Delcam's Unique Range of Strategies in New PowerMILL

December 07, 2001 - Delcam is to incorporate a unique range of new strategies in the latest release of its PowerMILL machining software. PowerMILL 4 will include enhancements in three key areas - high-efficiency roughing, high-speed finishing and 5-axis machining. Together these improvements will help toolmakers and other precision machinists to optimise the efficiency of their machine tools and so shorten delivery times, boost productivity and increase profitability.

High-efficiency roughing

Delcam has added a number of new high-efficiency roughing strategies to take full advantage of the latest cutter designs that can cut with the side of the tool and so take deeper cuts. The most novel technique is called raceline machining, for which Delcam has a patent pending. With this option, the roughing passes are progressively smoothed out as the toolpaths move further from the main form. The resulting paths minimise any sudden changes in direction and so allow faster machining, with less wear on the cutter and lower stress on the machine tool.

Delcam has also added a new trochoidal machining option. This avoids full-width cuts when machining slots by generating toolpaths that progressively shave material from the block in a circular motion. The new option automatically adjusts the toolpath to maintain efficient and safe machining at any direction changes in the slot.

An additional feature to protect the cutter is the automatic fitting of arcs to raster toolpaths as the tool approaches any steep face. Without the arc, there will be a sudden increase in the load on the tool as it engages the steep surface. To prevent damage, the feed rate must be reduced so overall machining times will be increased. With the arcs added, a smoother toolpath results that can be run at higher speed with less wear.

For semi-finishing, PowerMILL 4 features a new optimised raster option. To leave the minimum material for final finish machining, many companies like to undertake two raster semi-finishing operations, in perpendicular directions. This approach, which can also be used for finishing, can lead to unnecessary re-machining of surfaces that are already within tolerance. Delcam's optimised raster limits the second toolpath to areas where excess material is known to remain and so eliminates this duplication.

The same basic requirements for roughing - consistent tool loading and the fewest possible sudden changes in direction - are also needed for high-speed finishing. To meet these priorities, PowerMILL 4 includes a new combination strategy, which uses 3D offset finishing on flatter areas and Z-level finishing on steeper areas. The 3D offset toolpaths are calculated with the surface stepover varying so that a constant cusp height is applied over the part.

An alternative to conventional Z-level finishing - spiral constant Z - is also offered that again takes advantage of cutting with the side of the tool. Instead of using the conventional approach of machining down the job level by level, the new Delcam strategy uses a single, smooth toolpath that machines upwards in a spiral from the bottom of the surface. This keeps the cutter in constant contact with the job and so eliminates air moves. The smoother toolpaths also minimise any dwell marks as well as protecting the cutter and machine tool.

5-axis machining

PowerMILL 4 sees the addition of many more options for continuous five-axis machining alongside the existing routines for positional five-axis operation (also known as 3 + 2 machining). The range now includes machining through a point or to a point, or to or from a line, swarf machining, 5-axis trimming and 5-axis profiling.

For all options, the software incorporates automatic adjustment of tilt angles for both lead and lean (Lead is measured in the cutting direction; lean at right angles to the cutting direction.). Control of lead angle gives better cutting conditions, while the lean angle can be used to avoid collisions. In addition to the comprehensive gouge prevention applied to all toolpaths, new routines have been added for the calculation of gouge-free leads and links as the machine tool moves between the various surfaces within a part. These ensure that gouges are prevented and that collisions do not occur between the tool or tool holder and the part being machined.

An important advantage of five-axis machining with PowerMILL is that the software works with the full range of different cutting tools, including end mills, tapered cutters, and ball-nose, tipped-radius and off-centre, tipped-radius cutters. Some of the systems currently available are limited to using only ball nosed and end mill cutters, which are not always the most efficient. 

www.delcam.com 

www.delcam.co.uk 

 

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