The latest release of Delcam's PowerMILL machining software, PowerMILL 3.1, includes a range of enhancements for all manufacturing operations. However, priority has been given to additional features for high-speed machining and 5-axis machining. Delcam is already ranked as the most successful international supplier of NC software and services to the toolmaking industry by US consulting and market research firm CIMdata.
The company expects that this new version will further consolidate its leading position.
PowerMILL has had a reputation as the most advanced software for high-speed machining for many years.
PowerMILL 3.1 sees the introduction of another unique Delcam machining strategy - spiral offset finishing.
This technique combines the benefits of spiral and 3D offset strategies to give more consistent tool loadings during high-speed finishing and so allow faster machining rates without risking damage to the cutter.
It also gives an improved surface finish and so minimises any need for hand finishing.
One of PowerMILL's great advantages for high-speed machining has always been its exceptionally fast calculation and re-calculation times.
For PowerMILL 3.1, Delcam has continued to make calculation times faster throughout the program.
Of particular note are the improved speeds with 3D offset, projection and rotary machining.
In addition, corners in constant-Z finishing are now handled more efficiently, while the calculation speed and quality of corner machining toolpaths have both been improved.
PowerMILL 3.1 includes a considerable increase in the five-axis machining capabilities within the program.
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 will enable the generation of safe toolpaths for five-axis machining through a point or to a point, and for automatic adjustment of tilt angles for both lead and lag.
Until now, 5-axis machining been used mainly in the aerospace industry and has had limited application in toolmaking.
PowerMILL's new features will encourage the use of 5-axis machining in mould and die manufacture by allowing the machining of complex shapes in a single set-up, so saving time, and by enabling shorter cutters to be used in deep cavities, so giving increased machining speed and accuracy.
PowerMILL 3.1 offers a more efficient method for setting Z-levels for roughing of flat areas.
Other systems offer the option to add Z-levels manually that match flat areas.
This can be difficult, especially since the user must remember to include allowances for stock to be left on and machining tolerances.
PowerMILL automatically sets the Z-heights to match flat areas, with due allowance for stock and tolerances.
The program can then automatically fill in additional Z-heights with the required step-down to give the minimum number of slices without exceeding the safe cutting depth of the tool.
Once this process has been completed, the user still has the option to add any extra Z-heights, if required.
Like other CAM programs, earlier versions of PowerMILL would simply refuse to process CAD files including poorly-defined surfaces, for example, those with trimming errors, without highlighting the exact source of the problem.
In contrast, PowerMILL 3.1 takes any unsatisfactory surfaces within a model and automatically places them on a separate level.
The user can then quickly and easily identify these surfaces.
One can choose to delete them if, for example, they are duplicates or are so small that they are within the machining tolerance.
Alternatively, the surfaces can be exported back into a modelling package, such as Delcam's PowerSHAPE, for the errors to be corrected.
A number of other changes will make PowerMILL 3.1 even easier to use.
Training of new programmers has been improved through the incorporation of on-line tutorials.
These include 'show me' buttons to help new or inexperienced users find the appropriate commands within the software.
In addition, enhancements to the user interface have simplified the creation and management of a tooling database.
'As software developers, we are always faced with demands both to increase the capabilities of the program and to make it easier to use,' commented Delcam's CAD Development Director, Steve Hobbs.