Acu-Rite Control System MILLPWRG2 User Manual

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8.2 Additional Milling Functions
Reverse step
The reverse step feature instantly switches the From and To points 
and Tool Offset.
To reverse a milling function:
From the PGM screen, use the ARROW keys to highlight the step that 
you want to reverse.
Press the Step Functions soft key.
Press the Reverse Step soft key.
Reverse path
With the reverse path option, you can reverse any continuous tool 
path. This will especially come in handy when youre working with 
DXF files. As you import DXF files, MILLPWR
G2 will sort and then 
group the steps into a logical order, creating continuous paths. In 
some cases, the paths may need to be reversed after theyve been 
imported so that your tools offset, direction and beginning and end 
points satisfy your machining requirements.
As you become more familiar with this feature, youll find other 
creative ways to use it to your advantage. For instance, you can save 
time as youre cutting a part by using a heavy cutting tool and a 
conventional cut for a rough first pass. On the second pass, switch to 
a finish cutter, then copy and reverse the path for a climb cut on the 
finish pass.
To reverse a continuous tool path:
From  PGM mode, highlight any step within the continuous tool path 
that you want to reverse. 
Press the Step Functions soft key.
Press the Reverse Path soft key.  The original steps are replaced 
with steps in the reverse order. 
						

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8.2 Additional Milling Functions
Change steps
The Change Steps feature gives you the ability to change or edit the 
depth, offset and feed rate of several steps simultaneously.
You can use this feature from anywhere within your program and 
does not require the specific step to be highlighted.
To Change Steps:
From the PGM screen, press the Step Functions soft key.
Press the Change Steps soft key.
Enter the first and last step numbers that you would like to change 
in the Step Range field.
Use the ARROW keys to select each field that you want to change and 
enter the new data.
Press the USE key.
Highlight the changed steps in the program sequence, then press the 
ENTER key. Each step should include the new settings.
Shift/Rotate steps
The purpose of the Shift/Rotate Steps feature is to transpose a range 
of steps from one location to another on the actual work piece.
This feature can be used from anywhere within the program, and 
does not require the specific step(s) to be highlighted.
To Shift Steps:
From the PGM screen, press the Step Functions soft key.
Then press the Shift/Rotate Steps soft key.
Then press the Shift soft key.
Enter the first and last step numbers to be transposed.
Enter in each axis field the distance to shift per axis. Leaving a field 
empty will result in no shift per that axis.
Press the USE key.
To Rotate Steps:
From the PGM screen, press the Step Functions soft key.
Then press the Shift/Rotate Steps soft key.
Then press the Rotate soft key.
Enter the first and last step numbers to be transposed.
Enter the X and Y axes coordinates for the center point of rotation. 
Enter the angle of rotation.
Press the USE key to apply the rotation to the selected steps.
Highlight the changed steps in the program sequence, then press the 
ENTER key. Each step should show the new axis coordinates. 
						

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8.2 Additional Milling Functions
Delete steps
MILLPWRG2 provides options for deleting steps in two ways: using 
the Delete Steps soft key or using the CLEAR key.
When deleting single steps, highlight the step, then press the CLEAR 
key.
When deleting a range of steps, the Delete Steps feature is usually 
the best option.
To delete a group of steps from a program:
From the PGM screen, press the Step Functions soft key.
Press the Delete Steps soft key.
In the Step Range field, enter the first and last step numbers to be 
deleted.
Press the USE key.
Copy/move steps
Copy/Move operations make it easy for you to duplicate or rearrange 
steps within your program. Youll find the Move feature especially 
useful for editing steps generated from a DXF file.
After you press the Copy/Move Steps soft key, youll be asked to enter 
a step range, then either copy or move the steps and select a location 
where to copy or move the steps (i.e. Paste Location). 
Press the Move soft key to relocate the steps. Press the Copy soft key 
to create an identical copy of the steps youve chosen (the original 
steps will remain in place). After you press the USE key, the new steps 
will be inserted into your program.
To copy or move steps:
From the PGM screen, highlight a step where you would like to add or 
insert the step(s) that you want to move or copy. If you are already in 
Copy/Move Steps  then press Paste Location and scroll in the program 
where you want to move or copy the steps.
Press the Step Functions soft key.
Press the Copy/move Steps soft key.
Enter the first and last step numbers that you would like to move or 
copy.
Press either the Move Or Copy soft key.  Make sure the desired 
location is selected in the program or, use Paste Location to select 
where to move or copy the steps.
Press the USE key. 
						

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8.2 Additional Milling Functions
Custom pockets
A custom pocket step must immediately follow a closed contour.
You can create a custom pocket from any closed contour. A closed 
contour is any shape consisting of lines, arcs, and/or blends (or 
chamfer), where the last step ends at the same point where the first 
step begins. MILLPWR
G2 will indicate a closed contour with double 
lines to the right of the applicable steps in the program list.
The Custom Pocket step must be placed immediately following the 
last step of the closed contour. MILLPWR
G2 will automatically fill in 
the step range for you. You’ll still need to fill in the Staging Point and 
set the feed rate for the custom pocket. 
If a finish cut is specified, the system will mill the central portion of the 
pocket first, leaving the finish amount on the bottom and side. It will 
then mill the bottom pass followed by the side pass.
Custom pocket
Create a closed contour.
Position the cursor immediately below the closed tool path contour.
Press the Program Steps soft key.
Press the Custom Pocket soft key and select Custom Pocket. 
MILLPWRG2 will automatically fill in the step range for you.
Enter the X and Y axes coordinates for the Staging  Point. The tool 
retracts and moves to the staging point before and after machining 
the pocket.  The tool will also retract and move to this location 
between roughing and finish cycles.  Choose a staging point that 
helps avoid interference with fixturing.
Enter either the number of passes or the distance between each 
pass. Pass refers to the cuts that are used to machine the pocket to 
its End depth. What is shown on the dialogue is what was selected 
in JOB SETUP.
Enter the feed rate for the Z axis.
Enter the table’s feed rate.
In the Finish field enter the amount of material to be removed during 
the finish Cut.
Enter the feed rate for the finish cut. 
For Direction, press either the CW soft key for clockwise or the CCW 
soft key for a counter-clockwise direction. The direction is applied to 
both the bottom and side finishes.
Enter the stepover percentage (how much you want your tool to 
overlap on each pass).
Press the USE key.
The staging point is not the location at which the tool will 
enter the pocket material.  Entry points are determined at 
run-time based on the pocket and tool geometry. 
						

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8.2 Additional Milling Functions
Island
An island is a raised area (e.g. a boss) within a custom pocket that 
remains after material has been removed from around all of its sides.
Though islands are easy to program, they must be placed correctly 
within the program sequence. Steps for the islands continuous tool 
path must appear first, followed by the Island step. Steps for the 
custom pockets continuous tool path must appear next, followed by 
the Custom Pocket step. You may program more than one island 
within the Custom Pocket.
To program an island:
Program a closed contour for the island.
From the PGM screen, place the cursor below the last step of the 
island’s closed contour.
Press the Program Steps soft key.
Press the Custom Pocket soft key.
Select Island in the popup Menu.
Check that the first and last steps listed in the step range match the 
first and last steps for the island’s continuous tool path. If they’re 
correct, press the USE key; if they’re not, press the CANCEL key and 
check that the closed contour for the island is correct and/or the 
correct step has been highlighted.
Tool path description for custom pocket, island, and pilot drilling
Machining of the custom pocket begins at a location based on 
pocket geometry. The software automatically determines this 
location.  
If a pilot drill operation is programmed, a prompt is displayed to use 
the pilot tool.  Pilot holes are then drilled at each of the custom 
pockets calculated entry locations.  A prompt is then displayed to 
use the roughing tool.
The roughing tool ramps or plunges into the material at the Z feed 
rate. If pilot drill step was programmed then roughing tool will enter 
the material in the same locations where the pilot drilling was 
performed.
The CW/CCW direction of roughing passes is determined by the 
direction of the profile formed by the custom pocket.
The XY step size is determined by the system and will not exceed 
the specified percentage of the tool diameter.  
The system will determine the best location to start 
feeding into the part. Depending on the shape of the 
pocket and island contours, the pocket may be split into 
more than one region. The system will machine each 
region separately. 
						

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8.2 Additional Milling Functions
The percentage must be 50% or less. This is required to make sure 
that all material is removed.  
The pocket is machined at the feed rate programmed in the custom 
pocket step.  When the tool makes a cut greater than the step over, 
the full cut override is applied to the feed.  Depending on the 
complexity of the pocket, the tool will change feed as needed.  The 
full cut override only applies to the rough pass.  Bottom and side 
finish passes run entirely at the programmed finish feed.
The Z step size is determined by the system and will not exceed the 
specified distance or number of passes.  
The tool retracts to the active datums retract position between Z 
passes.  
A finish allowance is optional but recommended.  If specified, this 
amount is left on the bottom and sides of the pocket and islands to 
be removed on the finish pass.  
When the finish feed is 0, the finish pass will be skipped.  The tool 
retracts to the active datums retract height and the specified 
staging position between rough, bottom finish, and side finish 
operations.
A Custom Pocket will include all Islands that are within the 
custom pocket reguardless of which step has been 
selected when the GO key is pressed.  
When a finish cut is specified on a 2 axis system, the 
finish applies only to the side.  The system runs a rough 
pass at programmed depth followed by a separate side 
finish pass.  For additional control over rough, bottom and 
side finish operations, use the advanced custom pocket 
cycles described in the next section.   
						

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8.2 Additional Milling Functions
Advanced Custom Pocket Machining
Machining of custom pockets can be further enhanced using special 
cycles.  These optional steps apply specifically to the custom pocket 
and programmed after the custom pocket/island path.  In the program 
listing, they are shown as part of the custom pocket using dashed 
continuity lines.
Pilot Drilling
If the tool programmed to machine the custom pocket is not able to 
feed directly into the material, a pilot tool step and pilot drill step 
should be programmed as part of the custom pocket.  The system 
determines the location of each entry move and drills pilot holes at the 
entry locations.
A Pilot Drill is programmed before rough milling. If no rough milling 
steps are programmed after the Pilot Drill, the rough and finish 
operations are performed using the parameter settings in the custom 
pocket step.
To program a pilot drill operation:
From the PGM screen, place the cursor immediately below the 
custom pocket step.
Program a Set Tool step with the pilot drill tools size and parameter 
settings.
Press the Program Steps soft key.
Press the Custom Pocket soft key.
Select Pilot Drill in the popup menu.
Enter either the number of pecks or the distance between each 
peck.
Enter the Z axis feed rate.
Press the USE key. 
						

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8.2 Additional Milling Functions
Rough Milling
It is possible to rough mill a custom pocket with multiple tools, starting 
with a larger tool to remove large amounts of material quickly followed 
by smaller tools to remove material inaccessible to the previous tool.  
Each subsequent tool change and rough mill cycle only removes the 
material left by the previous coarse tool.
Rough milling is programmed after pilot drilling and before finishing 
operations.  If no finish steps are programmed after roughing, the 
finish operations are performed using the parameter settings in the 
custom pocket step.
To program a rough mill operation:
From the PGM screen, place the cursor immediately below the 
custom pocket or pilot drill step.
Program a Set Tool step with the rough drill tools size and 
parameter settings.
Press the Program Steps soft key
Select Rough Mill in the popup menu.
Enter the number of passes or distance between each rough pass 
in the Z axis.
Enter the Z axis feed rate.
Enter the tables feed rate.
Press the USE key. 
						

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8.2 Additional Milling Functions
Bottom Finishing
The Bottom Finish removes the material from the bottom of the 
custom pocket.
The Bottom Finish step must be programmed after the rough milling 
cycle(s) and before side finishing.  If no side finish step is programmed 
after the Bottom Finish step, the side finish operation is performed 
using the parameter settings in the custom pocket step.
To program a bottom finishing operation:
From the PGM screen, place the cursor immediately below the last 
rough mill step.
If necessary, program a Set Tool step with the finishing tools size 
and parameter settings.
Press the Program Steps soft key.
Select Bottom Finish in the popup menu.
Enter the Z axis feed rate.
Enter the tables finish feed rate.
For Direction, press either the CW or CCW soft key.  The direction is 
applied specifically to the bottom finish operation.
Press the USE key. 
						

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8.2 Additional Milling Functions
Side Finishing
The Side finish step removes material from the side wall of the custom 
pocket.  It is possible to program multiple tool change and side finish 
steps
Side Finish steps are programmed after the Bottom Finish step.
To program a side finishing operation:
From the PGM screen, place the cursor immediately below the 
bottom finish step.
If necessary, program a Set Tool step with the finishing tools size 
and parameter settings.
Press the Program Steps soft key.
Select Side Finish in the popup menu.
Enter the Z axis feed rate.
Enter the amount of side material to remain after this operation.  
Enter 0 to remove all of the remaining side material.
Enter the tables finish feed rate
For Direction, press either the CW or CCW soft key.  The direction is 
applied specifically to this side finish operation.
Press the USE key.
Warning:  Rough milling must be programmed before 
bottom and side finish operations.
Warning:  It is possible to start running a program from 
one of the cycles following the custom pocket.  This 
should only be done if the previous cycles have already 
been run.  Otherwise, the tool may rapid into material that 
the system assumes has been machined.