PowerMILLSpecialist NC CAM software for the manufacture of the complex shapes. PowerMILL 2011 makes the programming of safe toolpaths easier than ever thanks to new stock model engagement options that protect both the cutting tool and the machine from excessive loading.

Present Version of Software- The present version of software is PowerMILL 2011.

Having following features- Powerful efficient high-speed five-axis CAM machining

PowerMILL 2011 makes the programming of safe toolpaths easier than ever thanks to new stock model engagement options that protect both the cutting tool and the machine from excessive loading.

Name Of Developer - In 1965 Donald Welbourn, Director in Industrial

Co-operation at Cambridge University, had the vision to see the possibility of using computers to assist pattern makers to solve the problems of modeling difficult 3D shapes.

In July 1997, Delcam plc was floated on the Alternative Investment Market (AIM). In preparation for this, Delcam UK was established to spearhead UK sales and customer support. Overseas activities continued to develop, with strong emphasis on joint ventures, especially in the Americas, Europe and the Far East. Delcam now had more that seventy sales offices worldwide and has a wholly owned subsidiary in the USA, exploiting the country's massive complex manufacturing market.

The Power Solution

During 1998 DUCT was gradually replaced with a new incorporated range of products, which covered the full manufacturing cycle from conceptual design through to manufacture. Delcam’s Power Solution range of products, which built upon the functionality of the DUCT suite, incorporated the latest user interface technology and offered users many new benefits. Delcam's commitment to providing the best tools for our customers lead to the development of these individually 'Best of Breed' products, which were developed to combine seamlessly and give a truly integrated solution.

Delcam's Power Solution Software

Delcam currently operates throughout the Americas, Europe, the Far East and Australasia using a tight-knit network of regional headquarters and sales offices. Regional Offices, for example Delcam Inc, a wholly owned subsidiary in Canada, offer support and assistance to the numerous sales offices within their area who are each able to concentrate on certain markets and locations. Delcam has several wholly owned Sales offices around the world, for example Delcam Malaysia offers the same service to those Sales Partners in the Far East. This strong structure includes over a hundred sales offices all working together to promote Delcam products and offer local support and training to Delcam customers.

In addition to the development, sales and support of software, Delcam is unique in being the only international CADCAM software supplier with its own toolroom. Based alongside the company’s development headquarters in Birmingham, UK, the centre houses some of the latest machining and inspection technology from manufacturers such as Mecof, Anyak, Matsuura, Bridgeport, Renishaw and POLI. The main aim of the facility is to allow comprehensive real-world testing of software before it is released to customers. However, it also operates as a working toolroom which is profitable in it's own right.

Name OF Modules Of Sotware-

Stock Model Engagement Fixed Tool Axis Angles Smart Selection for Machining Toolpath and Wireframe Transformation Tool Holder and Shank Definition Lead In Lead Out Feedrates Improved Toolpath Boundary Limiting Toolpath and Boundary Outside Block Block Enhancements Curve Editor Improvements

Capability OF each Module Of Software-Other enhancements include:-

New editing capabilities to simplify the machining of duplicate items More versatile control of feedrates for leads and links Improved sketching Clearer dialogs for the complete range of strategies

 Stock Model Engagement  

Stock Model Engagement is a fantastic new option available within all finishing forms to accurately control the optimum amount of stock you wish to machine.

Benefits of this new option include:-

1.Avoids the tool damage that can occur when machining excess stock2.Allows higher feedrates as excessive tool engagement is eliminated3.Machining times are improved by removing toolpath segments which machine very little, or no material

    Fixed Tool Axis Angles  

There is a new option inside the tool axis form to lock the rotary axis of the machine tool to avoid unnecessary tool axis motion.

By reducing any unnecessary machine axis motion, you will also see improvements to surface finish and ultimately machining times.

Fixed Angle control is available for all tool axis definitions except for those with a tool axis of Fixed Direction and Automatic.

    Smart Selection for Machining  

Similar to the drilling methods functionality in PowerMILL, Smart Selection allows you to import data and automatically select combinations of surfaces to machine based on colour, level or model name. These selections can be added to Thickness Sets and saved with a toolpath template.

Example ways to use this functionality include:-

1.Machine surfaces which are red or yellow on Level 152.Ignore surfaces in model “XXX” which are not green

    Toolpath and Wireframe Transformation  

Toolpath transformation is now much simpler and multiple transformations can be performed at the same time.

A new toolbar allows a choice of translation, mirror, rotation or pattern transformation and a preview picture allows the required transformations to be viewed immediately.

Similar functionality has been added in the Curve Editor for Patterns and Boundaries.

    Tool Holder and Shank Definition  

The tool holder and shank can now be defined directly from a pattern.

Complex tool assemblies can now be defined quickly and easily by way of the PowerMILL curve editor or via imported profiles.

It is also possible to draw the shank and holder when the tool is drawn on the cursor.

   

 Lead In Lead Out Feedrates  

The Lead in & Lead out feedrates can now be defined independently of the main cutting feedrate.

Slower material entry and exit will help to improve tool life and minimise the risk of part damage in brittle materials.

    Improved Toolpath Boundary Limiting  

A significant improvement has been made to the way toolpaths are limited to boundaries.

Toolpaths are now trimmed using a 3D limiting method, ensuring better and more accurate results.

 Toolpath and Boundary Outside Block  

Toolpaths and Boundaries can now be extended beyond the block limits.

This functionality will help to ensure that all parts of the model are machined.

 Block Enhancements  

There have been a couple of enhancements to the block form

1.Reference Surfaces can now be considered in the calculation for block size2.The block or model can now be saved as a DMT or STL file.

 Curve Editor Improvements  

There are several improvements to the Curve Editor toolbar:-

1.You can now create an arc which is tangential to existing lines and arcs, as well as at specific points using the Arc 3 Items button2.Fillets can now be modified in two ways3.You can now create a line which is tangent to a curve4.Also applicable to Patterns and Boundaries

Conclusion-

  Leading Global CAM Specialist

High Speed Machining- The ability to machine components in the shortest possible time is an issue of ever increasing importance. Any development in engineering which can give faster delivery, and at the same time improve quality, must, therefore be given serious consideration by the toolmaker.

For many years Delcam has been at the leading edge in the development of High Speed Machining (HSM) strategies. These use a combination of techniques to ensure rapid delivery of high quality machined components. There are many elements to efficient High Speed Machining including; the cutting tool, the CNC machine, the material being cut not to mention the use of a high quality CAM system.

Modern developments in cutting tool technology have led to a revolution in the way CNC programmers now tackle jobs. These specialist tools have totally different cutting characteristics to traditional tooling. Whereas traditional programming methods would consider machining a component from the top down, modern HSM tooling can sometimes prefer to cut from the bottom up.

PowerMILL leads the way with it's unique approaches to efficient area clearance. The main requirements of these machining strategies are to keep the load on the cutter as consistent as possible and to minimise any sudden changes in the cutting direction. One of the basic changes in strategy needed to achieve these conditions is the use of offset machining for roughing rather than the traditional raster approach.

Multi Axis Machining- 5 Axis machining has been used in aerospace applications for many years but it is only recently that the toolmaking industry has shown similar interest. The main advantage of 5 Axis machining is the ability to save time by machining complex shapes in a single set-up. Additional benefit comes from allowing the use of shorter cutters that permit more accurate machining.

Positional 5 Axis machining has long been available within PowerMILL. With this technique, the head is oriented into a series of positions and machining carried out as a set of discreet operations.

In addition to this, PowerMILL now offers continuous 5 Axis machining. Continuous 5 Axis machining allows the user to create continuous 5 Axis toolpaths across complex surface, solid and triangulated models. The toolpaths are fully gouge checked and support a wide range of machining strategies and all tool types.

“We can machine the surface in areas that would previously have been impossible to access economically. In addition, difficult surfaces that would have needed long series cutters are now simple. Easier access is allowing us to use shorter tools resulting in improved surface finish and a reduction in the number of post machining operations, including EDM.” David Gaskin, AF Gaskin Ltd, UK.

Benefits of Positional 5 Axis Machining Ideal for machining deep cores and cavities Short cutters give increased accuracy and higher quality surface finish Allows the machining of undercuts Significant time benefits through use of only one set up

Benefits of Continuous 5 Axis Machining Ideal for Profiling parts Ideal for machining deep corners and cavities Shorter cutters give increased accuracy and higher quality surface finish

Allows for machining with the flank or bottom of the tool Can be used with a full range of tool types Full gouge protection Can be used with models in STL format

Features and Functions Surface Finishing Swarf Milling Profiling Trimming: Pocketing Slotting Multi axis Drilling Integrated 5 Axis Post Processo

Electrode Manufacture 

Power and flexibility Ease of use and rapid toolpath generation Ability to works with all tool types Powerful toolpath editing Totally customizable with macros, templates, Visual Basic and HTML 

Confidence and reliability Animation and dynamic stock simulation Machine tool simulation Integrated toolpath verification Feedrate optimisation

References-

http://www.powermill.com http://forum.delcam.com/viewforum.php?f=8 http://www.mailers.delcam.com/customers/ams/PMILL2011.html http://en.wikipedia.org/wiki/

Delcam#Parallel_Processing_in_PowerMILL_10:_A_White_Paper http://forum.featurecam.com/