User Guide

Tutorial

From Delcam,
the creators of
PowerSolution

Version: 1.1
Information contained in this manual is subject to change
without notice and does not represent a commitment by
Delcam plc. The software described in this manual is
furnished under licence agreement and may be used or
copied only in accordance with the terms of such licence. No
part of this manual may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including
photocopying and recording, for any purpose without the
express permission of Delcam plc.

MillWizard 1.1 Copyright © 2000 Delcam plc.

All rights reserved.

Important Notice
MillWizard can only be used in accordance with the Software
Licence Agreement.

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.
Contents
Important Notice ii
Installing MillWizard 5
Installation 5
Operating System 5
Security codes 5
Using MillWizard 6
Introduction 6
The Wizard Pages 7
Page 1: Select File 7
Page 2: Cut Direction 10
Page 3: Resize Model 12
Page 4: Cut Plane 13
Page 5: Setup Material 14
Page 6: Roughing Tool 15
Page 7: Finishing Tool 17
Page 8: Strategy 19
Page 9: Calculate 21
Page 10: Save Paths 24
The main Menu 26
Menu options 26
File Menu 26
Help Menu 27

MillWizard User Guide Contents • iii

Installing MillWizard
Installation
Insert the CD and the MillWizard installation browser will
automatically start.
If nothing happens, open Windows Explorer,
Select the CD-ROM drive
Double click on the file install.exe
Click on the Install MillWizard icon and follow the instructions
to complete the installation.

Operating System
MillWizard can be installed and used on any of the following
Windows operating systems.
Windows 95TM
Windows 98TM
Windows NT 4.0TM
Windows 2000TM

Security codes
When you purchase the program from Delcam plc (see
www.millwizard.com) you will receive a new installation CD
and security code. The security codes will allow you to load
and machine your own model files.
The evaluation version (download) MillWizard is supplied
with a number of sample files that you can open, scale,
rotate and cut on your milling machine.

MillWizard User Guide Installation • 5

Using MillWizard
Introduction

MillWizard is an easy to use machining wizard that creates

roughing and finishing raster toolpaths over 3D DXF, STL
and 3DS models. You can import 3D models from design
software such as AutoCAD, TrueSpace, Rhino, FormZ, 3D
Studio, 3D scanners and the Roland Picza digitiser.
MillWizard provides a simple step by step approach to
setting up toolpaths, and you can be machining parts within
minutes. MillWizard includes a simulation mode that lets you
verify your toolpaths before actually cutting.
This User Guide takes you through the 10 steps within
MillWizard.

6 • Introduction MillWizard User Guide

The Wizard Pages
MillWizard consists of the following pages.
When running MillWizard, use the ’< Prev’ and ’Next >’
buttons situated in the bottom right corner to move
backwards and forwards.

Page 1: Select File

On this page you can select and load a 3D Model you wish
to machine. You can load DXF, STL or 3DS files.
Press 'Select File…' button to browse for a file. Once a file is
loaded you can use the 3D view to look at it and you will also
be able to see the size and dimensions of the model.
If you are working in millimeters but the model you are
loading has its sizes defined in Inches then click the Model
was in Inches check box and the model’s dimensions will be
converted automatically for you.

MillWizard User Guide The Wizard Pages • 7

This is also the case when you are working in Inches and
you load a model that was defined in millimeters, there will
be a Model was in mm check box which you can click to
convert the other way.

Working Units
Selecting the Set Units option from the File menu brings up
the dialog shown below. This option lets you change the
units used for the model, tooling and block, to be either
Inches or Millimeters.

Using the 3D View

You can manipulate the model in the 3D view in the following
ways:
• Rotate the model by clicking and dragging with the left
mouse button.
• Zoom in and out by clicking and dragging with the right
mouse button.
• You can Move / Pan the model by clicking and dragging
with both the left and right mouse buttons pressed.

8 • The Wizard Pages MillWizard User Guide

The buttons on the toolbar offer predefined views of the
model, allowing you to view the model in a sensible position.
They are,

Isometric View

View Along X

View Along Y

View Along X

Fit Model to View

Press these icons to see what happens to the model in the

3D view.
The final button on the toolbar is for colour shading and is
used later in this guide.

Click the ’Next >’ button to move onto the next page.

Tutorial step 1
1. From the File menu Set Units = Inches
2. Click on the Select File button.
3. Select the 3D Studio file named - nefertiti.3ds
4. You will see that the triangle model has been loaded into
the 3D view. Click and drag with the left mouse button to
move the model around.
5. Note that the model size is 51.4 x 67.6 x 89
6. Click on the Next button in the bottom right corner.

MillWizard User Guide The Wizard Pages • 9

Page 2: Cut Direction

You now have the option to orientate the model relative to

the cutting axis. This is done by choosing the cut direction.
The view of the model that you see assumes you are looking
from the front of the machine, along the y-axis, to the back
and that the cutting tool will be coming down from the top of
the screen.

View onto the model from front of milling machine

10 • The Wizard Pages MillWizard User Guide

Click on the radio buttons to see what happens. The model
will be orientated so that it is the right way up for machining.
You can also rotate it by 90 degrees if you prefer the longest
axis of the model to lie along x instead of y, or vice versa.

Using the View

You can only rotate the model around Z whilst on this page,
this is so that you always see the tool from the top. Click and
drag with the left mouse button to rotate the model.

Tutorial step 2
7. Check the option for cut direction = Front
8. Check the box to Rotate the model by 90 degrees
9. The 3D window should now look like this,

10. This shows that the tool will cut from the top of the
screen onto the top face of the model.
11. Click on the Next button.

MillWizard User Guide The Wizard Pages • 11

Page 3: Resize Model

On the size page you can resize the model. The edit boxes
are all linked to each other so the model can only be resized
proportionally along all axes.
Typing 100 in the % edit box will always return the model to
its original size.
Once the model is the size you want, press ’Next >’

Tutorial step 3
12. Enter 4.00 inches in the X field. This will scale the model
proportionally along all axes.
13. Click on the Next button.

12 • The Wizard Pages MillWizard User Guide

Page 4: Cut Plane

The cut plane specifies how far down the Z-axis the tool will
cut into the material. This allows you to restrict the area the
cutting tool will machine. Placing the cut plane in the centre,
allows the model to be machined in two halves and then
joined back together to make a complete shape.
The cut plane is drawn in red.
Remember that you can always change the orientation of
the model by pressing the ’Prev >’ button to go back a stage.

Tutorial step 4
14. Click the Centre in Model button. You will see that this
places a Red line across the screen, passing through the
middle of the model. This is the plane from which the
toolpaths will be calculated.
15. Click on the Next button.

MillWizard User Guide The Wizard Pages • 13

Page 5: Setup Material

On this page you specify the thickness of the block of

material you are machining into. You can also set the z
position of the model within this material block.
You must enter a material thickness equal to or greater than
the thickness of the 3D model. If your material is thicker, use
the slider, or the edit boxes to move the model up and down
within the material.
The material thickness you define will be remembered when
you next open this page.

Tutorial step 5
16. Accept the defaults provided by MillWizard. This shows
that the model is 1.520 inches high (Z axis).

17. Click the icon - View Along Y .

18. Click on the Next button.

14 • The Wizard Pages MillWizard User Guide

Page 6: Roughing Tool

You now have the option of generating a roughing

cutterpath. This option is particularly useful for removing
excess material, quickly with a large diameter cutter, and
then finish machining the job with a smaller diameter cutter.
If you require a roughing pass, tick the ’Generate Roughing
Pass’ check box. This will enable the tool selection window.
You now need to select a Tool type, either Ball-nose or Flat
End Mill and fill in all the relevant information.
The Cutting Length specified for the tool is used to
automatically determine whether multiple passes are
required when rough machining. If the model height is
greater than the cutting length, MillWizard automatically
calculates multiple roughing passes.
The stepover is the distance between each raster toolpath
line and it can be specified in two ways,
• As a percentage of the tool diameter
• As a physical width / step in mm or inches

MillWizard User Guide The Wizard Pages • 15

Whichever way you do it the other edit field will update
automatically. If you change the diameter, the percentage
stepover will remain the same.

The other machining parameters, Spindle Speed and Feed

Rates need to be set for the material being cut and the type
of tool being used. Contact your suppliers for details.
The tool information on this page is automatically
remembered, so if you use the same tool again on the next
job, you do not have to fill in all the information again.

Tutorial step 6
19. Check the box - Generate Roughing Pass
20. Specify the tooling parameters
Type: End mill (Flat end)
Diameter: 0.125
Length: 0.500
Stepover: 0.060
Spindle Speed: 6000
Feed rate: 50 (Wax and soft materials)
Plunge rate: 20 (Wax and soft materials)
21. Click on the Next button.

16 • The Wizard Pages MillWizard User Guide

Page 7: Finishing Tool

The Finishing Tool is normally used to machine the job to the

required size. Simply complete this page with details of the
tool you want to use.
Multi-level finish machining passes cannot be calculated.
However, the tool’s Cutting Length is used to warn you if the
job height is greater than the cutting flute length.
As with Rough machining, the other tool parameters, Spindle
Speed and Feed Rates should be suitable for the material
being cut and the type of tool being used. Contact your
suppliers for details.
This information is remembered, so if you use the same tool
again on the next job you won’t have to fill in all the
information again.
The stepover between passes determines the surface finish
produced on the machined component. Generally, the

MillWizard User Guide The Wizard Pages • 17

smaller the stepover the smoother the surface finish, and the
longer the machining time.

Rough surface finish Smooth surface finish

Tutorial step 7
22. Specify the finish machining tooling parameters.
Type: Ball Nose (rounded end)
Diameter: 0.0625
Length: 0.500
Stepover: 0.020
Spindle Speed: 10000
Feed rate: 50 (Wax and soft materials)
Plunge rate: 20 (Wax and soft materials)
23. Click on the Next button.

18 • The Wizard Pages MillWizard User Guide

Page 8: Strategy

Machining Direction
The finishing toolpath can be calculated to run parallel to the
X axis, Y axis or to do a pass parallel to each axis.

Machine Z Position
This option lets you set the machine Z zero position relative
to either the material / block surface or to the machines table
/ bed. If Top of Block is selected you then touch the tip of the
tool onto the material and set this to be Z0.

Allowance
You can specify an allowance or amount of material to leave
on the surface of your model when roughing and finishing
passes. A small allowance is usually left on the job when
rough machining and none on the finishing pass. MillWizard
will warn you of various problems when you click ’Next >’

MillWizard User Guide The Wizard Pages • 19

and will not allow you to continue until these values are
sensible.

Safe Z Height
Setting a Safe Z Height ensures that the tool will not crash
into the component, when it returns to the home position. At
the end of each machining pass the tool is retracted up the Z
axis to the Safe Z height above the highest point in the
model.

Add Border
Finally you can add a border around the model. The border
added is automatically set to the last value you used, or the
radius of the largest tool you have specified, whichever is the
larger of the two. This ensures that you can machine around
the sides of your object.
You are able to change this value to zero if you wish.

Tutorial step 8
24. For Machining direction check the ’Raster in X’ box.
25. Set Machine Z Zero Position to be Top of Block.
Touch the tip of the tool onto the material surface and set
this to be the tools Z 0 position in the control system.
26. Roughing allowance = 0.010
Leaves 0.010" on the job for the finishing tool to remove
27. Finishing allowance = 0.000
28. Safe Z Height = 0.125
Ensures all rapid moves are 1/8" above the job
29. Add border = 0.125
Allows a 0.125" border around the model.
30. Click on the Next button to continue.

20 • The Wizard Pages MillWizard User Guide

Page 9: Calculate

This page allows you to calculate the defined toolpaths and

then simulate them to verify the surface quality.

Calculating Toolpaths
Calculate the roughing (If you wanted one) and the finishing
passes by selecting them in the checkboxes and clicking on
the ’Calculate’ button.
If there are no problems that MillWizard warns you about you
will see red lines begin to be drawn over the object, this is
the toolpath being calculated.
If at any time you wish to stop the calculation process, simply
click anywhere in the view or click on the Cancel button that
appears on this page. A dialog will appear asking if you want
to stop.

MillWizard User Guide The Wizard Pages • 21

Click the Cancel Button to stop toolpath calculation.

Simulate
When toolpaths have been calculated you will be able to
simulate them.
Click on the ’Simulate’ button and it will simulate whichever
toolpath you have selected in the checkboxes above the
button. Simulation can also be stopped by clicking in the
view or the cancel button and yields some interesting half-
machined results. For example you could let the roughing
pass be fully simulated and stop the simulation halfway
through the finishing pass. When this is shaded you will be

22 • The Wizard Pages MillWizard User Guide

able to see the difference between the two passes on the
one model, which looks quite nice!
’Reset’ gives you a fresh block to simulate on again.
When you have created a simulation model you will be able
to toggle between the simulation and the model by clicking
on the ’Show Simulation’ checkbox.

Tutorial step 9
31. Make sure that both the Roughing and Finishing check
boxes are ticked.
32. Click the Calculate button.
You will see the two toolpaths being calculated.
33. Remember that at any time you can cancel the toolpath
calculations by clicking the Cancel button.
34. Once the toolpaths have been created they can be
simulated in a ’virtual’ block of material.
35. Click the Simulate button. Remember that at any time
you can cancel the simulation by clicking the Cancel
button.
36. If you are happy with the machining results click the Next
button to continue.

MillWizard User Guide The Wizard Pages • 23

Page 10: Save Paths

This is the final stage.

Select the machine type suitable for your CNC machine, and
and save your toolpaths to disk. Each toolpath is saved into
a separate file.
If you wish to machine another 3D model, simply click ’File >
Open...’ from the Main menu and start again.

Select Machine
This is a pull-down list of the available postprocessors or
output file options available in MillWizard.
For example, selecting the G-Code (Inch) postprocessor will
save a standard G & M code file that has a .tap extension,
i.e. finish.tap
If you cannot find your milling machine in the list of
postprocessors, take a look at the FAQ section on the

24 • The Wizard Pages MillWizard User Guide

MillWizard web site (www.millwizard.com). Here you will find
the Postprocessor Manual that shows you how to edit and
configure your own postprocessors.

Tutorial step 10
37. Open the pull-down list of machine tool postprocessors
and select the appropriate one for your milling machine.
For example, G-Code(inch)
38. Select the Save Finishing button, navigate to the folder
where you wish to save the toolpath and enter a suitable
name for the file.
39. Select the Save Roughing button, navigate to the folder
where you wish to save the toolpath and enter a suitable
name for the file.
40. Load the appropriate roughing tool (0.125 diameter End
Mill) into your milling machine and set the X, Y and Z
datum position.
41. Select the roughing toolpath you have just saved from
MillWizard and send it to your CNC machine. This
procedure will differ for each CNC control type.

MillWizard User Guide The Wizard Pages • 25

The main Menu
Menu options
All of MillWizards functionality is accessible using the wizard
pages. You only need to use the Main menu bar to set the
working units or to open the on-line Help file.

File Menu

Open File
This option allows you to open a new file for use in the
wizard. It performs the same function as the Select File
page, except that you can always select ’File > Open...’ on
any page in the wizard and start again with a new model.

Set Units
Use this option to change the units in MillWizard to either
Millimeters or Inches.

26 • Menu options MillWizard User Guide

If the working units are changed at any stage, MillWizard will
automatically return to page 1.

Exit
Select this to quit this application.

Help Menu

Contents
Displays the contents page for the on-line help file.

About MillWizard…
Displays information about the program version number.

MillWizard User Guide Menu options • 27