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Product category: Software, off-line programming, CAM, for metal cutting machine tools
News Release from: Delcam | Subject: PowerMILL and PowerINSPECT software
Edited by the Manufacturingtalk Editorial Team on 22 March 2006

Novel adaptive machining methods
featured

A range of adaptive machining solutions for the aerospace industry use in-process measurement to close any information gaps in the machining process chain.

Delcam will demonstrate its range of adaptive machining solutions for the aerospace industry at the UK's Farnborough Air Show, which takes place this year from 17th to 23rd July These novel techniques are based on Delcam's unique combination of expertise in software for both machining and inspection, which has been built up over many years of development of PowerMILL, the world's leading specialist CAM system, and PowerINSPECT, the leading hardware-independent inspection software

The programming of most machining operations is based around knowing three things: the position of the workpiece on the machine, the starting shape of the material to be machined, and the final shape that needs to be achieved at the end of the operation.

Adaptive machining techniques allow successful machining when at least one of those elements is unknown, by using in-process measurement to close any information gaps in the process chain.

They are being applied for an increasing number of applications in the manufacture and repair of large and complex components in the aerospace industry.

The most common case is that where the exact position of the workpiece is unknown.

With larger components, such as aerospace structures, achieving the correct position and orientation of the stock on the machine is a major challenge, taking many hours of checking and adjustment.

It is often easier to adjust the datum for the toolpaths to match the position of the workpiece, than it is to align the stock in exactly the desired position.

This approach has been used in the machining of geometric features for some time.

Delcam now offers an equivalent solution for the manufacture of complex surfaces that gives the same benefits of shorter set-up times and improved accuracy.

Examples where the exact starting shape is unknown can result from near net shape manufacturing processes, like casting and forging, or from imprecise repair techniques, such as welding.

The main requirement here is to allow an even distribution of material to be removed around the stock to avoid over-machining in some areas and under-machining in others.

Other benefits include the ability to give a smooth transition between machined and un-machined areas, a reduction in air cutting and improved control over the feed rate as the cutter enters and leaves the material.

The most challenging adaptive machining operations are those where the exact final shape of the component is unknown.

This can be the case when undertaking repairs to components that have been changed from their nominal CAD shape during service, for example, turbine blades that have been distorted by the high temperatures in aircraft engines.

Companies wanting to use adaptive machining processes must understand that they tend to be much more complex and process-specific than conventional CAM programming.

As a result, most adaptive machining projects will require some specific consultancy and customisation work by Delcam as part of their implementation. Request a free brochure from Delcam ...

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