

• Define top as Absolute 0.0 and the Bottom as Absolute -40.0. Apply and
Close.

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 With the Features, all complete, we are now ready to machine.

• Create a new tool from Tool > Tool Database and select Tool

• Select the D10TR1 tool

• Calculate a Block defined by Box and the Type as Feature.

Rough Pockets

• Set safe Area to defaults

• Set Lead Ins to Ramp following a Circle with a TDU 0.65 at 4 degrees to
a height of 5.0.

• Open a Feature Area Clearance toolpath from the Feature Machining

options and rename Rough

• In PowerMill explorer open the Features page

• From the Select features selection, deselect Feature 1 by holding down

the Ctrl key and selecting.

• From the Feature area clearance page select Offset Model

• Set Profile and Area cut directions to Climb and Climb

• Set Tolerance 0.1, Thickness - Radial 0.5 Axial 0.0, Stepover 5.0 and
Stepdown 5.0

• In the Offset page tick Spiral, Then Calculate and Close

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Finish pockets

• From the Tool Database select the EM10 tool.

• Open a Feature Profile toolpath

• Enter the following in the Feature Profile page, Cut direction Profile
Climb, Tolerance 0.01, Thickness 0.0, Stepdown 10.0

• In the Approach page, turn of the Add approaches from outside option

• In the Leads and Links page change the Lead Ins\Outs to Pocket
Centre. Calculate.

• save and Close project.

Summary

In the exercise, we have created both Features and hole Features and with
Feature Machining we could rough and finish the 2 pockets

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Exercise 2 2D Machining

• Create an empty Pattern

• Insert File…\PMData\Models\2DExample.dgk

• Save Project as…\COURSEWORK\PMProjects\2DExample-EX1

• Create a two Feature Groups named Pocket Boss and Slot and a Hole
Feature set using the dimensions given above

Be aware that the Pocket and small Boss require a 5-degree draft.

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 For the Slot, create Rectangular feature and add 10mm corner radii.

Main Block and Central Pocket

• Create the following tools from the Tool Database D10TR3A5, D10TR3,
DRILL15 and EM10

• Select Feature Group > Active and from the pull-down menu select
Pocket Boss to Activate

• Calculate a Block to a Feature.

Roughing Pocket Area

• From the Toolpath Selector, select the Feature Area Clearance

strategy and name D10TR3-ROUGH

• Set the Style to Offset Model. Set both Cut Directions to Climb, Tolerance
0.1, Radial Thickness 0.5, Axial Thickness 0.0, Stepover 3.0 and a
Stepdown of 5.0

• Open Step Cutting page and tick the Step Cutting box to activate and
enter a value of 2.5

• Set Lead ins to Circular Ramp at 0.25 TDU with a 4 Degree angle, with a
height of 5.0

• Calculate and close.

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• Simulate toolpath in ViewMill and save current state of Viewmill model.

Step cutting allows for a more defined net shape when there is a large stepdown.
The stepup value only rest cuts and does not fresh air cut the whole area and steps
up from each area clearance level, maximising the use of the flute length.

Finishing Pocket Area

• From the Toolpath Selector, select the Feature Profile strategy

• In the Features page, deselect the Feature named 1

• Change the tool to D10TR3A5

• Then in the Feature Profile page change the Tolerance to 0.01, Thickness
0.0

• In the Step Cutting page untick Step Cutting.

• In the Approach page untick Add Approaches from Outside.

• Open the leads and Links page and apply the following: Lead in/Outs 1st
Choice Horizontal Arc left – Angle 90, Radius 3.0. Links 1st Choice
Straight – Constraint 8.0.

• Calculate and close.

• Simulate toolpath in ViewMill and save current state of Viewmill model.

Drilling Holes

• From the Toolpath Selector, select the Deep Drill strategy.

• Select Holes Page and from Feature Set select the feature named 1

• Change tool to Drill15

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• In the Drilling page select Through hole as Operation. Input a Peck
Depth of 12.0.

• Click on the Select button to open Feature Selection page, select 15.0
from the Diameter list and transfer to Selection Filter, Select and Close
page.

• Calculate and Close.

• Simulate toolpath in ViewMill and save current state of Viewmill model.

Rough Slot

• Activate the Tool EM10 and Feature Slot.

• Select Feature Slot Machining strategy from Toolpath Selector

and name Rough Slot

• Recalculate Block.

• Open Feature Slot Machining page and enter the following: Tolerance
0.0, Thickness 0.0, Stepdown 2.0

• Calculate and Close

• Simulate toolpath in ViewMill and save current state of Viewmill model.

Finish Slot

• Undraw all but the wireframe model

• Create a Pattern and name it Slot

• Select the Curve Editor and draw two diameters 20.0 circles on the ends
of the slot centreline

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• Create two tangent lines between circles and Limit to intersection

• Select the Four new curve segments and Merge to create one
complete segment

• Accept to Close the Curve Editor

• From the Toolpath Strategy Selector, select Curve Machining then open
2D Curve Profile strategy and rename Finish Slot

• Open the Curve Profile page and from the Curve Definition pulldown
menu select Slot

• Select the Position as Contact

• Set the Lower limit to -10.0, the Tolerance 0.01, Cut direction to Climb and
curve thickness of 0.0

• Calculate and Close

• Apply a suitable start point and Leads and links

• Simulate toolpath in ViewMill and save current state of Viewmill model.

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• Save and Close project.

Summary

• In this exercise, we have created features from a wireframe model and

then generated toolpaths from the Feature machining strategy’s. At the
completion of each toolpath we created and saved a viewmill model.

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Exercise 3 - Creating Features directly from holes in the Model

Objectives

• Import Model.

• Create Hole Features directly from Model.

• Create both individual and compound hole features.

• Select suitable Drilling options

Exercise 3

• Import Model…\PMData\Models\Drilling.dgk

• Save project as…\COURSEWORK\PMProjects\DrilledHoles-Example

• Box select Model to select all the surfaces.

• Create a Hole feature set

• Select Create to open the Create Holes form

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• Select Model from the Create from pulldown menu. Untick the Create
Compound holes and Apply.

• Rename Hole Feature Set as All Features.

33 individual features have been created in the set. They include Chamfers, Counter
bores and Through holes.

• Create a new Hole Feature Set named Compound holes and

select all the surfaces.

• Select Create and tick the Create Compound Holes and Apply.

This time only 17 features have been created as the Chamfer, Counter bore and
Through hole are to be included as one.

Drilling

• Create the following Tools from the Tool Database:

DRILL 4.2, DRILL 5, DRILL 8, EM8, EM12, Chamfer D18, CENTRE

DRILL D6

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 We will now spot-drill all the holes in the Hole Feature Set Compound

• Activate Tool CENTRE DRILL D6 and Hole Feature Set Compound

• From the Strategy selector chose Drilling then the Single Peck as the
strategy

• Open the Drilling page from the explorer and from the Operation pulldown
menu select Centre drill.

• Set the Clearance to 2.0 and the Depth to 1.0

• Click on Select to open the Feature Selection dialog and select all the
holes in the Diameter field, then add the list to the selection Filter

• Close Feature Selection

• Set Links to Skim and in Rapid moves set the Incremental plunge Distance
to 2.0 and the Axial Clearance to 5.0

• Calculate and Close

• Open the Block Editor and delete Block From the Defined by

pulldown menu select Triangles, select the Load block from File
Select Drilling.dmt from PMData\Models and Accept

• Run a ViewMill simulation and Store the current state. Turn off image
and suspend Viewmill

We will now drill all the holes

• Activate DRILL 4.2 tool and the Hole Feature Set called All Features

• Open a Deep Drill strategy and name Drill 4.2 holes

• Open the Drilling page and set Operation to Drill hole to depth. Set the
Peck Depth to 2.0

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• Click on Select to open the Feature Selection dialog and Clear all

selections . Select 4.2 from Diameter and transfer to the selection

Filter. Select and Close

• Calculate and Close

• Run a ViewMill simulation and Store the current state. Turn off image
and suspend Viewmill

• Repeat for holes: 5.0 and 8.0

Keep Operation as Drill to depth for the Dia 5.0 holes, but change to Through
for the Día 8.0 holes.

• Run a ViewMill simulation and Store the current state. Turn off image
and suspend Viewmill

Next we will Helical mill the Dia 12 Counterbores and the Dia 22 circular pocket

• Activate the EM8 tool and the Hole Feature Set called All Features

• Select the Helical Strategy from Drilling Strategy category and name
Helimill Dia12

• Change the Operation to Drill to hole depth and the Pitch to 0.5

• Clear Selection and transfer 12.0 to the Selection Filter

• Calculate and Close

• Repeat for Dia 22 pocket using the EM12 tool

• Run a ViewMill simulation and Store the current state. Turn off image
and suspend Viewmill

Finally, we will now chamfer the countersinks

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• Activate the Chamfer D18 tool and the Hole Feature Set called
Compound

• Select the Single Peck Strategy from Drilling Strategy category and name
Chamfer all

• Change the Operation to Chamfer

• Clear Selection and transfer 6.42 and 14.0 to the Selection Filter

• Calculate and Close

• Run a ViewMill simulation and Store the current state. Turn off image
and suspend Viewmill

• Save and Close Project.

Summary

• In this Exercise, we have created 2 types of Hole Feature Set, with the
Compound selected, 17 hole features where generated.
If the Compound option is turned off, 33 will be generated as individual
features. These Hole Feature sets where then used to generate the hole
toolpaths

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Exercise 4 Internal Thread Milling

• Open Project…\PMData\Projects\ThreadMILL

• Save project as…\COURSEWORK\PMProjects\ThreadMILL-Example1

• Activate Toolpath D50t6-RGH-a1 (to reinstate the Block settings)

• Simulate the NC program MC-All in viewmill and Store the current state.
Select No Image and suspend Viewmill

• Activate the Thread Milling tool named M40-Coarse-Pitch 5

• Activate Hole Feature Set Named Pocket

• From the Drilling Strategy’s Select Thread mill and name M40-RH-
IntThread.

• Open the Drilling page and change the Operation to Drill to Hole depth,
set Turns to 1.0, Pitch 5.0, Tolerance 0.01, both Axial and Radial
Thickness -3.0

• Open the Threading page and enter 3 in the Number of passes and 1 in
the Allowance

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 By entering the above figures the tool will make three 1mm passes to reduce the
load on the tool

• Open Cutter Compensation page and tick to activate CNC cutter

compensation and In Type select Tool Wear.

• Calculate and Close.

• Run Viewmill simulation of the M40-RH-IntThread and Store the current

state. Select No Image and suspend Viewmill

• Save Project.

Exercise 5 External Thread Milling

• Activate Feature Group Boss and the tool M40-Coarse-Pitch 5.

• From the Feature Machining Strategy Category, select Feature External

Thread Milling.

• Name toolpath M40-RH-ExtThread

• In the Feature External thread Milling page enter as follows:

• Clearance 0.0, Depth Type Feature, Turns 1, Pitch 5.0, Radial Passes 3,
Tolerance 0.01, Stepover 15.0, Cut Direction Climb, Handedness Right,
Thickness -3.0

• Open Cutter Compensation page and tick to activate CNC cutter

compensation and In Type select Tool Wear.

• Calculate and close

• Simulate toolpath M40-RH-ExtThread in Viewmill

• Save Project.

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Additional Exercise

• Make a copy of the Threadmill toolpaths this time using the single point
M40-Coarse-Single Point tool

Add more than one Turn to cover the distance. For example the internal thread will
require 11 Turns

Summary

• This lesson has covered both Internal and External Thread milling. The
Internal uses a Drilling strategy with a Thread milling. While the external
uses a Feature strategy called Feature External Thread Milling.

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Exercise 5 - 2D Curve Machining
Objectives

• Create Face Milling Strategy.

• Create 2D Curve Area Clearance strategy.

• Create 2D Curve Profile strategy.

• Create Chamfer Milling strategy.

Face Milling

• Open Project…\PMData\Projects\2DCurve

• Save project as…\COURSEWORK\PMProjects\2DCurve-Machining

• Activate the pattern CurveAll and D50T6 tool.

• Create a Block defined by Box and Type as Active Pattern. Set the Min Z
to -22.0 and Max Z to 5.0 Accept form.

• Calculate Safe Area to defaults

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• Reset Lead Ins/Outs to None and the Links 1st Choice to Circular Arc with
the Constraints set to a Distance of less than 40.0

• Open Face Milling from the Curve Machining Strategy Category

• Open Face Milling page and select the icon to pick the Z value of
the face

• select anywhere on the geometry of the Pattern CurveAll to autofill the

Face Z position (z)

• Change the Tolerance to 0.01, Style Two Way and a Stepover 35.0

• Open Cut Distances page, enter a Stock Depth (d) of 5.0 and a
stepdown of 2.0

• Open finishing page and tick Floor Finishing, Enter a value of 0.2 for the
Final Stepdown.

• Calculate and close.

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Rough and Finish the curve Pockets.

Roughing

• Activate the D16T3 tool.

• Open 2D curve Area Clearance from Curve Machining Strategy

Category and name Rough

• In the Curve area clearance page select CurvePockets in the Curves

definition pulldown menu.

• Select the Interactively Modify Machinable sections option to

display toolbar

Check that the tool is on the correct side of the curve and that the direction
is climb. If they are not use the toolbar bar to correct.

• In the Lower limit enter -10.0, in Style Offset, Tolerance 0.1, Cut Direction
Climb, Curve Thickness 1.0 and a stepover of 8.0

• Open Cut distances page and in Vertical Extent select Stock depth from
the menu. In Stock depth enter (10.0), Stepdown (5.0), Horizontal Stepover
(8.0).

• Open Finishing page and tick the Floor Finishing option, in the Final
Stepdown enter 0.2

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• Set lead Ins to Circle Ramp at a 4 Degrees, a TDU of 0.65 and a Height
of 3.0

• Set Links to Skim

• Calculate and close.

Finishing

• Activate EM16 tool.

• Open 2D Curve Profile from the Curve machining Strategy category and
name Finishing

• In the Curve Profile page change the Tolerance to 0.01, Curve Thickness
0.0

• In Cut distances, change the stepdown to 10.0

• In the Finishing page, deselect Floor finishing.

• Open the High speed page and from the Links pulldown menu select
Smooth

• From the Leads and Links page set the Lead Ins/Outs to Pocket Centre

• Calculate and close.

Chamfer Pockets

• Activate D25Tr1A45 tool.

• Open Chamfer Milling from the Curve machining category and name
Chamfer

• Open Chamfer Milling page and in the Curve definition menu select

CurvePockets. From the Position menu select Corner . Change the

Tolerance 0.01, Curve Thickness 0.0. In the Chamfer definition select

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 Tool a Width and Depth of 5.0 and for the Tool Position select

Bottom Axial Depth and set a value of 1.0

• Open Cut distances page and change the Vertical Extent option to
Number of Cuts with a value of 1

• Calculate and close.

• Run Viewmill Simulation of the whole machining process.

Save and Close Project.

Summary

• In this lesson, we have created a face milling toolpath to remove 5mm of

stock at 2mm step-down’s leaving a finishing pass of just 0.2mm. The
toolpath tracks are the linked with a Smooth move

For roughing out the pockets we used 2D area clearance and for finishing
a 2D profile strategy.

Finally, for chamfering the pocket edges we used Chamfer strategy.

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Exercise 6 - Cutter Compensation
Objectives

• Create a Pattern

• Create a toolpath with No compensation.

• Create a toolpath with Full radius compensation.

• Create a toolpath with Tool wear compensation.

• Out NC code for all 3 programs

Setup

• Save project as…\COURSEWORK\PMProjects\Cuttercomp-example

• Create a Single Workplane on the XY plane at XYZ 0.0

• Create a Pattern and in Curve Editor use any of the Line, Continuous, or
Rectangle options to create a rectangle with the dimensions L: 100 W: 50
and starting at XYZ 0.0

• Create EM10 Tool from the Database.

• Create a Block defined by Box and Type Active Pattern.

• Set Min Z to 20.0. Lock the Min and Max Limits and enter a value 15.0 in
the expansion option

• Calculate and Accept.

• Calculate Safe Area to defaults

• Set lead Ins/Outs to Horizontal Left with Angle 110.0 a Radius of 10.0 and
both with an Extended Move of 10.0

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Toolpath with No Compensation

• From the Curve Machining category, select the 2D Curve Profile strategy
and rename NoComp.

• In Curves definition select pattern 1, check the Machineable areas

Make sure the tool is cutting on the outside of the curve and is cutting in a climb
milling direction

• Set the Lower Limit to 0.0, Tolerance 0.01, Cut direction Climb, Curve
Thickness 0.0

• Calculate and Close

Toolpath is offset by the tools radius value and will have no G41 or RL compensation
when output in NC code.

Toolpath with Full Radius Compensation

• Make a copy of toolpath NoComp and rename FullComp

• Open Cutter Compensation page and tick the CNC compensation box
and select Full radius from the Type pulldown menu

• In the Minimum radius field enter a value of 0.1 in the Minimum radius
window.

• Calculate and Close.

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 At first the toolpath appears to be no different than the NoComp toolpath.

however if we select Display Compensated Toolpath from Toolpath >

Draw > Display we will see the Programed path and not the compensated offset
toolpath.

Toolpath with Tool Wear Compensation

• Make a copy of toolpath FullComp and rename ToolWear

• Open the Cutter Compensation page and select Tool Wear.

• Calculate and Close.

When Tool Wear is applied, the toolpath looks the same as a toolpath with no
compensation, other than it will be a darker colour to indicate that it has Tool wear
applied.

• Create an NC Program from Nc Program > Create

• Rename as No Comp Accept and Close

• Select Preferences from Nc Program > Edit > Options to open the
NC Preferences dialog.

• Select the Output tab. And make sure the Use Project is Off.

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• For the Output folder, navigate to C:\temp\NCPrograms.

• For the Machine Option File, navigate to

C:\ductpost\Heidenhain_3axis_ref.pmoptz. Close Dialog.

• From Toolpath > Active select the toolpath NoComp from the Active
pulldown menu to activate.

• From Toolpath > Add To select the New NC Program pulldown

menu and select the NC Program

• Repeat this for FullComp and ToolWear

• Open the NC Program > Active and select the Nc Program NoComp

• In the NC Program > Post select Write

• Repeat this for FullComp and ToolWear

3 programs have now been output and can be found in C:\temp\NC Programs.

• Save Project and Close.

Protected Cutter Compensation

When using CNC Cutter Compensation with Type – Full Radius we can apply a Minimum radius to protect the
cutter when entering an internal corner with a radius smaller than the tool radius.

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In the example below a Ø20 endmill is used to cut an internal corner radius of 9mm, which would leave a sharp
corner on the toolpath. If we apply a Minimum radius of 2mm we will achieve a R2 interpolation for the corner.

Summary

In this lesson, we have created 3 toolpaths using 2D Curve Profile strategy to machine a pattern. The first
toolpath used no compensation and produced a toolpath that simply offset by the radius of the cutter and allows
for no compensation adjustment in the outputted NC program.

In the second we applied Full Radius Compensation, this outputs an NC program with G41 or RL compensation
commands. Any adjustments may be made by altering the value of the tool in the Tool radius page of the control.

Thirdly Tool Wear Compensation was applied; this outputs a NC program with G41 or RL compensation but with
the toolpath offset to the radius of the cutter. Any adjustments may be made by altering the value of the tool in
the Tool Wear page of the control.

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