instructables classes

POWERMILL CLASS
3 Lessons Beginner Level

PowerMill provides comprehensive milling strategies for high-speed and 5-axis machining,
providing you with the tools you need for manufacturing molds, dies, and highly complex parts. In
this class, we will take a look at using PowerMill to program a variety of different milling parts.
While this class is meant to familiarize you with the details of programming parts in PowerMill, the
main objective of this class is to teach you the workflow of programming parts in PowerMill.
Focusing on the workflow as opposed to specific tools and details in the software will ensure the
smoothest possible transition between programming parts in this class, and confidently taking
what you've learned into your own shop.
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more about what PowerMill has to offer, visit our PowerMill website for more details.

Class Author:
Autodesk Make
Autodesk helps people imagine, design and create a better world. Everyone -- from design professionals, engineers and
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challenges.

PowerMill Class: Page 1

 Lessons

Lesson 1: Introduction to Milling

In this lesson, we will take an introductory look at programming parts
using PowerMill's traditional roughing and finishing strategies.

Lesson 2: Intermediate Milling

In this lesson, we will take a deeper look at PowerMill's traditional
roughing and finishing strategies, while also introducing 2.5D
machining in PowerMill.

Lesson 3: Introduction to 5-Axis Milling

In this lesson, we will take an introductory look at programming 5-axis
part in PowerMill, all while reviewing the information covered up to this
point in the class.

PowerMill Class: Page 2

 LESSON 1: INTRODUCTION TO MILLING

In this first lesson, we will program a basic part utilizing PowerMill's traditional machining
strategies. However, before we dive into our first part, we will first take a look at the
workflow of programming parts in PowerMill. Whether you are programming the parts in
this class, or your own parts in your shop, this worflow will help guide you through the
programming of any part in PowerMill.

https://vimeo.com/238436140

PowerMill Class: Page 3

Introduction to the Workflow

Whether you are new to PowerMill, or manufacturing in general, this class will help you
build a solid foundation in PowerMill by focusing on the fundamental workflow of
PowerMill. While each part we program in this class will differ, the workflow we follow to
program them will always remain the same. At the end of this class, you will be able to
utilize the workflow outlined in this class to tackle any project you may encounter in your
shop. Whether you are working on a basic training part from this class, or a complex 5-axis
aerospace or mold part in your shop, you can approach the programming process for each
part with this same basic workflow to help ensure you part is programmed as safely and
efficiently as possible.
Setup: Import your own model, and prepare your part for programming.

Tool: Create a tool to be used in a given machining strategy.

Toolpath Strategy: Indicate a strategy to be used to machine your model's surfaces.

Settings: Customize both cutting and non-cutting portions of the newly created toolpath.

Verify/Simulate: Visualize the machining of your part, while ensuring that the program is safe to
run.

Revise: Make any necessary changes to the toolpath based on verification/simulation results.

NC Code: Generate the code required to physically machine you part.

https://vimeo.com/238436174

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Setup

Open PowerMill, import instructables model into PowerMill

We need to create a block to machine our part from.

Select the block option from the home tab
Calculate the block size and apply

Calculate the toolpath safe area:

Open the toolpath connections dialog from the home tab
Select calculate on the right-hand side of the dialog box for safe area
Apply the changes and close the dialog

With our model imported, block set up, and toolpath connections calculated, we are ready
to begin programming!
Download
http://staging.instructables.com/ORIG/FNA/3O4H/J6CG7L56/FNA3O4HJ6CG7L56.dgk
…

https://vimeo.com/238436192

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Roughing

Video 3: Roughing
First, we’ll create a tool for the roughing pass
Create a Tip Radiused Tool
Length: 40 mm
Diameter: 12 mm
Tip Radius: 1 mm
Name the tool D12TR1 and close the tool dialog

Now that we have our tool for the roughing pass, we can create the necessary toolpath
Create a Model Area Clearance strategy and name it D12TR1-RGH
Offset Model
Thickness: 0.5 mm
Stepover: 5 mm
Stepdown: 5 mm

Calculate the Toolpath

Run a ViewMill simulation of the roughing pass.

Right click on D12TR1-RGH and select simulate from start. Click the red circle in
the ViewMill section of the simulation ribbon to turn on ViewMill.
Click the play button to run the simulation

With our model roughed, we are ready to finish programming the model by adding a
finishing pass.

https://vimeo.com/238436204

Finishing
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To get our part to have a clean finish, we will run a finishing pass across the block.
First, we’ll need to create the necessary tooling:
Create a ball nosed end mill for finishing the part
Diameter: 8 mm
Length: 30 mm

Name the tool BN8 and close tool dialog

Activate the tool

Now we’ll create the finishing toolpath using our ball nosed end mill.
Create a Raster finishing strategy and name it BN8-FIN
Tolerance: 0.02 mm
Stepover: 0.5 mm

Calculate and close the dialog

Run a ViewMill simulation for the finishing pass.

Right click on BN8-FIN and select simulate from start.
Click the play button to run the simulation

A warning pops up about a possible gouge when the tool approaches the boss.
We can add a radial clearance in the toolpath connections dialog
Moves and Clearances
Radial Clearance: 5 mm
Apply and accept the dialog

Run another ViewMill simulation of the revised finishing pass.

The model looks mostly finished after our finishing strategy, but some of the faces don’t
quite seem to be up to par. It would appear to make sense to add another pass that runs
perpendicular to our toolpath. Luckily, we can do that within our raster finishing strategy.
Add a perpendicular pass into the toolpath BN8-FIN
Right click on the toolpath in the explorer and select settings
Click the recycle button in the upper left corner
Check the Perpendicular Pass option in the raster finishing section
Recalculate the toolpath

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 Run a new ViewMill simulation for our updated toolpath

The finish now appears uniform across our model. Feel free to experiment with the settings
in the finishing toolpath to learn more about what every command does. Through
experimentation of these settings you will quickly see how much control PowerMill gives us
over the toolpath.

https://vimeo.com/238436216

NC Code

Our toolpaths have been simulated and appear successful, so now it’s time for us to
generate the NC code.
Right click on NC programs in the explorer and select Create NC Program
Give the program an appropriate name

Right click on NC programs in the explorer and select Preferences

Select the desired postprocessor for our NC code

Drag all toolpaths into the program and run a full simulation.
Right click on the program
Simulate from Start

Generate NC code by simply right clicking on the program and selecting Write.

Note: This exercise is for educational purposes. While this exercise outlines the process of
generating your NC Code, no actual code is to be generated as a part of this class.

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 LESSON 2: INTERMEDIATE MILLING

In this second lesson, we will take a deeper look at some of PowerMill's traditional
roughing and finishing strategies, while also exploring the world of 2.5D milling in
PowerMill. While this part differs in many ways from the last, we will continue to utilize the
same workflow to systematically approach the programming of this part.

https://vimeo.com/238437930

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Setup

Open PowerMill, and drag and drop model into the graphics area
Model file will need to convert

We need a new workplane to help us machine this part.

Box select the entire model

Select the Create Workplane drop down menu from the home tab
Select the Top of Selection Workplane
Activate the new workplane and name it Top

We need to create a block to machine our part from.

Select the block option from the home tab
Calculate the block size
Expand the block 5 mm in the z-direction
Lock the x and y minimum and maximum values
Lock the z minimum value
Enter an expansion of 5 and recalculate the block

Accept the dialog box

Let’s calculate the safe area for our tooling.

Open the toolpath connections dialog from the home tab
Select calculate on the right-hand side of the dialog box in the safe tab
Apply the changes and close the dialog

Now that our setup is complete, we are ready to begin creating tools and toolpaths to
program our model!
http://staging.instructables.comhttps://app4.instructables.com:8080/files/orig/FIF/31Z1/J8UH1U5R/FIF31Z1J8UH1U5R.x_t

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 Download
http://staging.instructables.com/ORIG/FXN/RBFW/J8YRFL0U/FXNRBFWJ8YRFL0U.zip
…

https://vimeo.com/238437951

Roughing

First, we’ll need to create a roughing tool for the first roughing pass.
Create a Tip Radiused Tool
Diameter: 25 mm
Tip Radius: 2 mm
Length: 35 mm
Add appropriate shank by selecting the shank tab and pressing the add shank
button
Name the tool D25TR2 and close the tool dialog

Now that we have our tool for the first roughing pass, we can create the necessary
toolpath.
Create a Model Area Clearance strategy and name it D25TR2-RGH1
Offset all
Stepover: 10 mm
Stepdown: 8 mm
Lead in: select Ramp for the first choice
Ramp Options:
Follow the toolpath
Max zig angle: 4
Circle diameter: 0.65 TDU
Click accept

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 Lead out: same as lead in
Calculate the toolpath

Run a ViewMill simulation of the roughing strategy.

Right click on D25TR2-RGH1 and select simulate from start. Click the red circle
in the ViewMill section of the simulation ribbon to turn on ViewMill.
Click the play button to run the simulation

After the simulation has completed, select the store button in the ViewMill section to store this
snapshot of the machining process for later

Mode
No Image

If the first roughing pass looks good, let’s move onto the second roughing pass.

https://vimeo.com/238437978

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Rest Roughing

We’ll need to create a smaller roughing tool for the second roughing pass.
Create an End Mill
Diameter: 15 mm
Add appropriate shank
Name the tool EM15 and close the tool dialog

Now that we have our tool for the rest roughing pass, we can create the necessary
toolpath.
Create a Model Rest Area Clearance strategy and name it EM15-REST-RGH
Offset all
Thickness: 1 mm
Stepover: 5 mm
Stepdown: 5 mm
Rest
Rest machining: toolpath
D25TR2-RGH1

Detect material thicker than: 0.333 mm

Calculate the toolpath

Perform a ViewMill simulation for our second roughing pass.

Right click on EM15-REST-RGH and select simulate from start. Change the
mode in ViewMill to rotatable and click restore.
Click the play button to run the simulation

After the simulation has completed, select the store button in the ViewMill section to store this
snapshot of the machining process for later

Mode
No Image

Now that our part is properly roughed, it’s time to focus on finishing the part.

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 https://vimeo.com/238437998

Finishing

In order to get our part to have a clean finish, we can run a finishing pass across the block.
First, we’ll need to create the necessary tooling:
Create a ball nosed end mill for finishing the part
Diameter:8 mm
Length: 35 mm
Add an appropriate shank
Name the tool BN8 and close tool dialog

Now let’s create a finishing toolpath using our ball nosed end mill.
Create a Steep and Shallow finishing strategy and name it BN8-FIN
Check the spiral option for shallow
Stepdown: .5 mm
Stepover: .5 mm
Tolerance: 0.1 mm
Go to the limits section in the local explorer
Check the z minimum value
Click the icon left of the text box and select the top edge of the pocket

Calculate and close the dialog

Let’s run a simulation of the finishing toolpath.

Right click on BN8-FIN and select simulate from start. Change the mode in ViewMill to
rotatable and click restore
Click the play button to run the simulation.

NOTE: this simulation takes a long period of time. Once you feel you’ve seen enough of
the simulation, you may pause it. DO NOT STORE the simulation once you have stopped
it.
Machining around the pockets and machining the holes took a significant amount of time;
we can edit these to shorten the machining time.
Let’s revise the toolpath to hopefully make it more efficient.
Right click on the toolpath BN8-FIN and select settings

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 Select the recycle button to enable editing
Go to the limits section
Lower the z minimum to -36.42 (0.15 less than the previous)

Recalculate the toolpath

Notice how the toolpath around the pockets is less complicated; this will shorten the time.
Now we can address the holes.
Hide the Leads and Links by selecting the toolpath tab on the top ribbon and deselecting leads
and links

Hide the block and model, so that only the toolpath is visible

Select the portions of toolpath that would be machining the holes by viewing the model from
the top

Right click on the selected portion, then select edit then delete selected components

The toolpath will now look like this:

Now that we have successfully revised our toolpath, we can run another ViewMill
simulation.
Click the simulation tab

In the ViewMill section, change the mode to rotatable and select restore to return the block to
after the second roughing pass

Right click on BN8-FIN and select simulate from start

Play the simulation and once complete, store the new block and change the mode to no image

The new simulation was significantly shorter than our initial one, which shows that editing
toolpaths in PowerMill can be very effective.

https://vimeo.com/238438020

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2.5D Machining - Holes

We’ll start with drilling the holes on the corners. We will perform both a center drilling and a
drilling operation.
In the global explorer, right click on hole feature sets and select create holes=
Name the feature set: HOLES
Keep the default Create From option: model
Check only Use Active Workplane Only
Check Find Holes Going Down
Box select the entire model
Click apply and close the dialog

First, we need to create a tool for the center drilling process.

Create a spot drill that has a larger diameter than the holes
Diameter: 10 mm
Length: 25 mm
Taper Angle: 45
Add an appropriate shank
Name the tool SD10

Now we can create the toolpath for our center drilling operation.
From the toolpath strategies dialog box, select drilling, and then select single peck and click ok
Name the toolpath SPOTDRILL
Operation: Centre Drill
Depth: 4 mm
Leave all else as default
Click the select button at the bottom of the window
Click the 8 mm diameter from the left textbox and press the right
arrow between the textboxes
Click select at the bottom of the feature selection dialog and close the
dialog

Calculate the toolpath and close the dialog box

Next, try simulating the toolpath on your own using the ViewMill option. Remember, you can
always go back and review the simulation process.

Now, we’ll create the tool for the final drilling operation.
Create a drill with the same diameter as the holes
Diameter: 8 mm
Add an appropriate shank

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 Name the tool DRILL8

Let’s create the final drilling toolpath by cloning the previous toolpath.Right click the spot
drilling operation and open the settings.
Clone the toolpath (symbol next to recycle button).
Name: BREAKCHIP
Tool: DRILL8
Cycle type: Break chip
Operation: Through Hole
Peck Depth: 5 mm
Check the select window again to ensure only the holes are selected

Calculate the toolpath and close the dialog

Repeat the simulation process you followed with the center drilling process. The block
should appear like this after the holes have been drilled:

With our drilling of the holes complete, all we have left is machining the two pockets on our
part.

https://vimeo.com/238438052

2.5D Machining - Pockets

Now we’ll create the pockets features.

Select the feature group tab in the top ribbon

In the detect section, select the features button

Mode: single
Hover over each pocket and select both by clicking
Once both pockets are selected, click accept to create the feature group

Right click on the new feature group in the explorer, and select rename
Name: POCKETS

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Next, we’ll create a tool that can rough out the pockets.
Create an endmill smaller than the corner radii in the pockets
Diameter: 6 mm
Add an appropriate shank
Name the tool EM6

Now we’ll use a new type of toolpath to machine the pockets, starting with the roughing
phase
Enter the toolpath strategies dialog and select Feature Machining and then select Feature
Pocket Area Clearance
Name the process RGH-POCKETS
Stepover: 2 mm
Stepdown: 3 mm
Clicking the icon in the thickness section causes another text book to open. On
the left, you have the radial thickness and on the right, you have the axial
thickness
Limits:
Leave the axial thickness as 0, thus we’re finishing the bottom with
our roughing pass.
Uncheck z minimum so that the entire pocket will be programmed

Calculate and close the dialog.

We can see that the toolpath ramps in from an unnecessary height. We can revise our
toolpath.
Right click on RGH-POCKETS and select settings
Click the recycle symbol to enable editing
Limits:
Z maximum: click the top of a corner

Recalculate the toolpath

Run a ViewMill simulation of the roughing toolpath

It’s time to finish the pockets and ultimately finish our part!
We’re going to use the same tool that we used for roughing for the finishing pass.
Create a new toolpath. Select the Feature Machining option then select Feature Pocket Profile.
Name the toolpath FIN_POCKETS.
Tolerance: 0.01 mm
Radial and axial thickness: 0 mm

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 Stepdown: 5 mm
Limits:
These will remain the same as our roughing pass
Calculate the toolpath and close the dialog.

Once again, simulate this toolpath using the ViewMill feature.

Because we’ve finished the part, you could run a simulation of each toolpath in order to
ensure the part will be machined correctly.

Now, with all of your toolpath created, we're ready to generate our NC code!

https://vimeo.com/238438071

NC Code

Our toolpaths have been simulated and appear successful, so now it’s time for us to
generate the NC code.
Right click on NC programs in the explorer and select Create NC Program
Give the program an appropriate name

Right click on NC programs in the explorer and select Preferences

Select the desired postprocessor for our NC code

Drag all toolpaths into the program and run a full simulation.
Right click on the program
Simulate from Start

Generate NC code by simply right clicking on the program and selecting Write.

Note: This exercise is for educational purposes. While this exercise outlines the process of
generating your NC Code, no actual code is to be generated as a part of this class.

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 LESSON 3: INTRODUCTION TO 5-AXIS MILLING

In this third and final lesson, we will take our first look at 5-axis milling in PowerMill. This
lesson will serve as a introduction to 5-axis simultaneous and 3+2 milling in PowerMill, as
well as a review of the topics covered in the previous two lessons. As always, we will use
PowerMill's fundamental workflow to help guide us through the programming of this part.

https://vimeo.com/238439364

PowerMill Class: Page 20

Setup

Open PowerMill, and drag and drop model file into the graphics area
Model file will need to convert

We need a new workplane to help us machine this part.

Box select the entire model

Select the Create Workplane drop down menu from the home tab
Select the Top of Selection Workplane

Activate the new workplane and name it Top

We need to create a block to machine our part from.

Select the block option from the home tab
Calculate the block size
Coordinate System: Named Workplane
Top

Accept the dialog box

Let’s calculate the safe area for our tooling.

Open the toolpath connections dialog from the home tab
Select calculate on the right-hand side of the dialog box in the safe tab
Apply the changes and close the dialog

Now that our setup is complete, we are ready to begin creating tools and toolpaths to
program our model!
http://staging.instructables.comhttps://app4.instructables.com:8080/files/orig/FID/7KTT/J8UGZ960/FID7KTTJ8UGZ960.x_t

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 Download
http://staging.instructables.com/ORIG/FIT/AOXW/J8YRFKZF/FITAOXWJ8YRFKZF.zip
…

https://vimeo.com/238439376

Basics Review

Now we need a tool rough our model with.

Create an tip radiused tool
Diameter: 20 mm
Tip radius: 1 mm
Length: 40 mm
Add appropriate shank

We need to add a holder because this model will involve 5 axis processes
Holder tab, add holder
Upper diameter: 30 mm
Lower diameter: 25 mm
Length: 10 mm
Overhang: 50 mm

Add another holder:

Lower/Upper diameter: 30 mm
Length: 30 mm

Name the tool D20TR1 and close the tool dialog

Let’s add the necessary toolpath.

In the 3D Area Clearance tab, select Model Area Clearance

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 Name: D20TR1-RGH
Offset Model
Tolerance: 0.1 mm
Radial thickness: 1 mm
Axial thickness: 0 mm
Stepover: 5 mm
Stepdown: 5 mm
Lead in/out: Ramp
Calculate the toolpath

Let’s verify the toolpath because this will be necessary when we have the tool at
orientations other than vertical.
Right click on the toolpath and select verify then toolpath
Check for gouges first, select apply
If no gouges, select collisions
Holder clearance: 2 mm
Shank clearance: 1 mm

If no gouges or collisions occur, the symbol next to the toolpath in the explorer should now
appear as a blue checkmark.

Now we can move onto the finishing strategy for the top pocket. First, we’ll need to create
a pocket feature.
Use the detect feature to create a pocket feature and name it ‘TopPocket.’

Let’s create a tool to finish our top pocket.

Create an end mill
Diameter: 10
Length: 40
Add appropriate shank and holder
Name the tool EM.5 and close the tool dialog

Now we can choose our finishing strategy.

Select a Feature Pocket Profile strategy and name the strategy EM10-FIN-TopPocket
Tolerance: 0.01 mm
Thickness: 0 mm
Stepdown: 7 mm
Lead in/out: surface normal arc
Angle: 90
Radius: 5 mm

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 Calculate the toolpath

Verify the toolpath as we did before, then run a ViewMill simulation.

https://vimeo.com/238439404

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Swarf Finishing

Swarf finishing maintains contact between the cutting portion of a tool and any continuous
surfaces that need to be finished. We will perform this strategy on the wall of the boss
feature and the sloped surface.
For the tooling for our swarf strategies, we will use the EM10 tool that we already created.
Activate EM10

With our tool selected, now we can create our Swarf Finishing toolpath
Select the Swarf Finishing strategy from the Toolpath Strategy Dialog
Give the toolpath a descriptive name like EM10-SWARF-wall
Leave all options as default.
Select the surfaces that make up the wall around the boss.
Calculate the toolpath.

Verify the swarfing toolpath and run a ViewMill simulation.

NOTE: slow the simulation down, as swarfing toolpaths are often very short.
Repeat the same strategy as above for the sloped surface of the boss and name the
toolpath EM.5-SWARF-slope. Once we attempt to simulate, we will immediately get a
warning popup due to a possible rapiding of the tool into the part. We can revise this by
editing the settings of our new swarf toolpath.
Open the toolpath settings for EM10-SWARF-slope
Rapid Moves:
Type: Sphere
Center: (0,0,-28.575)
Calculate

Swarf Finishing
Position
Offset: -1.25 mm

After recalculating the toolpath, we can verify and simulate the second swarfing strategy.
As you can see, the tool axis is automatically adjusted to swarf the necessary surfaces.

Now that our swarfing processes are finished, we can move onto programming the
pockets.

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 https://vimeo.com/238439421

3+2 Machining

This is where we will need to incorporate techniques for 3+2 programming. From an ISO 1
view, we will program the pocket that is visible first. We won’t be able to machine the entire
pocket with a vertical tool axis, so we need to create a new workplane that has its z-axis
perpendicular to the floor of the pocket.
Create a new workplane using the Workplane Aligned to Geometry option
Pin the workplane to the bottom of the pocket
Location isn’t important as long as the z-axis is perpendicular to the
bottom

Name the workplane Pocket1

Create a pocket feature for the first pocket that we’ll be programming using the same process
from previous videos and name it SidePocket1.

Because we have a new workplane, we need to change our safe area or we could gouge
the model.
Go into the toolpath connections, and recalculate the safe area after changing the workplane
to Pocket1.

Create a stock model representing all of our previous toolpaths

Create a stock model by right clicking stock model and selecting create stock model.
Accept the default values for the stock model

Drag all toolpaths into the stock model then right click the stock model and calculate

Edit the view of the stock model

Right click and select drawing options
Shaded
Show rest material

PowerMill Class: Page 26

Create a tool for roughing out the pocket.
Create an end mill
Diameter: 6 mm
Add appropriate shank and holder
This is especially important for this process as it isn’t a vertical tool
axis

Name the tool EM6 and close the tool dialog

Create a roughing strategy for the pocket.

Select the Feature Pocket Rest Area Clearance strategy and name it EM6-RGH-Pocket1
Offset Model
Tolerance: 0.1 mm
Radial thickness: 1 mm
Axial thickness: 0 mm
Stepover: 2 mm
Stepdown: 3 mm
Go into the workplane section and select Pocket1
Rest: Stock model
1
EM10-SWARF-slope

Lead in/out: ramp with height of 2.5 mm

Calculate the toolpath.

Verify the roughing strategy and then perform a ViewMill simulation. Once everything appears
in order, let’s move onto finishing the pocket.

We will use the EM6 tool again for our finishing pass.
Create an appropriate toolpath for the finishing strategy.
Select a Feature Pocket Profile strategy and name it EM6-FIN-Pocket1
Tolerance: 0.01 mm (ignore the warning)
Radial and Axial thickness: 0 mm
Stepdown: 10 mm
Lead in/out: Vertical arc
Angle: 90
Radius: 5 mm

Calculate the toolpath

PowerMill Class: Page 27

 Verify that our finishing pass will be error free and then perform the appropriate simulation.
If everything looks good, try to program the second pocket on your own. If you ever get
stuck, simply review that process used for the first pocket.

Once the second pocket has been finished, we can move onto the NC code.

https://vimeo.com/238439441

NC Code

Our toolpaths have been simulated and appear successful, so now it’s time for us to
generate the NC code.
Right click on NC programs in the explorer and select Create NC Program
Give the program an appropriate name

Right click on NC programs in the explorer and select Preferences

Select the desired postprocessor for our NC code

Drag all toolpaths into the program and run a full simulation.
Right click on the program
Simulate from Start

Generate NC code by simply right clicking on the program and selecting Write.

Note: This exercise is for educational purposes. While this exercise outlines the process of
generating your NC Code, no actual code is to be generated as a part of this class.

PowerMill Class: Page 28