PowerMILL

12. Patterns

12. Patterns
Introduction.
Patterns are specific 2D or 3D wireframe entities mainly used as the basis for toolpath creation. A Pattern is either projected onto the model or traced in situ using Pattern Finishing. Other useful applications include controlling the shape of 3D Offset Finishing strategies, and as the medium for taking wireframes in and out of the PS-Sketcher (PowerSHAPE wireframe constructor). Unlike Boundaries, Patterns can contain open segments.

Select Delete All and Reset Forms. Right click Patterns from the explorer and select Toolbar.

Select the Create pattern icon and this generates an empty Pattern named 1, into which the user can insert geometry.
When created the Pattern is automatically numbered and made Active as shown in the Explorer (left).

A Pattern can be created using the following options: Automatic Pattern generation (Open the Pattern Maker form). Insert file into active pattern (picture or dgk file). Insert boundary into active pattern. Insert active toolpath into active pattern. Insert selected model into active pattern (Selected Model). Insert a sketch into active pattern. Insert a sketch from PS-Sketcher.

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12. Patterns Patterns applied to 3D Offset machining

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A Pattern can be used as the specified shape to be offset across the machining area of a 3D Offset Finishing strategy allowing tailoring of the toolpath. The following exercise involves the creation of a Selected Surface Boundary on part of the model and a Pattern is then created along the one of the edges to be use in conjunction with 3D Offset Finishing.

Open the example, model speaker.dgk and select an Iso3 view. Define a 6 Ball Nose called bn6. Define a block to Min/Max limits and reset the Safe Heights and Tool Start Point. Select the 3 surfaces shown shaded in the following diagram.

Create a Selected Surfaces Boundary to a Tolerance of 0.02.

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From the Pattern toolbar click the Create Pattern icon the Insert Boundary into active pattern icon .

followed by

Undraw both the model and Boundary to visually isolate the Pattern.

Only the leading edge of the Pattern is required. The remaining parts are to be removed.

Select the single Pattern, segment by dragging a box around it. Right click on Pattern 1 in the Explorer and select Edit Split Selected (The Pattern is now divided into many small, individual segments). Select and delete the top and side segments of the profile to leave the bottom, leading edge.

On closer inspection it is evident that the remaining Pattern still consists of many small segments. It is now necessary to Merge all of these back into one.

Drag a window around the Pattern to select it. From the pattern 1 in the Explorer select Edit -> Merge.

PowerMILL confirms that it has merged the Pattern into one segment.

Select OK on the form and redraw the model.

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Select a 3D Offset Finishing strategy and enter data into the form exactly as shown below.

At the moment the toolpath contains a lot of movement in fresh air. To reduce the amount of lift moves the Links need to be forced to be On Surface.

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Select the Lead and Links icon . Select the Links tab and put the short links On surface and Apply.

The toolpath follows the contour of the Pattern across the Boundary limits.

If Use Pattern had not been ticked the 3D Offset strategy would have followed the shape of the Boundary segment as shown left.

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12. Patterns Automatic Pattern Generation

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The Automatic Pattern Generation icon opens the Pattern Maker form. This provides a series of 6 specialized options allowing the user to create 4 different types of Offset Patterns between 2 open segments, an Offset Pattern inside a closed segment, as well as a Trochoidal Pattern across a segment.

Delete all and Reset forms. Open the Example model speaker_core.dgk. Calculate the Block to model limits. Define a diameter 6mm Ball Nose tool named bn6. Reset Safe Heights and Start Point. Select an Iso2 to display the model in the orientation shown below.

Be careful not to select any other surrounding surfaces not required for this exercise. Hold down the Shift key for multi select and the Ctrl key to deselect surfaces.

In the Patterns toolbar select the icon Create Pattern

followed by

. select Insert model into active pattern With the above surfaces still selected create a Selected Surface Boundary with the box labeled Roll Over, ticked. Undraw the model and Boundary leaving a view of the new Pattern on its own in the graphics window.

The edges of the surfaces are captured and a Pattern is created. The Pattern must be Split into small geometric segments to enable the deletion of the unwanted sections while retaining the 2 sides (arrowed).

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Select the Pattern by Dragging a window over it, right click over Pattern 1 in the explorer, and in the menu select Edit -> Split Selected. Delete the top and bottom straight segments to leave the two side sections.

The two remaining profiles still consist of many small segments are now Merged to form two.

Right mouse click on the Pattern in the explorer or in the graphics area to open the local menu and select Edit -> Merge.

A form will appear, similar to this one, informing the user that the Pattern has been merged as two separate open curves.

Select OK to close the dialogue.

The next step will be to ensure that the direction of each segment is the same. This is important when using Automatic pattern Generation later in the exercise.

Drag a window around both segments in the graphics area, right click over the Pattern in the Explorer, and select Instrument (displays segment directions).

It is now noticeable that the two segments are travelling in opposite directions. This segment will be reversed.

Select the segment (arrowed) above with the mouse, right click over the Pattern, and select Edit -> Reverse Selected.

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The segments now travel in the same direction and as a result are now suitable for use with Automatic Pattern Generation.

Select them both again and select Instrument again (Switch off display segment directions). Select both of the above Pattern segments. From the Pattern toolbar select the icon Create Pattern the Automatic pattern generation icon . followed by

The form allows you to create various styles of automatic Pattern.

As shown in the above diagram select the option for Create pattern along curves, two way and input a Stepover value of 1. Apply and Accept the form.
The new Pattern has been generated between the two selected segments of the original, de-activated Pattern.

Select a Pattern Finishing strategy.

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Enter the settings in the form exactly as shown (including Keep Inside Boundary 1) then Apply and Cancel the form. Undraw the model and Pattern1 to view the toolpath.

The Pattern Finishing, toolpath is created and limited to the inside of the Selected Surface Boundary created earlier. The Short Links are set to Safe Z at present but would benefit from being changed to On Surface to reduce the machining time.

Open the Leads and Links form and select the Links tab. Set the Short Links to be On Surface. Apply and Accept the form.

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The amount of lifts has been dramatically reduced.

Below is a diagram of an alternative toolpath running along the shut off face in a one-way, Climb Milling direction. It starts at the bottom and works its way up the shut off face. This strategy is more typical of a High Speed Machining application.

By Utilising the same 2 Pattern, segments used in the previous example apply the Automatic Pattern Generator to create the alternative Pattern Finishing strategy described in the above pargraph.

Use these two straight segments to produce this toolpath shown with the Links undrawn.

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Trochoidal Pattern Generator

The Trochoidal Pattern option within the Automatic Pattern Maker form is a technique for machining slots especially in High Speed Machining applications. The Trochoidal Pattern consists of a continuous spiral of advancing loops which have the effect of restricting the tool contact area to only a part of its circumference. This method creates the need to use a tool diameter that is smaller than the slot to be machined. The CNC controller then performs spiral movements to mimic the full width tool. Since the tool is no longer cutting at full width the problem of overheating is effectively removed. (particularly important for coated solid carbide cutters used in High Speed Machining).

Delete All, Reset Forms, and Import the Examples model dashboard.dgk.
This slot to be machined using the Trochoidal Pattern method.

Define the Block to Min/Max limits. Create a new Pattern and use insert file into active pattern input the file \PowerMILL_DATA\Patterns\trochoidal_pattern.pic. to

Before the slot can be produced a Helically drilled hole of diameter 8mm will be machined to create clearance for a slot drill to plunge down to the full slot depth. This can be achieved using Feature Sets. (Covered in more detail in the next chapter.)

Define a Ball Nose cutter of 6mm diameter. Right click over Feature Sets in the Explorer and select Create Feature Set to open the Feature Form. Select the curved Pattern (1st click) and end point (2nd click).

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Fill in the Feature Form exactly as shown below (Create tab selected).

A new Feature will be created that represents the hole ready for the helical drilling.

Apply and Close the form. Select the Toolpath Strategies icon on the Main toolbar. Select the Drilling icon then OK to open the Drilling form.

Before the toolpath can be calculated, the Hole Feature must first be selected.

Click on the Select button.

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Click on the Diameter 8.5 on the left of the form. Click the Select Button and Close the form.

Fill in the form with the values shown then Apply and Close the form.

It is noticeable on animation that the tool is Climb Milling in an anti-clockwise direction. The 8.5mm Diameter hole has now provided the clearance necessary for a smaller tool to plunge into the slot prior to the Trochoidal milling operation.

Note: Feature Sets are not gouge checked to a Surface model so care must be taken when creating them with regard to both size and position.

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Create an End Mill of diameter 6mm called em6. Deactivate Pattern 1 (trochoid_curve), but keep it displayed. (Toggle the lightbulb; the Pattern will be displayed green). Create another empty Pattern (2). Select the curved Pattern (1) with the mouse then click on the Automatic pattern generation icon .

Fill in the form as shown then Apply and Accept.

Note: The Radius must not be a value greater than half the Width. A fine Stepover is required when applying to High Speed Machining of hardened steel.

If the Radius value used in the Pattern Maker form were 2.5 the resultant Pattern would appear as shown to the left.

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Select the Toolpath Strategies icon on the Main toolbar then select the Pattern Finishing strategy to open up the following form

Fill in the form exactly as shown. Apply and Cancel the form.

The 6mm end mill tool will plunge into the previously created 8.5mm clearance hole. The Trochoidal toolpath defaults to a Climb Mill direction and is ideally suited to High Speed Machining applications.

Activate toolpath 1 (drilling) in the Explorer.

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Open the Block form.

Fill in the form exactly as shown to create a Block definition locally along the back half the slot width. Accept the form.

Position the Block in the graphics area in preparation for toggling into Viewmill. Select the Raise ViewMILL Toolbar icon. Select the Toggle ViewMILL Window icon. Check both the Helical and Trochoidal toolpaths in turn with ViewMILL.

Helical drill toolpath.

Trochoidal mill toolpath.

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