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Powering your productivity

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PowerMILL is the world’s leading specialist NC CAM software for the

manufacture of complex shapes, providing advanced-machining
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 World-leading high-speed machining strategies.
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 www.powerinspect.com

PowerINSPECT leads the way in today’s inspection market. It

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visit: www.delcam.com | watch: www.delcam.tv | learn: www.delcam.tv/lz
 PowerMILL 2014 R2

What's New

Issue 1
PowerMILL
Copyright 1996 - 2013 Delcam plc. All rights reserved.
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.
The functionality and user interface in this manual is subject to
change without notice in future revisions of software.
The software described in this manual is furnished under licence
agreement and may be used or copied solely in accordance with the
terms of such licence.
Delcam plc grants permission for licensed users to print copies of
this manual or portions of this manual for personal use only.
Schools, colleges and universities that are licensed to use the
software may make copies of this manual or portions of this manual
for students currently registered for classes where the software is
used.

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.
Patents
The Raceline smoothing functionality is subject to patent
applications.
Patent granted: 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
The Vortex machining functionality is subject to patent applications.
Patent application: 1121277.6 Adaptive Clearance
The MachineDNA functionality is subject to patent applications.
Patent application: 1204908.6 Machine Testing
Licenses
Intelligent cursor licensed under U.S. patent numbers 5,123,087
and 5,371,845 (Ashlar Inc.)

PowerMILL 2014R2. Published on 8 January 2014

Contents
Summary of new features 1
Toolpath preparation ........................................................................................... 1
Toolpath generation ............................................................................................ 1
Advanced simulation ........................................................................................... 2
Toolpath output ................................................................................................... 2
User interface ..................................................................................................... 2
Automation.......................................................................................................... 2
General enhancements....................................................................................... 2

Toolpath preparation 3
Composite curve creator ..................................................................................... 3
Selecting curves to create a composite curve ............................................ 8
Selecting surfaces to create a composite curve ....................................... 10
Composite Curve Direction toolbar ........................................................... 12
Composite Curve Jump Confirmation dialog ............................................ 15
Creating a composite curve from surface geometry ................................. 17
Automatic creation of a composite curve .................................................. 20
Creating a composite curve from wireframe geometry ............................. 22
Creating a composite curve from 'gappy' wireframe geometry ................. 24
Creating a composite curve using marker points ...................................... 27
Composite curve creator options .............................................................. 31
Improved hole creation and editing ................................................................... 36
Create Holes dialog .................................................................................. 36
Edit Holes dialog ...................................................................................... 44
Enhancements to the Feature Set menu .................................................. 59
Enhancements to the individual feature set menu .................................... 60
Hole creation options ................................................................................ 63
Boundary editing history ................................................................................... 64
Improvements to specifying the tool stock material .......................................... 68

Toolpath generation 70
Drilling enhancements ...................................................................................... 70
Drilling enhancements .............................................................................. 71

Advanced simulation 72
Dynamic machine control mode ........................................................................ 72
Repositioning the machine tool interactively............................................. 74
Using the Dynamic machine control mode toolbar ................................... 76

PowerMILL 2014 R2 What's New Contents • i

Toolpath output 85
NC program updates......................................................................................... 85
Drawing toolpaths in an NC program ....................................................... 85
Duplicating toolpaths in an NC program ................................................... 86

User interface 87
Positioning a machine tool ................................................................................ 87
The new Machine Tool Position dialog ..................................................... 88
The new Machine Tool Collisions dialog .................................................. 90

Automation 91
Macro programming .......................................................................................... 91

General enhancements 92
Creating custom toolbars .................................................................................. 92
Creating and managing custom toolbars .................................................. 92
Adding buttons to toolbars ........................................................................ 94

Index 95

ii • Contents PowerMILL 2014 R2 What's New

Summary of new features
PowerMILL is the leading NC CAM software specialising in the
manufacture of complex shapes typically found in the toolmaking,
automotive, and aerospace industries. PowerMILL 2014R2 offers all
of the original features of PowerMILL 2014, but with numerous
improvements. This document describes the most significant
improvements.

Toolpath preparation
There is a new composite curve creator which greatly enhances
2.5D machining and flowline machining (see page 3).
There is now a separate dialog for hole creation and editing. This
simplifies the Feature dialog as it no longer contains the hole specific
options.
 There is an improved process for hole creation because it is
significantly different to the creation of other features (see page
36). There is now a separate dialog for hole creation so the
Feature dialog no longer contains the hole specific options.
 There is a new dialog to control hole editing and hole
intersections (see page 44).
 There are several changes to the Feature Set and individual
feature set menus (see pages 59–60).
 You can now see a history of your boundary edits. This is similar
to the history of your toolpath edits (see page 64).
You can now see a history of your boundary edits (see page 64).
There are improvements to specifying the tool stock material (see
page 68).

Toolpath generation
When drilling compound holes, you can now choose which hole
components you want to drill (see page 71).
When creating a drilling method, you can now add an existing
drilling toolpath and notes (see page 70).

PowerMILL 2014 R2 What's New Summary of new features • 1

 Advanced simulation
The new Dynamic machine control mode enables you to simulate and
adjust the configuration and tool axis of a 3+2 machine tool, so you
can quickly and easily improve the machine tool's access to the
workpiece (see page 72).

Toolpath output
There are several improvements to NC programs functions. You can
now:
 Multi-select NC programs (see page 85).
 Draw all the toolpaths used in an NC program (see page 85).
 Add toolpaths to the NC program multiple times (see page 86).
 Create fixture offset more easily (see page 70).

User interface
The new Machine Tool Position and Collision dialogs replace the
Machine Information dialog (see page 87).
The new dialogs:
 Improve the presentation of machine tool position and collision
data.
 Enables easier jogging of a machine tool’s axes.

Automation
There are enhancements to the macro programming language (see
page 91).

General enhancements
There is an improved process for creating and managing custom
toolbars. In PowerMILL 2014R2 you can have up to thirty-two
custom toolbars at any time (see page 92).

2 • Summary of new features PowerMILL 2014 R2 What's New

Toolpath preparation

Composite curve creator

There is a new composite curve creator which greatly enhances
2.5D machining and flowline machining.
The Create Composite Curve mode toolbar merges adjacent arcs,
lines, curves, and surface edges into one composite curve. This
offers very similar functionality to PowerSHAPE's composite curve
creator.

Selecting displays the Create Composite Curve mode toolbar.

is available from:
 the Curve Creation toolbar on the Curve Editor mode toolbar

 the Pattern toolbar

 the Boundary toolbar

Activating a mode disables most of PowerMILL's functionality

until you exit from the mode. For more information, see Mode
toolbars.
You build a composite curve from existing geometry, starting by
selecting a curve (see page 8) or surface (see page 10). Where you
select the curve or surface determines the default direction. Then
the options enable you to guide the path of the curve to create the
required composite curve.
The Create Composite Curve toolbar works on curves (not
surfaces). If a surface is in an area of interest, it selects the surface
edge curve and operates on that. This edge curve is always a
complete closed loop that goes all the way around the perimeter of
the surface.

PowerMILL 2014 R2 What's New Toolpath preparation • 3

 Surface marker — Click to display the surface markers.

deselected:

selected:

Surface selection point

The surface markers use the same colour scheme as the curve
selection:
 Pink indicates the surface edge automatic sketching follows.
 Yellow indicates alternate surface edges.
 Blue indicates the current surface for the current curve.
 Grey indicates an alternative surface for the current curve. This
is an option you are unlikely to use because it returns to the
start point, but along the other surface. For more information,
see Selecting curves to create a composite curve (see page 8).

4 • Toolpath preparation PowerMILL 2014 R2 What's New

 Reset — Click to go back to the start and deselect all curves. It
still displays the Create Composite Curve mode toolbar.

Marker point 1 — When sketching a composite curve, click

and then click on a curve to specify the marker point. The marker
points prevent the composite curve progressing beyond this point
(see page 27).

If the composite curve doesn't meet this marker point, the

marker point has no effect on the composite curve.

Rewind — Click to go back to either the previous branch point,

or the beginning (if no branch points exist).
Starting with:

Clicking gives:

PowerMILL 2014 R2 What's New Toolpath preparation • 5

 Backward — Click to go back to the previous curve. This takes
you back to where two or more curves meet, so it may not take you
back as far as the previous branch point.
Starting with:

Clicking gives:

Forward — Click to proceed to either the next branch point, or

the end (if no branch points exist).

Fast Forward — Click to proceed along the automatic path as far

as possible.

6 • Toolpath preparation PowerMILL 2014 R2 What's New

 Marker point 2 — When sketching a composite curve, click
and then click on a curve to specify the marker point. The marker
points prevent the composite curve progressing beyond this point
(see page 27).

If the composite curve doesn't meet this marker point, the

marker point has no effect on the composite curve.

Reverse — Click to change the direction of the curve.

Starting with:

Start point
Curve direction

Clicking gives:

PowerMILL 2014 R2 What's New Toolpath preparation • 7

 Save and Restart — Click to save the current selection as a
composite curve. This still displays the Create Composite Curve mode
toolbar, so you can create another composite curve in this pattern
or boundary.

Direction — Hover over the button to display the Direction

toolbar. The option you select determines the default direction at a
branch point. When PowerMILL encounters a branch point, the
composite curve creator displays the choices using an arrow and
colour (see page 12).

Composite curve creator options — Click to raise the Options

dialog with the Composite curve creator page displayed (see page
31).

Accept changes — Click to accept the current composite curve.

This returns you to the Curve Editor mode toolbar.

Cancel changes — Click to delete the current composite curve.

This returns you to the Curve Editor mode toolbar.

Selecting curves to create a composite curve

When the Create Composite Curve mode toolbar is displayed, where
you select the curve affects the default direction of the composite
curve.
The forward direction points to the curve-end closest to the
selection point. So, selecting the curve at point , gives a forward
direction of upwards.

8 • Toolpath preparation PowerMILL 2014 R2 What's New

 Selecting the curve at point , gives a forward direction of
downwards.

 The blue asterisk (*) indicates the start point of the composite
curve.
 The blue arrow indicates the current end point of the composite
curve.
 To extend or change your composite curve either click on the
next curve, or use the play buttons.

When you have created the required composite curve, click

or to accept or cancel the curve creation.
 The red curve indicates the current extents of the composite
curve.
 The pink curve indicates the direction PowerMILL follows if you
click , or . You can also select this direction by clicking the
pink curve.
 The yellow curve indicates an alternative direction. To select this
direction, click the yellow curve.

PowerMILL 2014 R2 What's New Toolpath preparation • 9

 Selecting surfaces to create a composite curve
You can create a composite curve using surface edges. You don't
need curves to create a composite curve.
With the Create Composite Curve mode toolbar displayed, where you
select the surface affects:
 the default direction of the composite curve.
 the surface used to create that section of the composite curve.
The forward direction is towards the surface corner closest to the
selection point. Selecting a surface at point creates the start
point at the bottom right corner of the fillet surface ( ) and a
current-curve-end at the bottom left corner of that fillet ( ). The
curve used to create the composite curve is the surface edge of the
fillet.

It is easier to see if you undraw the shaded model:

10 • Toolpath preparation PowerMILL 2014 R2 What's New

 If you select the surface around , the composite curve looks the
same, but the curve used to create the composite curve is the
surface edge of the vertical face.

If you select the surface around , PowerMILL selects the surface it

considers best. It does this by inspecting the p-curves of the
underlying surfaces, and then selects the surface that is least likely
to produce a 'faceted' curve. For instance, the edge of a cylinder
produces a much better quality curve than a circle trimmed out of a
plane. For example, if you select a boss or pocket in the
powerdrill.dgk model, PowerMILL does not pick the trimmed plane.
 The blue asterisk (*) indicates the start point of the composite
curve.
 The blue arrow indicates the current end point of the composite
curve.
 To extend or change your composite curve either click on the
next curve, or use the play buttons.

When you have created the required composite curve, click

or to accept or cancel the curve creation.
 The red curve indicates the current extents of the composite
curve.
 The pink curve indicates the direction PowerMILL follows if you
click , or . You can also select this direction by clicking the
pink curve.

PowerMILL 2014 R2 What's New Toolpath preparation • 11

  The yellow curve and surface markers indicate alternative
directions and alternative surfaces that PowerMILL uses to create
the next section of the composite curve. To select a yellow
option, click on the appropriate yellow curve or surface marker.
 The grey arrow and surface indicate a possible, though unlikely,
solution. Clicking it enables you to create a composite curve
which has a start point at the bottom right corner of the fillet
surface and goes along to the bottom left corner of the fillet and
then returns to the start point by following the vertical surface
edge.

Composite Curve Direction toolbar

Hovering over Direction on the Create Composite Curve toolbar
displays the Direction toolbar. Use the toolbar to determine the
default direction at a branch point.

12 • Toolpath preparation PowerMILL 2014 R2 What's New

 Clicking Straight gives:

Pink indicates the direction that automatic sketching follows.

Yellow indicates an alternative.

Clicking Left gives:

PowerMILL 2014 R2 What's New Toolpath preparation • 13

 Clicking Right gives:

Clicking Stop at discontinuity gives:

This is the same as Straight provided the angle at the branch

point is less than the discontinuity angle specified on the Composite
curve creator page of the Options dialog. However, it stops if the
angle at the branch point is greater than the discontinuity angle
specified (see page 31).

14 • Toolpath preparation PowerMILL 2014 R2 What's New

 Clicking on the pink curve gives:

In this case, the composite curve extends as far as point .

Because the angle at the branch point is greater than the
discontinuity angle, the composite curve creator extends the curve
from the other end (point ).

Composite Curve Jump Confirmation dialog

When creating a composite curve, PowerMILL stops when it reaches
a gap in the geometry. Click on the curve you want to join.

Clicking on the orange curve displays the Composite Curve Jump

Confirmation dialog.

Use tangents to create the curve — When deselected, joins the curves
with a straight line. When selected, joins the curves with a
tangential curve.

PowerMILL 2014 R2 What's New Toolpath preparation • 15

 Use tangents to create the curve deselected:

Use tangents to create the curve selected:

Next start tangent — Click to cycle through the various tangent

options.
Next end tangent — Click to cycle through the various tangent
options.
Yes — Click to accept the join and return to the Create Composite
Curve toolbar (see page 12).
No — Click to reject the join and return to the Create Composite
Curve toolbar (see page 12).
For more information, see Creating a composite curve from 'gappy'
wireframe geometry (see page 24).
If you are creating a composite curve by selecting surfaces rather
than existing curves, and you want to bridge a gap, the Composite
Curve Jump Confirmation dialog has an extra field.

16 • Toolpath preparation PowerMILL 2014 R2 What's New

 Use tangents to create the curve deselected:

— When displayed, the composite curve remains an embedded

curve. Hover over to display more information.
Use tangents to create the curve selected:

— When displayed, the composite curve is no longer an

embedded curve. Hover over to display more information .

If you create a composite curve by selecting surfaces or

curves extracted from a surface, the resulting composite
curve is an embedded pattern.

Creating a composite curve from surface geometry

This example shows how to create a composite curve from surface
geometry. The result is a composite curve which is also an
embedded pattern.
This uses the 5axis_with_holes.dgk model in the Examples folder.

1 Click on the Pattern toolbar to create a new pattern.

2 Click on the Pattern toolbar. This displays the Curve Editor

mode toolbar.

3 Click on the Curve Creation toolbar.

PowerMILL 2014 R2 What's New Toolpath preparation • 17

 This displays the Create Composite Curve mode toolbar.

4 Click on the Direction toolbar.

5 Click on the surface near .

This selects the right edge of the surface.

 Red indicates the selected surface curve.
 Pink indicates the surface that automatic sketching follows.
 Yellow indicates an alternative surface.
 Grey indicates an alternative surface for the current curve.
This is an option you are unlikely to use because it returns to
the start point, but along the other surface. For more
information, see Selecting curves to create a composite curve
(see page 8).

18 • Toolpath preparation PowerMILL 2014 R2 What's New

 6 Click on the Create Composite Curve mode toolbar to create
the automatic path.

Use the Esc key or click (next to the progress indicator)

if you want to stop the composite curve creation.

7 Click on the Create Composite Curve mode toolbar.

8 Click on the Curve editor mode toolbar. This creates an

embedded pattern which follows the surface edges.

PowerMILL 2014 R2 What's New Toolpath preparation • 19

 Automatic creation of a composite curve
This example shows how to create a composite curve automatically
by clicking a surface edge.
It uses the 5axis_with_holes.dgk model in the Examples folder.

1 Click on the Pattern toolbar to create a new pattern.

2 Click on the Pattern toolbar. This displays the Curve Editor

mode toolbar.
3 Use the Alt key while selecting the surface edge near .

20 • Toolpath preparation PowerMILL 2014 R2 What's New

 PowerMILL creates a composite curve using the default options.
The resulting curve is highlighted.

Use the Esc key or click (next to the progress indicator)

if you want to stop the composite curve creation.

4 Click on the Curve editor mode toolbar. This creates an

embedded pattern of the resulting curve.

PowerMILL 2014 R2 What's New Toolpath preparation • 21

 Creating a composite curve from wireframe geometry
This example shows how to create a composite curve from
wireframe geometry.
This uses an edited boundary generated from the
5axis_with_holes.dgk model in the Examples folder.
1 Double-click on the curve, near point , to raise the Curve Editor
mode toolbar.

2 Click on the Curve Creation toolbar.

This displays the Create Composite Curve mode toolbar.

22 • Toolpath preparation PowerMILL 2014 R2 What's New

 3 Click the curve near point .

 Red indicates the selected curve.

 Pink indicates the curve that automatic sketching follows.
 Yellow indicates an alternative route.
4 Click the yellow curve.

PowerMILL 2014 R2 What's New Toolpath preparation • 23

 5 Click the yellow curve.

6 Click on the Create Composite Curve mode toolbar.

7 Click on the Curve editor mode toolbar.

If, before step 3, you selected a Direction of , you can click

on the Create Composite Curve mode toolbar to create the
automatic path.

Creating a composite curve from 'gappy' wireframe

geometry
When creating a composite curve you have the ability to 'jump'
gaps in the geometry. For example:
1 Starting with a curve with a gap between neighbouring
segments.

24 • Toolpath preparation PowerMILL 2014 R2 What's New

 2 When creating a composite curve, PowerMILL automatically stops
when it reaches the gap.

3 Click the end of the orange curve, around . This displays the
Composite Curve Jump Confirmation dialog.

Deselecting the Use tangents to create the curve option joins the
curve with a straight line.

PowerMILL 2014 R2 What's New Toolpath preparation • 25

 Selecting the Use tangents to create the curve option joins the
curves with a tangential curve.

4 Click Yes on the Composite Curve Jump Confirmation dialog.

5 Click on the Create Composite Curve mode toolbar.

6 Click on the Curve editor mode toolbar.

You don't have to select the end of a curve you can select any
point along it. For example, clicking around in step 2 gives:

26 • Toolpath preparation PowerMILL 2014 R2 What's New

 Creating a composite curve using marker points
This example shows how to create a composite curve limited by
marker points. You can have up to two marker points on any
composite curve.
This uses an edited boundary generated from the
5axis_with_holes.dgk model in the Examples folder.
1 Double-click on the curve, near point , to raise the Curve Editor
mode toolbar.

2 Click on the Curve Creation toolbar.

This displays the Create Composite Curve mode toolbar.

3 Click the first Marker Point button.

PowerMILL 2014 R2 What's New Toolpath preparation • 27

 4 Click the curve near point . This places a red circle at the
selection point.

To remove the marker point, click the first Marker Point

button and then click the marker.

If the circle is blue, you have selected the second Marker

Point button, not the first.

5 Click the second Marker Point button.

6 Click the curve near point . This places a blue circle at the
selection point.
7 Click the curve near point .

28 • Toolpath preparation PowerMILL 2014 R2 What's New

 8 Click the yellow curve. The composite curve creator goes as far
as the first marker point, . It then reverses and continues to
the next branch point, .

9 Click the pink curve.

PowerMILL 2014 R2 What's New Toolpath preparation • 29

 10 Click the yellow curve. The composite curve creator goes as far
as the second marker point and stops.

PowerMILL ignores the marker point if you choose a route

that doesn't meet the marker point.

The first marker point shows the start and end point of the
closed composite curve.
The second marker point, which is ignored.

11 Click on the Create Composite Curve mode toolbar.

12 Click on the Curve editor mode toolbar.

30 • Toolpath preparation PowerMILL 2014 R2 What's New

 Composite curve creator options
The Create Composite Curve mode toolbar has various default
options which you can specify on the Composite curve creator page
of the Options dialog. This is available from Tools > Options > Curve
Editor > Composite curve creator menu.

Search both ways — When selected, the Composite Curve Creator

searches both ends of the curve to find adjacent segments. When
deselected, the composite curve creator searches only the current
curve to find adjacent segments.
Keep original curves — When selected, keeps the individual curves
used to create the composite curve as well as the composite curve.
This prevents the removal of the original curves from the
pattern/boundary.
Follow edges only — When selected, follows surface edges. When
deselected, and the wireframe is displayed, enables you to select
internal constant parameter lines within a surface as well as the
surface edges. This can be useful for generating the drive curve for
flowline machining.

PowerMILL 2014 R2 What's New Toolpath preparation • 31

 Starting with this model:

If you select the surface around .

32 • Toolpath preparation PowerMILL 2014 R2 What's New

 With Follow edges only selected:

You can select surface edges ( ), but not surface internals.

With Follow edges only deselected, and the wireframe displayed:

You can select surface edges or surface internals ( ).

PowerMILL 2014 R2 What's New Toolpath preparation • 33

 With Follow edges only deselected, you can create curves such as:

Gap jumping multiplier — Enter a value to determine if PowerMILL

can automatically jump the gap. This value is multiplied by the
Closure tolerance to give an actual value. If the gap is larger than
this value the Composite Curve Jump Confirmation dialog is
displayed. If the gap is smaller than this value PowerMILL works as
if there is no gap (see page 15).
Maximum discontinuity angle — Enter the maximum angle, at a
branch point, which is still considered as straight.
Changing the Maximum discontinuity angle effects the options
presented when you select a direction of .
If you enter a small Maximum discontinuity angle the options are
almost straight, in this case, .

34 • Toolpath preparation PowerMILL 2014 R2 What's New

 If you increase the Maximum discontinuity angle the number of
options increase, in this case, and .

Further increasing the Maximum discontinuity angle adds more

options, in this case, , , and .

Direction at branch point — Select the default direction displayed on

the Create Composite Curve mode toolbar (see page 12).

PowerMILL 2014 R2 What's New Toolpath preparation • 35

 Improved hole creation and editing
There are several enhancements to hole creation and editing:
 There is an improved process for hole creation as it is
significantly different to the creation of other features. There is
now a separate dialog for hole creation so the Feature dialog no
longer contains the hole specific options (see page 36).
 There is a new dialog to control hole editing, and hole
intersections (see page 44).
 There are several changes to the Feature Set menu and
individual feature set menu (see page 60).
 There is a new page on the Options dialog to specify the hole
creation options (see page 63).

Create Holes dialog

Use the Create Holes dialog to create holes.

Display the Create Holes dialog by either:

 selecting Create Holes on the Feature Sets menu; or
 selecting Create Holes on the individual feature sets menu.
Name root — Enter a name for the hole. Each hole has the root
name followed by a number. If there is no root name then the hole
just has a number.

36 • Toolpath preparation PowerMILL 2014 R2 What's New

 Create from — Select how to recognise holes.
Points — Select to create holes from points in the pattern. These
points define the centre of the hole.
Circles — Select to create holes from circles in the model.
Model — Select to create holes from holes in the model.
Pairs — Select to create holes from pairs of circles in the model.
Curves — Select to create holes from any curve in the model that
can flatten into a circle in the given workplane.
Lines — Select to create holes from lines in the pattern. These
lines define the top, bottom, and axis of a hole.
Plunges — Select to create holes from the plunge moves of the
active toolpath.
Normals — Select to create holes from contact-normal moves of
the active toolpath.

If you select a Create from of Model, the dialog options are

different. For more information see Create Hole > From Model
dialog (see page 40).
Define top by — These options determine the height of the top of the
hole.
Absolute — Select to define the top as an absolute Z height.
Height from Bottom — Select to define the top as a distance from
the bottom of the feature/hole.
Maximum Curve Z — Select to define the top as the maximum Z
height of the selected curve, location . All features use a curve
(bits of model or pattern) as the input data. These curves have a
minimum and a maximum Z value, which you can use for feature
definition. This is useful for hole definition where you have a set
of Z positions that represent the top or bottom of the hole.
Minimum Curve Z — Select to define the top as the minimum Z
height of the selected curve, location .

Maximum Z
Minimum Z

PowerMILL 2014 R2 What's New Toolpath preparation • 37

 Curve centre — Select to define the top as halfway between the
top and bottom of the curve (midway between and ).
Top of Block — Select to define the top as the height of the top of
the block.
Line Start — Select to define the top as the start of the line.

This option is available only if you selecte a Use of Lines.

— Enter the height of the top of the feature.
Define bottom by — These options determine the height of the
bottom of the hole.
Absolute — Select to define the bottom as an absolute Z height.
Depth from Top — Select to define the bottom as a distance from
the top of the feature/hole.
Maximum Curve Z — Select to define the bottom as the maximum
Z height of the selected curve, location . All features use a
curve (bits of model or pattern) as the input data. These curves
have a minimum and a maximum Z value, which you can use for
feature definition. This is useful for hole definition where you
have a set of Z positions that represent the top or bottom of the
hole.
Minimum Curve Z — Select to define the bottom as the minimum
Z height of the selected curve, location .

Maximum Z
Minimum Z

Curve centre — Select to define the bottom as half way between

the top and bottom of the curve. Midway between and .
Bottom of Block — Select to define the bottom as the height of
the bottom of the block.
Line End — Select to define the bottom as the end of the line.

This option is available only if you selecte a Use of Lines.

— Enter the height of the bottom of the feature.
Upper diameter — Enter the upper diameter of the hole.

The Upper diameter is the same as the Lower diameter unless

the hole has a Draft angle.
Draft angle — Enter the draft angle of the hole.

38 • Toolpath preparation PowerMILL 2014 R2 What's New

 Draft angle of 0: Draft angle of 10:

Group holes by axis — When selected, sorts the holes into feature
sets by workplane. In this case, your machine tool must have3+2-
axis drilling capability. When deselected, places all the holes in one
feature set. In this case, your machine tool must have multi-axis
drilling capability.
This example uses the RetainerPlate.dgk model. It has an active
workplane, and the whole model is selected:

PowerMILL 2014 R2 What's New Toolpath preparation • 39

 Deselecting Group holes by axis gives:

Selecting Group holes by axis gives:

Edit after creation — When selected, clicking Apply creates the holes
and then displays the Edit Hole dialog (see page 44).

Create Holes from model dialog

Use the Create Holes dialog with a Create from of Model to create
holes from holes in the model.

40 • Toolpath preparation PowerMILL 2014 R2 What's New

 To display this dialog, select Create Holes on the Feature Sets menu.
Name root — Enter a name for the hole. Each hole has the root
name followed by a number. If there is no root name the hole just
has a number.
Create from — Select how to recognise holes.
Points — Select to create holes from points in the pattern. These
points define the centre of the hole.
Circles — Select to create holes from circles in the model.
Model — Select to create holes from holes in the model.
Pairs — Select to create holes from pairs of circles in the model.
Curves — Select to create holes from any curve in the model that
can flatten into a circle in the given workplane.
Lines — Select to create holes from lines in the pattern. These
lines define the top, bottom, and axis of a hole.
Plunges — Select to create holes from the plunge moves of the
active toolpath.
Normals — Select to create holes from contact-normal moves of
the active toolpath.
Tolerance — Enter the tolerance used to create holes.
Create compound holes — When selected, creates one compound
hole containing several components. When deselected, creates
several individual holes (superimposed on each other).
A compound hole is one hole containing several components; in this
case, a hole named 1 with components 0 and 1.
If you create them as individual holes, there are two holes named 1
and 2.

For more information, see Compound Holes.

Use active workplane only — Select to create only the holes that
have a Z axis that aligns with the Z axis of the active workplane.

PowerMILL 2014 R2 What's New Toolpath preparation • 41

 This example uses the RetainerPlate.dgk model. It has an active
workplane, and the whole model is selected:

Selecting the Use active workplane only gives:

Deselecting Use active workplane only gives:

Find holes in both directions — When Group by hole axis is selected,

places holes from both directions into a single multi-axis feature
set. When Group by hole axis is deselected, splits the holes into two
feature sets (one for up and one for down).
Find holes going up — Places the holes going up into a single feature
set.
Find holes going down — Places holes going down into a single
feature set.

42 • Toolpath preparation PowerMILL 2014 R2 What's New

 Group holes by axis — When selected, sorts the holes into feature
sets by workplane. In this case, your machine tool must have3+2-
axis drilling capability. When deselected, places all the holes in one
feature set. In this case, your machine tool must have multi-axis
drilling capability.
This example uses the RetainerPlate.dgk model. It has an active
workplane, and the whole model is selected:

Deselecting Group holes by axis gives:

Selecting Group holes by axis gives:

Try to recognise partial holes — Select to enable the creation of holes

from a model that has poorly, or incompletely defined, holes. For
example, creating a hole from a pair of arcs.

Use this option as a last resort because it may find many

unwanted (or unexpected) holes.

PowerMILL 2014 R2 What's New Toolpath preparation • 43

 Ignore holes with no open ends — When selected, creates holes which
have at least one open end, and ignores holes with two closed ends.
Edit after creation — When selected, clicking Apply creates the holes
and then displays the Edit Hole dialog (see page 44).

Edit Holes dialog

Use the Edit Holes dialog to edit the geometry, properties or hole
intersections.

Display the Edit Holes dialog by either:

 selecting Edit Holes on the Feature Sets menu; or
 selecting the Edit after creation option on the Create Hole dialog
(see page 36).
There are three tabs associated with this dialog:
 Geometry — Select to edit the size of the hole, or hole
component (see page 45).
 Properties — Select to edit the hole metadata, for example name
and colour (see page 57).
 Intersection — Select to delete hole intersections (see page 58).

44 • Toolpath preparation PowerMILL 2014 R2 What's New

 Edit Holes > Geometry
The Geometry tab on the Edit Hole dialog edits a component of a
hole (see page 44).

Move Up — Click to move the selected component up one

position.

Add component — Click to add a component. The new

component is the same size as the selected component. You can
then edit its size in the lower half of the dialog.

Delete Selected — Click to delete the selected component.

Move Down — Click to move the selected component down one

position.
The graphic displays the hole you are editing. For compound holes,
the currently editable component is cross-hatched blue. To edit a
different component, select it in the graphics pane.

You can use the keyboard arrows ( ) to select the relevant

component which can be useful when selecting small
components.

PowerMILL 2014 R2 What's New Toolpath preparation • 45

 If you select multiple holes that are the same size and have
the same components, you can edit them all together. If you
select multiple holes that differ, the differing components are
grey. However, you can still move them and edit the values in
the lower part of the dialog.

Where the selected holes have the same value, the value is
displayed (for example Draft angle).
Where the selected holes have differing values, the field is empty
(for example Upper diameter).
Upper diameter — Enter the diameter at the top of the current
(cross-hatched component. This must be greater than or equal to
the Lower Diameter.
Depth — Enter the vertical height of the component.
Lower diameter — Enter the diameter at the bottom of the current
(cross-hatched) component. This must be less than or equal to the
Upper Diameter.
Draft angle — Enter the draft angle of the hole.

46 • Toolpath preparation PowerMILL 2014 R2 What's New

 Draft angle of 0: Draft angle of 10:

Fillet radius — Enter the radius.

A Fillet radius of 0 gives a standard hole component with no fillet:

PowerMILL 2014 R2 What's New Toolpath preparation • 47

 Entering a Fillet radius gives:

The minimum fillet radius has a diameter equal to the length

( ) of the hole component. The length of the component is
the same as the Depth for a hole with no draft angle.

The diameter of the fillet must be at least as large as the

length of the component.

48 • Toolpath preparation PowerMILL 2014 R2 What's New

 Fillet type — Select either a Concave or Convex fillet.
Fillet type of Concave:

Fillet type of Convex:

PowerMILL 2014 R2 What's New Toolpath preparation • 49

 Hole position — Enter the x, y, z coordinates of the centre of the
hole.

— Click to display the Position dialog. Use the dialog to manually

enter coordinates and locate items in the graphics window.
Hole axis — Enter the orientation of the Z axis of the hole.

— Click to display the Direction dialog, which enables you to edit

the direction of an item.
— When displayed, hover over to see more information.

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 (see page 50).

Editing automatically identified holes

This example shows how to edit holes generated automatically from
the Create Holes option. It uses the RetainerPlate.dgk model in the
Examples folder.

1 Select part of the model, including some of the holes.

2 From the Feature Sets menu, select Create Holes.
This displays the Create Holes dialog.

50 • Toolpath preparation PowerMILL 2014 R2 What's New

 3 On the Create Holes dialog:
a Select a Create from of Model.
b Select Create compound holes.
c Deselect Group holes by axis.
d Select Edit after creation.
e Click Apply.
PowerMILL recognises the selected holes.

Standard holes with the Z axis of the hole aligned with the
workplane Z axis.

PowerMILL 2014 R2 What's New Toolpath preparation • 51

 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 you want to edit.

You can also edit holes graphically.

5 On the Edit Holes dialog, edit the required fields, in this case, the
Upper Diameter, and X and Y coordinates.

52 • Toolpath preparation PowerMILL 2014 R2 What's New

 Altering the Upper Diameter automatically updates the Lower
Diameter.

If you edit a compound hole, select the relevant component in

the graphical area of the dialog (the selected component is
cross-hatched), and then edit the appropriate values.

the selected component.

PowerMILL 2014 R2 What's New Toolpath preparation • 53

 When you select a hole where the Z axis of the hole is not
aligned with the workplane Z axis, the Hole position
coordinates are shown relative to the active workplane rather
than the workplane of the hole. In this case is added to the
dialog. Hovering over displays more information.

54 • Toolpath preparation PowerMILL 2014 R2 What's New

 Creating and editing compound holes
This example shows how to edit holes generated automatically from
the Create Holes option. It uses the RetainerPlate.dgk model in the
Examples folder.

1 Select part of the model, including some of the holes.

2 From the Feature Sets menu, select Create Holes.
This displays the Create Holes dialog.

3 On the Create Holes dialog:

a Select a Create from of Model.
b Select Create compound holes.
c Deselect Group holes by axis.

PowerMILL 2014 R2 What's New Toolpath preparation • 55

 d Select Edit after creation.
e Click Apply.
PowerMILL recognises the selected holes.
4 Select the hole you want to edit.

5 On the Edit Holes dialog:

a Click to add a second component.

b Select the lower component.
c Enter an Upper diameter of 50.
d Enter a Depth of 100.

56 • Toolpath preparation PowerMILL 2014 R2 What's New

 You can use this dialog to build up a more complex compound hole,
such as:

Edit Holes > Properties

Use the Properties tab on the Edit Hole dialog to edit the hole
metadata, for example, name and colour (see page 44).

PowerMILL 2014 R2 What's New Toolpath preparation • 57

 Name — Enter the name of the active hole.
Description — Enter a description. You can use this description as a
selection criteria when selecting holes or for drilling methods (you
can give a set of holes a description then state that the method only
applies to holes with that description). For more information, see
Select Features.
Hole Type — Enter a description. You can use this description as a
selection criteria when selecting holes or for drilling methods (you
can give a set of holes a description then state that the method only
applies to holes with that description). For more information, see
Select Features.
Edit Colour — Click to display the standard Windows Color dialog.
Select the relevant colour and click OK to close the dialog. Use to
change the colour of the selected feature or hole.

Edit Holes > Intersection

The Intersections tab on the Edit Holes dialog enables you to delete
hole intersections (see page 44).

58 • Toolpath preparation PowerMILL 2014 R2 What's New

 To use this you must first identify the hole intersections (from
the Feature Sets context menu, select Find Hole Intersections).
The left side of the dialog displays a list of the intersections of the
selected hole.

Delete — Click to delete the intersections selected in the left side

of the dialog.
For more information, see Reducing feed rates at hole intersections
or Deleting a hole intersection.

Enhancements to the Feature Set menu

There are several changes to the Feature Set menu.

The Feature Set Editor option is now on the Edit menu.

There are several new options:
Create Holes this displays the settings used to create the hole. Hole
creation now uses a different dialog to feature creation (see page
36). This combines the Create Feature Sets option (with a Type of
Hole) and the Recognise Holes in Model option.
Find Hole Intersections and Delete All Hole Intersections are lower in
the menu than in previous versions.
Select Hole replaces Select Feature. It is now called Select Hole
because you can use it only to select holes and not other features.
The Preferences option is no longer available because these options
are now available on the Create Feature Set or Create Holes options.

PowerMILL 2014 R2 What's New Toolpath preparation • 59

 Enhancements to the individual feature set menu
There are several changes to the individual feature set menu.

The Feature Set Editor option is now on the Edit menu.

There are several new options:
Select Hole was called Select Feature. It is now called Select Hole
because you can use it only to select holes and not other features.
Create Features replaces the Settings option in previous versions.
This displays the settings used to create the feature.
Create Holes displays the settings used to create the hole (see page
36).
Separate Compound Holes separates all compound holes into single
holes. This is on the Edit menu.

60 • Toolpath preparation PowerMILL 2014 R2 What's New

 In this example there are two standard holes and three compound
holes. The compound holes are orange.

Looking at the feature set you can see the holes:

Selecting Separate Compound Holes converts the compound holes to

their individual hole components.

If you select one (or more) compound holes then PowerMILL

separates only the selected holes.

PowerMILL 2014 R2 What's New Toolpath preparation • 61

 Combine Holes combines single holes into compound holes. This is
on the Edit menu.
In this example there are eight holes. Starting with these holes.

Looking at the feature set, you can see the holes:

Selecting Combine Holes converts the individual hole components,

which share a Z axis, to a compound hole.

62 • Toolpath preparation PowerMILL 2014 R2 What's New

 Hole creation options
There is a new page on the Options dialog of Hole Creation > Options.
The Hole Creation Options determine the default options used to
create a hole.

Use block to find direction — Select to use the block to determine the
direction of holes. When selected, holes point towards the block
centre.
Use surfaces to find direction — Select to use the surfaces to
determine the direction of holes.
Add components in gaps — Select to add extra hole components to
fill in vertical gaps between hole components in compound holes.
Maximum depth — Enter the maximum depth of a hole component
you can add when selecting Add components in gaps. No additional
components are added if a compound hole contains a gap larger
than this value.
Ignore outside surfaces — Select to use the inner surface to create a
hole, this is useful where you have a hole inside a boss.When
deselected, PowerMILL creates two holes: one for the inside and
one for the outside, this is useful for tapped holes where both
surfaces are modelled.

This option is disabled when Use surfaces to find direction is

deselected.

PowerMILL 2014 R2 What's New Toolpath preparation • 63

 Boundary editing history
You can now see a history of your boundary edits. This is similar to
the history of your toolpath edits.
Use the Boundary Editing History dialog to show a history of all the
edits on a boundary. It also enables you to edit some of them.

The Boundary Editing History dialog is available from the individual

boundary Edit > Boundary Editing History menu or by clicking on
the Boundary toolbar.
Boundary — Select the boundary to review and re-edit the
boundary's previous edits.
Edits — The pane displays a list of all the edits performed on the
boundary. The most recent edit is at the top of the list and the
original boundary is at the bottom of the list. The right side of the
dialog displays information on the selected edit.

64 • Toolpath preparation PowerMILL 2014 R2 What's New

 In this case, the edit moved the boundary by 20 mm in X and you
can edit these values.

If you make more than one transform before accepting the

result, PowerMILL shows a complex transform rather than the
separate individual transforms.
For example:
1 From the individual boundary menu, select Edit > Transform. This
displays the Boundary Transform mode toolbar.

2 Click on the Boundary Transform mode toolbar. This displays

the Move toolbar.

3 On the Move toolbar:

a Enter the coordinates 20 0 0 in the field on the status
toolbar.
b Click to close the Move toolbar.

4 Click on the Boundary Transform mode toolbar. This displays

the Rotate toolbar.

5 On the Rotate toolbar:

a Enter an Angle of 15.
b Click to close the Move toolbar.

PowerMILL 2014 R2 What's New Toolpath preparation • 65

 6 Click on the Boundary Transform mode toolbar to accept the
two transforms.
7 From the individual boundary menu, select Edit > Boundary
Editing History. This displays the two transforms as one complex
transform.

In this case, you can see the matrix that combines the move and
rotation but you cannot edit these values. You can delete this
transformation by clicking .

Delete — Click to delete the selected edit.

— When displayed, the boundary contains selective edits. Hover
over to display more information.

If your boundary edits contain selective edits you can modify

the edits, but clicking on the Calculate button only applies the
edits up to, but not including, the selective edit.

66 • Toolpath preparation PowerMILL 2014 R2 What's New

 A selective edit is an edit that requires you to select a curve
segment or a point. For example, Delete Selected Components.

The selective edit.

Indicates that if you edit any values, you can re-calculate
your boundary, but the history is not fully re-applied.
Notes — Type any specific notes to help you understand the edit.
If you select the boundary, rather than an edit, the right side of the
dialog displays the Boundary page.

Name — Displays the name of the boundary.

— Click to display the Boundary dialog. This is the same dialog

that is displayed when you create or edit a boundary.
Calculate — Click to recalculate the boundary based on edits you
make to this dialog.

PowerMILL 2014 R2 What's New Toolpath preparation • 67

 Improvements to specifying the tool
stock material
In previous versions of PowerMILL you could enter a new stock
material of a tool, but you were unable to see the existing stock
materials. So, it wasn't easy to use an existing material as you had
to match the spelling and capitalisation correctly. Now you can
select an existing material from a list, or create a new material.
Use the Tool Stock Material dialog to specify or change the stock
material of tools.

The Tool Stock Material dialog is available on the Tools context

menu, or on the individual tool context menu.
Tool — Use these options to identify the tools whose stock material
you want to change.
Specified tool — Select to enter a stock material for the tool selected
in the list.
— Select the required tool from the list.
Selected tools — Select to enter a stock material for all tools
selected in the explorer.
All tools — Select to enter a stock material for all tools in the
project.
With material — Select to enter a stock material for all tools which
currently have the material specified in the list.

68 • Toolpath preparation PowerMILL 2014 R2 What's New

 — Select the required material from the list. If no
material is selected, the material is applied to all tools which don't
have a material.
Material — Use these options to specify the required stock material.
— Select a stock material from the list. If there are
no materials listed, or the material you require isn't listed then you
must create a new material using .

New Stock Material — Select to create a new stock material. This

displays the New Stock Material Name dialog.
To create a new stock material:

1 Click to displays the New Stock Material Name dialog:

2 Enter a name for the new stock material

Spaces are not allowed in stock material names.

So, for example, Mild Steel is not a valid name because
there is a space in the name; but the names Mild_Steel or
MildSteel are valid.

3 Click .

PowerMILL 2014 R2 What's New Toolpath preparation • 69

Toolpath generation

Drilling enhancements
When drilling compound holes, you can now choose which hole
components you want to drill (see page 71).
When creating a drilling method you can now:

 Add a toolpath: select an existing drilling toolpath, then click

to add it to the drilling method.

 Add a note: click Note to display the Method Notes dialog. Use
the dialog to enter a note about the drilling method. The notes
appear at the top of the method xml file.

70 • Toolpath generation PowerMILL 2014 R2 What's New

 Drilling enhancements
When drilling compound holes, you can now choose which hole
components you want to drill.
On the drilling strategy dialogs you can now select the Bottom
component. If you select a Define top by of Component top you can
also specify a Top component.

For example, with this compound hole:

Selecting a Top component of 2 and a Bottom component of 3 or Last

produces a toolpath on the bottom two components.

PowerMILL 2014 R2 What's New Toolpath generation • 71

Advanced simulation

Dynamic machine control mode

The new Dynamic machine control mode enables you to adjust the
configuration and tool axis of a 3+2 axis machine tool, so you can
quickly and easily improve the machine tool's access to the
workpiece.
The mode includes:
 Interactive grab-handles let you drag the machine tool into new
positions (see page 74).
 The Dynamic machine control mode toolbar features a range of
buttons that compliment the use of the grab-handles. The Swap
machine tool configuration button is very useful for orientating
a machine tool with an asymmetrical head (see page 76).
 The Dynamic machine control mode dialog lets you manually
specify the machine tool position and tool axis, instead of using
the interactive grab-handles. The dialog also enables you to
specify the increment value for rotary axes (see page 78).

In this graphic, access to the workpiece is improved by rotating the

grab-handle to adjust the machine tool's configuration and tool axis.

72 • Advanced simulation PowerMILL 2014 R2 What's New

 Entering the Dynamic machine control mode

To use the Dynamic machine control mode, you must have the
PowerMILL Advanced Simulation licence (POWERMILL–
ADVSIM).
You can enter the mode at any time.

The mode is only available for the following tools: ball nosed,
tip radiused, end mill, tapered spherical or tapered tip.
Activating a mode disables most of PowerMILL's functionality
until you exit from the mode. For more information, see Mode
toolbars.

To enter the mode, click on the Tool toolbar. Entering the mode
displays grab-handles around the tool and the Dynamic machine
control mode toolbar.

PowerMILL 2014 R2 What's New Advanced simulation • 73

 Repositioning the machine tool interactively
You can improve the machine tool's access to the workpiece by
repositioning the machine tool with the new interactive features.

You may find it useful to use the interactive features to

reposition the machine tool approximately and then use the
Dynamic machine control mode dialog to position the machine
tool more accurately (see page 78).
The interactive features include:

Jump to a point
Double-clicking on the model makes the machine tool jump to the
selected point.

Grab-handles
Each grab-handle is associated with an axis. By dragging a grab-
handle, you move the machine tool within the associated axis. The
circular grab-handles rotate the tool axis, and the linear grab-
handles move the tool along a single axis. There are two sets of
grab-handles that you can toggle between so you can achieve the
best tool configuration and tool axis:
Clicking displays the grab-handles aligned to the active
workplane .
Clicking displays the grab-handles aligned to the axes of the
machine tool .

74 • Advanced simulation PowerMILL 2014 R2 What's New

 When you hover the cursor over a drag-handle, the drag-handle is
highlighted. You can then drag the machine tool into a new position.

Dragging the tool

When you hover the cursor over the tool, the cursor changes to .
This enables you to drag the machine tool free-hand across the
model.

Dragging the tool free-hand (or 'scanning' the model with the
machine tool) is a useful technique for quickly seeing if the
current tool axis is appropriate for machining the surface of
interest.

PowerMILL 2014 R2 What's New Advanced simulation • 75

 Using the Dynamic machine control mode toolbar
The buttons on the Dynamic machine control mode toolbar
compliment the use of the grab-handles. For more information
about using the grab-handles, see Repositioning the machine tool
interactively (see page 74).

Select tool — Click to select the tool you want to simulate.

This enables you to simulate an alternative tool to the one used by
the current toolpath. If the cutting geometry of the alternative tool
is the same as the original tool, you can click Update toolpath to
update the toolpath so it now uses the alternative tool.
Lock tool axis — Click to lock the tool axis. This limits the
machine tool movement to the X, Y, and Z axes, which is useful if
you want to preserve the tool axis while changing the configuration
of the machine tool.
Rotate around current workplane — Click to display the grab-
handles aligned to the active workplane (see page 74).
Use machine tool graphics — Click to display the grab-handles
aligned to the axes of the machine tool (see page 74).
Use tool positioning graphics — Click so you can simultaneously
move the machine tool in the X, Y, and Z axes of the active
workplane.
Advanced settings — Click to display the Dynamic machine control
mode dialog. The dialog enables you to specify the tool orientation
(position and axis), as well as increment values to restrict the
movement of the tool's rotary axes (see page 78).
Machine Tool Position — Click to display the Machine Tool Position
dialog. The Machine Tool Position dialog displays the position of each
machine tool axis. You can use the dialog for reference purposes
and to jog the machine tool's axes by using the dialog's interactive
features (see page 87).
Swap machine tool configuration — Click so PowerMILL
reorientates the machine tool but without changing the tool axis.
This is especially useful for moving an asymmetrical machine head
out of the way.
Align with view — Click to align the tool axis direction with the
direction of your current view.
Create workplane aligned with tool — Click to create a workplane
aligned with the machine tool.

76 • Advanced simulation PowerMILL 2014 R2 What's New

 Create workplane at tool tip — Click to create a workplane at the
tool tip.

Choose the workplane that suits your preferred working

method.
Update toolpath — Click to update the toolpath with the new
machine tool position.

After updating the toolpath, you must check the toolpath

for collisions using the Toolpath verification function.

The Update Toolpath function can be used only when you

are using a tool with a spherical tool tip. To update a
toolpath that uses a tool with a non-spherical tip, you have
to enter the values of the new tool position in the toolpath's
strategy dialog.

Undo — Click to revert to what it was before the last change.

Redo — Click to reinstate the edit you have just undone.

Nearest valid position — If you move the machine tool beyond its
physical limits, you can click so PowerMILL moves the tool to the
nearest valid position.
PowerMILL displays one of these icons if there is an
issue.The icon displayed depends on the severity of the issue. Hover
the cursor over the icon for more information.
Accept changes — Click to accept changes and resume normal
PowerMILL functions.

Close — Click to exit the mode without saving changes.

PowerMILL 2014 R2 What's New Advanced simulation • 77

 Using the Dynamic machine control mode dialog
There are four tabs on the Dynamic machine control mode dialog:
 Tool axis
 Position
 Machine tool
 Axis restrictions
To display the new dialog, click on the Dynamic machine control
mode toolbar (see page 76).

Tool axis tab

The Tool axis tab on the Dynamic machine control mode dialog
displays the tool axis direction as vectors and apparent angles. The
values update automatically when you use the grab-handles to
adjust the tool axis.

Tool name — The name of the tool.

Axis direction — Specify the tool axis as vectors.
Apparent angles — Specify the tool axis as apparent angles.

Direction — Click to display the Direction dialog. The dialog

enables you to specify the tool axis instead of using the grab-
handles.

You may find it useful to use the grab-handles to specify the

tool axis approximately and then use the Tool axis tab to
specify the tool axis more accurately.

78 • Advanced simulation PowerMILL 2014 R2 What's New

 Position tab
The Position tab on the Dynamic machine control mode dialog
displays the tool position in X, Y, and Z (relative to the active
workplane). The values update automatically when you use the
grab-handles to adjust the tool position.

Tool name — The name of the tool.

Contact point — Displays the contact point between the tool and the
model .
Tool tip — Displays the position of the tool tip .
Tool centre — Displays the position of the tool centre .

The Tool centre field is displayed only when you are

simulating a tool with a spherical tip.

Anchor point — The indicates which point PowerMILL is currently

using as the centre of rotation when you move the machine tool:
Contact point — Used when the tool is in contact with the model.
Tool tip — Used when the tool is not in contact with the model
and the simulated tool has a non-spherical tip.
Tool centre — Used when the tool is not in contact with the
model and the simulated tool has a spherical tip.

Position — Click to display the Position dialog. The dialog

enables you to define the position of tool by specifying the position
of the tip or centre of the tool.

You may find it useful to use the grab-handles to define the

tool position approximately and then use the Position tab to
specify the tool position more accurately.

PowerMILL 2014 R2 What's New Advanced simulation • 79

 Machine tool tab
The Machine tool tab on the Dynamic machine control mode dialog
displays the position of each machine tool axis. The values update
automatically when you use the grab-handles to adjust the position
of the machine tool's axes.

Tool name — The name of the tool.

Machine axes — Specify the position of the machine tool's axes.

You may find it useful to use the grab-handles to reposition

the machine tool's axes approximately and then use the
Machine tool tab to specify the position of the axes more
accurately.

80 • Advanced simulation PowerMILL 2014 R2 What's New

 Axis restrictions tab
The Axis restrictions tab on the Dynamic machine control mode dialog
enables you to enter the increment values of your actual machine
tool's axes, so the axes of the virtual machine tool move accurately.

Tool name — The name of the tool.

Restrict axis — Select to restrict the movement of the axis by the
specified increment value.
Increment value — Specify the increment value.

If you adjust an axis without an increment restriction, it is

possible that the axis position may not be achievable by your
actual machine tool.
If the current axis value is 83.34, for example, and you
restrict the axis with an increment value of 1, when you
adjust the axis, the axis value is rounded down to 83 and
then increases 83 – 84 – 85 and not 83.34 – 84.34 – 85.34.

PowerMILL 2014 R2 What's New Advanced simulation • 81

 Using the Dynamic machine control example
This example shows how to use the functions of the Dynamic
machine control mode to prevent collisions between the machine
tool and the workpiece.
The example uses the DynamicMachineControl_Example project in the
Examples folder.
1 In the Toolpaths branch of the explorer, right-click the toolpath
and select Simulate from Start.
As the machine tool machines down the surfaces of the
workpiece, the head and the A axis-component of the machine
tool collide with the workpiece.

2 On the Tool toolbar, click to enter the Dynamic machine

control mode.
This displays the Dynamic machine control mode toolbar and the
grab-handles around the tool.

3 On the mode toolbar, click to display the Machine Tool Position

dialog.

82 • Advanced simulation PowerMILL 2014 R2 What's New

 The dialog displays the position of each machine tool axis.
Displaying the dialog is useful because it enables you to see the
movement of the axes and, in particular, if you move an axis
beyond its limit.

4 Specify the increment values of the rotary axes of the actual

machine tool. This ensures that any adjustments you make to
the virtual machine tool's axes can be achieved by the actual
machine tool.
a On the mode toolbar, click to display the Dynamic machine
control mode dialog, and then select the Axis restrictions tab.
b For both A and B axes, select the Restrict axis option and
specify an increment value of 2.
5 Reconfigure the machine tool's position and tool axis.
a On the mode toolbar, click to display the grab-handles
aligned to the axes of the machine tool.
b Use the grab-handles to reconfigure the machine tool.

PowerMILL 2014 R2 What's New Advanced simulation • 83

 c Click to swap the machine tool's configuration. PowerMILL
improves the machine tool's clearance by adjusting the
configuration of the machine tool (in particular by rotating the
machine head by 180 degrees) but without altering the tool
axis.
d Double-click on various areas of the toolpath to make sure the
new configuration and tool axis do not cause any new
collisions.
6 Click to update the toolpath with the machine tool's new
position and tool axis.
7 The left side of the workpiece requires a similar toolpath. Repeat
step five to achieve a suitable machine tool position and tool
axis.

8 Click to create a workplane aligned with the tool. You can use
this workplane when you create the toolpath for the area.
9 Click to accept the changes.

84 • Advanced simulation PowerMILL 2014 R2 What's New

Toolpath output
NC program updates
There are several updates to NC program functions:
 You can now multi-select NC programs in the explorer in the
same way that you can multi-select other PowerMILL entities. In
previous version you could select only one NC program at a time.
 There is a new option which enables you to draw toolpaths in the
Toolpaths branch of the explorer that are used in an NC program
(see page 85).
 You can now add toolpaths to an NC program multiple times (see
page 86).
 In the NC program dialog, you can now create a new fixture
offset by entering its name in the Fixture offset list.

Drawing toolpaths in an NC program

The introduction of light bulbs next to toolpaths in an NC program
now enables you to choose which toolpaths in an NC program you
want to draw.
When you create an NC program, the toolpaths you add to it are
drawn but the NC program isn't. Click the NC program's light bulb to
draw the NC program and display the toolpaths.

PowerMILL 2014 R2 What's New Toolpath output • 85

 Drawing a toolpath, which is in an undrawn NC program,
automatically draws the NC program, so the toolpath is displayed.

In previous versions of PowerMILL, drawing an NC program

displays all the toolpaths in the NC program and, in the
Toolpaths branch, the lightbulbs next to the those toolpaths
update to .
In PowerMILL 2014R2, to display the toolpaths in the
Toolpaths branch that are included in an NC program, use the
new options on the individual NC program menu:
Draw toolpaths — Click to draw all the toolpaths in the
Toolpaths branch that are included in the NC program.
Undraw toolpaths — Click to undraw all the toolpaths in the
Toolpaths branch that are included in the NC program.

Duplicating toolpaths in an NC program

You can now place a toolpath into an NC program multiple times. In
previous versions of PowerMILL this was not possible.
PowerMILL 2014 R2 allows toolpath duplication by default. When
you write the NC program, PowerMILL displays a message to tell
you that the NC program contains duplicates of a toolpath.
To disallow duplicate toolpaths, deselect the Tools menu > Options >
NC Programs > Allow duplicate toolpaths option.

86 • Toolpath output PowerMILL 2014 R2 What's New

User interface

Positioning a machine tool

The new Machine Tool Position dialog replaces the Machine
Information dialog. The new dialog features a significantly
redesigned user interface that improves the presentation of the
machine-tool-position data and enables you to jog a machine tool
more easily (see page 88).
In previous versions of PowerMILL, the Machine Collisions tab
displayed collision data. In PowerMILL 2014R2, collision data is
displayed on the new Machine Tool Collisions dialog (see page 90).
To display the new dialogs:
 On the Machine Tool toolbar:
 click to display the new Machine Tool Position dialog.
 click the new Collisions button to display the Machine Tool
Collisions dialog.

 In the explorer, right-click the active machine tool and select the
new Collisions and Position options.

PowerMILL 2014 R2 What's New User interface • 87

 The new Machine Tool Position dialog
The new Machine Tool Position dialog includes the following
features:

The axis address (A) and the icon indicates the axis and the axis
type.
Indicates a linear axis.
Indicates a rotary axis
Drag the thumb to jog the axis. The value -90 is the current
position of the axis. The blue line and the values -112 and -58
indicate the furthest points that the axis has been jogged to during
the current simulation session.
You can also jog an axis by:
 clicking the the thumb and then using the mouse scroll-wheel
or arrow keys .
 clicking on a point along the slider.
 entering a value in the Position field (highlighted yellow).

88 • User interface PowerMILL 2014 R2 What's New

 The Min and Max axis values are displayed at either end of the
slider. The values displayed above the Min and Max values indicate
the maximum range you can move the slider in one go.
If the range of the slider is not large enough to jog the axis to its
Min or Max limit in one go:
 Drag the thumb to the end of the slider. PowerMILL displays
the remaining range of the slider, so you can jog the axis to
its Min or Max limit.

PowerMILL displays a warning if you enter an axis position (in

the Position field) that is greater than the axis limit.
Reset attained axis positions — Click to clear the blue lines
which indicate the range of movement of each axis. It is useful to
click before you jog or simulate the machine tool.

Home — Click to reset the position of the machine tool to its

home position.
Collisions — Click to display the new Machine Tool Collisions
dialog. The Machine Tool Collisions dialog displays any collisions that
occur when you simulate or jog the machine tool.

PowerMILL 2014 R2 What's New User interface • 89

 The new Machine Tool Collisions dialog
The new Machine Tool Collisions dialog has the same user interface
as the Machine Collisions tab in previous versions of PowerMILL. To
display the dialog, click on the:
 Machine Tool Toolbar
 Machine Tool Position dialog

90 • User interface PowerMILL 2014 R2 What's New

Automation

Macro programming
The macro programming language has a number of enhancements.
You can now:
 Use commands and functions to create, edit and delete files and
directories.
 Extract data from lists using more succinct expressions.
 Quickly and easily determine the name of active folders.
 Automate a sequence of edits, for example to a number of
template projects.
 Sort lists and arrays of scalars (numerics or strings) or objects
and entities in ascending or descending order.
For more information, see the Macro Programming Guide.

PowerMILL 2014 R2 What's New Automation • 91

General enhancements

Creating custom toolbars

There is an improved process for creating and managing custom
toolbars. In PowerMILL 2014R2 you can also have up to thirty-two
custom toolbars at any time.

Creating and managing custom toolbars

To display the new Customise dialog, from the View menu, select
Toolbar > Custom > Customise.

Create toolbar — Click to create a new toolbar.

The button is unavailable if you reach the maximum number

of thirty-two toolbars then.

Delete toolbar — Click to permanently delete the selected

toolbar(s).

92 • General enhancements PowerMILL 2014 R2 What's New

 Edit selected toolbar — Click to display the Edit Custom Toolbar
dialog. The dialog enables you to add, remove, and edit the buttons
on the selected toolbar (see page 94).

Select all toolbars — Click to select all toolbars.

Deselect all toolbars — Click to deselect all toolbars.

Toggle toolbar selection — Click to switch the toolbar selection so

selected toolbars are deselected and deselected toolbars are
selected.

Display selected toolbar(s) — Click to display the selected

toolbars.

Hide selected toolbar(s) — Click to hide the selected toolbars that

are currently displayed.

Sharing toolbars
PowerMILL 2014R2 has import and export options that enable you
to share custom toolbars:

 The Import toolbar and Export toolbar buttons let you

share toolbars between PowerMILL 2014R2 and future versions
of PowerMILL. The two seats of PowerMILL can be installed on
the same or different PCs.
 The Import from older version and Export to older version
buttons are legacy functions. The functions let you share custom
toolbars between PowerMILL 2014R2 and older versions of
PowerMILL. To share the toolbars, both versions of PowerMILL
must be installed on the same PC.

Import toolbar — Click to import toolbars created by another

PowerMILL user.

Export toolbar — Click to export the selected toolbars so you can

share them with another PowerMILL user.
Import from older version — Click to import custom toolbars
created in a previous version of PowerMILL.
Export to older version — Click to export custom toolbars to use
in an older version of PowerMILL.

The appearance and behaviour of a toolbar does not change

when you import or export it to a different version.

The legacy options are temporary.

PowerMILL 2014 R2 What's New General enhancements • 93

 Adding buttons to toolbars
The old Customise dialog features an updated design and is now
called the Edit Custom toolbar dialog.

94 • General enhancements PowerMILL 2014 R2 What's New

Index

Stop at discontinuity • 12
Surface marker • 3
A Composite curve creator options • 31
Adding hole components • 63 Composite curve direction toolbar • 12
Automatic generation of composite Composite curve jump confirmation • 15
curves • 20 Composite curves from poor wireframe
Axis restrictions • 78 geometry • 24
Composite curves from surfaces • 17
Composite curves from wireframe
B geometry • 22
Compound holes • 36
Boundary editing history • 64 Adding hole components • 63
Branch point direction • 31 Combine holes • 60
Creating and editing compound holes
• 55
C Drilling hole components • 71
Combine holes • 60 Hole components in gaps • 63
Composite curve creator • 3 Separate compound holes • 60
Automatic generation of composite Create holes • 36
curves • 20 Creating custom toolbars • 92
Composite curve direction toolbar • Curve creator • 3
12 Curve direction • 3
Composite curve jump confirmation • Curve discontinuity • 3
15 Curve jump confirmation • 15
Composite curves from poor Curves from surface edges • 17
wireframe geometry • 24
Composite curves from surfaces • 17
Composite curves from wireframe D
geometry • 22 Discontinuity angle • 31
Curve creator • 3 Drawing toolpaths in an NC program •
Curve direction • 3 85
Curve discontinuity • 3 Drilling
Curve jump confirmation • 15 Drilling hole components • 71
Curves from surface edges • 17 Duplicating toolpaths in an NC program
Jump confirmation • 15 • 86
Marker points • 3, 27 Dynamic machine control • 72, 76, 78
Selecting curves to create a Axis restrictions • 78
composite curve • 8 Dynamic machine control dialog • 78

PowerMILL 2014 R2 What's New Index • 95

 Dynamic machine control toolbar • 76 Hole direction • 63
Example • 82 Hole intersections • 58
Hole surfaces • 63
Select hole • 59
E Separate compound holes • 60
Edit holes • 44
Creating and editing compound holes
• 55
I
Edit hole geometry • 45 Interactive repositioning of machine
Edit hole properties • 57 tools • 72, 74
Editing automatically identified holes •
50
Hole intersections • 58 J
Editing automatically identified holes • Jump confirmation • 15
50

F M
Machine tool axis configuration • 72
Feature set enhancements • 59 Machine tool position dialog • 87
Repositioning 3+2-axis machine tools
• 72
G Macro programming • 91
Gap jumping multiplier • 31 Marker points • 3, 27

H N
History NC programs
Boundary editing history • 64 Drawing toolpaths in an NC program •
Hole components in gaps • 63 85
Hole creation • 36 Duplicating toolpaths in an NC
Hole creation from a model • 40 program • 86
Hole creation options • 63 General updates • 85
Hole direction • 63
Hole intersections • 58
Hole surfaces • 63 O
Holes Options • 31
Adding hole components • 63 Branch point direction • 31
Combine holes • 60 Composite curve creator options • 31
Create holes • 36 Discontinuity angle • 31
Creating and editing compound holes Gap jumping multiplier • 31
• 55 Options • 31
Edit holes • 44
Editing automatically identified holes •
50 P
Hole components in gaps • 63
Hole creation • 36 Positioning a machine tool • 87
Hole creation from a model • 40
Hole creation options • 63

96 • Index PowerMILL 2014 R2 What's New

R
Repositioning 3+2-axis machine tools •
72
Axis restrictions • 78
Machine tool position dialog • 87

S
Selecting curves to create a composite
curve • 8
Separate compound holes • 60
Simulating machine tool configuration •
72
Stock
Tool stock material • 68
Stop at discontinuity • 12
Surface marker • 3

T
Tool stock material • 68
Toolbar
Custom toolbars • 92
Dynamic machine control toolbar • 76

PowerMILL 2014 R2 What's New Index • 97

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