Milling, machining programming software is faster

Developing software further for 5-axis machining to include a powerful tool axis editor program as well as improved memory management for more detailed, high tolerance work.

Delcam will launch the latest version of its PowerMILL CAM system at the EMO exhibition to be held in Hannover, Germany, from September 17-22, 2007.

EMO will be the world's largest machine tool show this year and so is the ideal venue to launch the new release of the world's leading specialist CAM software.

Like other recent releases of the software, a major focus of PowerMILL 8 will be additional options for 5-axis machining.

However, the new version will also include enhancements and speed-ups throughout the program.

In particular, improved memory management within the software will give significantly faster calculation times, especially for large, complex components, like press tools for automotive bodywork, and for smaller, highly-detailed models, such as moulds for fine-tolerance and high-accuracy parts.

The most significant of the new 5-axis options is a powerful tool-axis editing function that allows the user to select any region of a toolpath and redefine the tool-axis vectors within that region.

Previously, a single tool-axis specification was applied to a complete toolpath, although this could be adjusted automatically to avoid any collisions.

The new ability to use different options in different regions of the toolpath will enable users to optimise cutting conditions and avoid any sudden machine tool movements that could result in a poor surface finish.

Swarf machining has been improved by the addition of an option that forces the toolpaths to follow the surface internal lines where possible.

This approach can be used to give smoother motion of the machine tool and more precise control of the machine, especially in tight corners and other areas where there could be rapid changes in the cutter orientation.

An improvement to area clearance toolpaths with both positional 5-axis operation and 3-axis machining allows the user to add different styles of 'tails' to the toolpath under certain stepover conditions.

These extra moves are needed to remove any upstands that might otherwise be left when cutting with a stepover more than 50% of the tool-end diameter.

The new options will give smoother toolpaths and will maintain the cut direction as either climb or conventional.

Pattern machining is one of the most flexible strategies in PowerMILL and this has been further enhanced.

With PowerMILL 8, users will be able to project any 2D pattern onto a model and undertake multiple cuts with a specified stepdown to reach any given depth.

PowerMILL has always supported a wide variety of cutting tool types.

This range will be further extended with the addition of machining strategies specifically for large abrasive disk cutters within PowerMILL8.

The new options include specific types of leads and links, plus dedicated gouge prevention functionality, to allow these disks to be used to cut around corners safely and accurately.

To make it easier to manage the wide range of tooling that is supported by PowerMILL, an easy-to-use tool database has been added to the new version that allows the user to perform a search operation to find the required tool.

The enhanced tool database, which will be shared with the recent release of FeatureCAM, will also be able to support much more information on recommended feeds and speeds taken from suppliers' tool catalogues.

Simulation and verification on the computer has become increasingly important for many users and the PowerMILL development team has been working on a number of improvements in this area.

In PowerMILL 8, ViewMILL simulations will be able to be created and viewed with a full three-dimensional model of the stock.

This allows the user to rotate the ViewMILL machining model and view it from any direction both during and after the simulation.

In addition, the user interface has been streamlined so that both cutting tool simulation and machine tool verification can be controlled from a combined toolbar.

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