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Product category: Measurement and Quality Software and SPC
News Release from: Delcam
Edited by the Manufacturingtalk Editorial Team on 13 October 2006

Motorsport CAM demonstration

Note: A free brochure or catalogue is available from Delcam about its services. Click here to request a copy.

Delcam will present unique new functionality for the machining of engine ports in the company's PowerMILL CAM software at a Motorsport Industry Association workshop.

Delcam will present unique new functionality for the machining of engine ports in the company's PowerMILL CAM software at a Motorsport Industry Association workshop during the 2007 Autosport Engineering exhibition The new options, which were introduced as part of the recent PowerMILL 7 release, will also be demonstrated on Delcam's stand at the exhibition, which runs from 11th to 12th January at the NEC, Birmingham

PowerMILL is already being used successfully at a number of leading engine manufacturers, including Zytek, the engine supplier for the A1 Grand Prix race series, and Wegner Motorsports, supplier of winning engines in nearly every NASCAR division.

The main benefit of the new release is the automatic division of the port machining process between areas that can be reached using three-axis techniques, and those that require positional or continuous five-axis operation.

With most machine tools, using three-axis or positional five-axis cutting offers greater rigidity and so allows more accurate machining, with less vibration of the cutter, at higher speeds.

However, engine ports require continuous five-axis machining for part of their manufacture.

The new version of PowerMILL automatically optimises the overall machining sequence so that as much material as possible is removed with three-axis and positional five-axis operation, and that continuous five-axis machining is only used where necessary.

This reduces the overall machining time, while maintaining the required level of surface finish.

The sequence uses a spiral motion for the roughing cuts but gives the operator a choice between using a spiral or a plunging approach for the finish machining.

Using a spiral approach produces cusps across the flow of gas and so increases turbulence, while using the plunging technique gives cusps parallel to the flow direction and speeds the passage of the gas mixture through the port.

PowerMILL also divides the CAD model automatically to create the surfaces that will be machined from either end of the port.

The user can specify the length of the overlap between the two sets of toolpaths to ensure a smooth transition between the two areas.

PowerMILL supports the full range of cutter types, including the lollipop cutters that are frequently used to access difficult to reach areas of the port.

The software can be used either to machine ports directly from solid material or for the finish machining of cast engine blocks.

PowerMILL incorporates comprehensive gouge and collision checking to ensure safe machining.

A verification module is available for full-machine simulation on the computer to give even greater confidence that the programs will operate as expected on the shop floor.

The new port machining strategies also benefit from the better control over the point distribution in PowerMILL 7.

Increasing the number of points in the toolpath can give more even machining with less vibration and more consistent loading on the tool.

Both these improvements give a better surface finish and less wear of the cutter. Request free introductory details about products from Delcam ...

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