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PowerMILL developments

PowerMILL developments. Chris Edwards European Business Development Director Delcam plc. PowerMILL benefits. Actual Part. Simulation. Easy to use Wide range of strategies for 2-5 axis machining Fast toolpath generation Powerful toolpath editing Integrated toolpath verification

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PowerMILL developments

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  1. PowerMILL developments Chris Edwards European Business Development Director Delcam plc

  2. PowerMILL benefits Actual Part Simulation • Easy to use • Wide range of strategies for 2-5 axis machining • Fast toolpath generation • Powerful toolpath editing • Integrated toolpath verification • Comprehensive gouge and collision checking and avoidance • Customizable with macros, Visual Basic, templates etc Editing Machine tool simulation

  3. High-efficiency machining • Raceline machining for smoother roughing • Combination offset and trochoidal to protect cutter • Spiral constant ‘Z’ finishing to minimize air cutting • Wide range of entry and exit options to minimize tool wear and dwell marks

  4. Five-axis machining • Wide range of 5-axis strategies – positional and continuous • Automatic calculation of optimum lead and lag • Gouge and collision checking on all toolpaths • Automatic collision avoidance • Support for the full range of cutters

  5. Blade/blisk/impellor module • Highly automated programming specifically for turbomachinery • Variable “lead/lag” tool-axis setting for optimum surface finish • Full collision avoidance of tool and holder assembly • 3, 3+2, 5, 5+1 and 6-axis continuous toolpaths

  6. Port machining module • Intelligent 3+2-axis roughing perpendicular to port centreline • 3+2-axis finishing moving into continuous 5-axis only when required • Supports both plunge & spiral finishing strategies • Automatic overlapping and push off elimination

  7. Hardware developments • Background processing • Toolpaths can be added to the calculation queue • Users can continue working in foreground as toolpaths are calculated in the background • Calculations continue until complete sequence is finished

  8. Hardware developments • Multi-threading • Multi-threading (parallel processing) performs different parts of a complex calculation at the same time • This reduces calculation times by using all the cores in the CPU chip

  9. PowerMILL 2011

  10. Optimum tool loading • Step-over and depth of cut are adjusted automatically to give consistent tool loading • This protects cutter and allows higher feed rates • Works on roughing and finishing

  11. Multiple copies • Multiple copies of toolpaths can be produced easily, e.g. for cavities in a mould tool • Complete sequence is optimised to reduce tool changes

  12. Leads and links • Improved control of feed-rates on entry and exit • Protects cutter and part from damage

  13. Five-axis flowline • Toolpath divided between drive curves with constant number of passes • Ideal for 5-axis multi-surface machining • Intermediate curves can be added for even more control

  14. Parametric spiral • Spiral 5-axis toolpaths can include undercuts • Finishes complete part on the surface • More even tool loading and better surface finish

  15. BBI module • Spiral machining option now in blade, blisk and impellor module • Gives smoother machining and better surface finish

  16. Tool-axis smoothing • Point distribution can be edited by angle as well as distance • Higher number of points gives smoother tool-axis changes • Better surface finish and smoother machine movement

  17. When is it needed? • Point separation angle (PSA) becomes important when the configuration of the machine tool and the shape of the surfaces cause large amounts of axis travel

  18. How does it work? • By adding in extra points, the machine tool has more reference points in these critical areas and the tool position is able to be more closely maintained PSA Off PSA Of 0.5º

  19. In-house testing • Using Delcam’s unique on-site Advanced Manufacturing Facility, we were able to test this new feature on a range of different configurations and brands of 5-axis machine tool

  20. Results Huron Table-Head 5-axis Sample PSA Off PSA 0.5º PSA 0.25º PSA 0.1º • A Point Separation Angle of 0.1º showed the best improvement of surface finish by giving the machine tool more reference points in these critical areas.

  21. Bezier curves assist toolpath creation • New tools to create and edit Bezier curves used to help create toolpaths • Helps minimise any polygonisation of curves • Improves surface finish

  22. Other enhancements • More control over tool and holder clearances • Thread milling • Workplane editing • Easier measuring with automatic form filling • More powerful macro language for repeat operations

  23. Conclusions • PowerMILL offers a comprehensive range of strategies for high-speed and 5-axis machining • Powerful editing and point distribution options allow more efficient machining and optimum surface finish • Integrated simulation enables prove-out on cheap computers instead of expensive machine tools • Optimising benefits from latest hardware gives fastest calculation times and increased productivity

  24. Thank you

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