Autodesk is ushering in its new 2017 Computer Aided Manufacturing (CAM) products for a multitude of advanced manufacturing applications ranging from CNC mill- and lathe-programming to complex mold and die manufacturing. These new products combine the heritage of industry leadership in CAM software from Delcam with Autodesk’s 3D design and manufacturing prowess, presenting Autodesk CAM customers with a powerful and unique user experience.

Autodesk’s 2017 CAM solutions include enhanced versions of FeatureCAM for automating CNC programming; PartMaker for precision part manufacturing with Swiss-type lathes; PowerMill for designing the most complex molds, dies and other components; PowerShape for the design of 3D complex parts; and PowerInspect hardware-independent inspection software. New capabilities for each of the 2017 CAM products are detailed below.

“Manufacturers need to iterate and innovate faster than ever before to stay competitive as the marketplace is redefined by a new future of making things,” said Mark Forth, manager of manufacturing industry strategy at Autodesk. “Autodesk’s new 2017 CAM products are designed to help our customers learn, improve and master advanced manufacturing techniques that ultimately lead to better designed and functional products being brought to market more quickly and efficiently.”

Next month during the IMTS 2016 conference in Chicago, IL, Autodesk will outline its broader vision and software portfolio to support manufacturers in this new competitive environment. In addition to the technologies unveiled today, the company will also spotlight solutions for additive manufacturing, CAM, composites and more.
FeatureCAM 2017 and PartMaker 2017

Autodesk FeatureCAM is an easy-to-use solution for milling machines, turning and turn/mill centers, and wire electrical discharge machines (EDMs). The automation tools within FeatureCAM help manufacturers reduce programming time, allowing parts to be made faster. They also increase programming consistency for maintaining part quality. The 2017 version of the product includes the following improvements:

New programming capabilities for dual-path Swiss-type lathes, further improving its range of CNC machine support
Ability to import and view product and manufacturing information directly from a model in order to help visualize design specifications
Access to functionality that allows pre-drilling when using Vortex toolpaths, ruling out the need for helical ramp moves
FeatureCAM
In addition to the features above, PartMaker 2017, which enables complex, high-precision part manufacturing with Swiss-type lathes, is now available within the FeatureCAM 2017 Ultimate product tier. The two products in combination form a complementary bundle that effectively addresses the programming requirements of today’s manufacturing shops.

“We have a great history working with FeatureCAM, and when we were asked to evaluate the new Swiss lathe functionality, it was a no-brainer for us,” said Bill Karas of Karas Kustoms. “In the past, I had been programming the Swiss machine by hand. Using FeatureCAM for the Swiss machines saves our company a ton of time with excellent results.”
PowerMill 2017

Autodesk PowerMill 2017 takes the ability to easily and effectively manufacture the most complex molds, dies and other components to new heights. This latest version includes the following new features:

More efficient 3D offset finishing toolpaths, greater simulation controls and constraint-based logic to optimize non-cutting link moves for safer, more efficient machining
For the first time, PowerMill also provides strategies to create turning routines for use on 5-axis mill-turn machines
These improvements continue to make PowerMill the ideal choice for manufacturers looking to solve the most demanding of 3-axis, high-speed and complex multi-axis applications.

PowerMill-Turning-Large-1920×1080
“PowerMill helps us to maintain a high level of consistency in our programming, which directly and positively affects time in process and customer satisfaction,” said Randy Lee Meissner, CNC Department Supervisor at Dynamic Tool and Design. “We develop processes where each engineer is using the same techniques and the same tools, so there is no variation among the work everyone is doing. In the old days, there may have been some hand-fitting, but today we can count on uniformity in the molds we create from order to order.”
PowerShape 2017

The design of 3D complex parts just became more effective with the following improvements to PowerShape 2017:

Accessibility shading to identify areas of a part that cannot be machined with 3-axis machining alone
A new rib capping tool allows users of EDM technology to automatically create surfaces in order to stop cutting tools from machining slots that will be produced by EDM. Hundreds of surfaces are created in a single command, saving hours of manual modeling.
The PowerShape electrode wizard offers improved EDM hardware integration for shop-floor burning
Finally, regular users of reverse engineering tools can benefit from improved fitting of surfaces to imported triangle meshes
PowerInspect 2017

Autodesk PowerInspect simplifies the inspection of complex shapes by providing a single solution for a wide range of measuring equipment. PowerInspect 2017 includes the following new features:

Support for portable measuring equipment, coordinate measuring machines (CMMs) and On Machine Verification (OMV) are offered in a single package for PowerInspect Ultimate users. This improves productivity and flexibility by making it easier for operators to select the most appropriate measuring equipment for each job.
The ViewCube feature offers specific benefits for visualizing inspection results and creating inspection reports
A single click mechanism to recall the principal CAD viewpoints, making the creation of consistent inspection report images faster and easier than ever before
Improvements to point-cloud performance now allows users to take advantage of the improved capabilities in the latest scanning equipment
A dedicated point-cloud single point item provides an easy way to evaluate target points from laser scan data

What are the products and technologies that Delcam will showcase at DMI 2016 in Bengaluru?
We will be showcasing some of our most sought after products and solutions during DMI 2016. Some of them are:-

PowerSHAPE: The 2016 release of PowerSHAPE Pro software will help users to complete complex tooling designs faster and more easily. A combination of new, more efficient, code and the extension of multi-threaded calculations to many commonly-used tasks will make the software significantly faster than any previous version. One key enhancement allows groups of features to be copied between two solids in a single operation.  While the features do not need to be of the same type, the most common application is expected to be in copying patterns of holes from one solid to another, for example, from one mould plate to any other plate in the mould stack.

PowerMILL: The main enhancement in PowerMILL 2016 is the ability to mirror complete machining projects in one operation and to maintain the machining characteristics automatically, for example to specify automatically whether climb or conventional milling should be used in each section of the toolpath.  Previously, only individual toolpaths could be mirrored. Automatic mirroring saves considerable time whenever tooling is needed to produce right- and left-hand versions of a part.  It will also be faster to program the machining of moulds for symmetrical objects, since it will be possible to program one half of the core or cavity and then mirror the toolpaths to generate the complete program. A new PowerMILL module for creating ribs in tooling makes it much easier and safer to program the machining of cavities for narrow ribs, even when the cutter’s length is much greater than its diameter.  Using the dedicated rib-machining strategy gives a better surface finish than using a standard finish-machining option and also improves efficiency by limiting the number of air moves.

PowerINSPECT: The latest release of PowerINSPECT makes it easier to complete fast and accurate inspection of complex assemblies, including mould tools.  The main improvement for users of CNC CMMs is the addition of support for MCR20 and FCR25 probe change racks.  PowerINSPECT can now incorporate probe changes into fully-automated measurement sequences.  The new version also includes automatic feature extraction for point-cloud batch inspection, easier navigation of the history tree, better control over RPS alignments and new options for collision checking.

The role TAGMA and DMI plays for the industry…
TAGMA has been an exemplary body, leading the Die-Mould Industry in the country towards better enablement and technology in the past 25 years. I believe DMI is probably one of the largest events of its kind in this part of the world. The die mould fraternity is a closely knit one and this event projects that to end customers enabling them with a macro perspective that helps build more confidence as well as note the massive innovation that players in this domain undertake.

With the Make in India campaign rolling out across the country, the business value of participation is invaluable. With a focus on manufacturing, tools, dies and moulds will be fundamental to the success of this campaign; networking with contemporaries, peers and customers at a single venue will multiply opportunities and learning’s for all.

What are the latest developments in the CADCAM industry? Please take us through the current technology trends in the industry…
The CADCAM industry is working constantly to improve the customer experience and provide them with tools that will help them be more efficient and precise. Technologies like MachineDNA that help assess various parameters & kinematics of a machine tool and provide appropriate output to the NC program in order to ensure that the cutting is optimal is something that I believe will help machinists immensely. Our parent organisation Autodesk is also leading the disruption with the Future of Making Things (FOMT) in manufacturing. Through FOMT, a better, faster decision making process, ability to work effectively with newer materials and fabrication methods (Advanced manufacturing) and enabling these technology solutions on the cloud will help transform businesses quickly, safely and efficiently, whilst delivering maximum competitive advantage to our customers.

India is home to many CAM solution providers, what would be your strategy to stay ahead in the competition?
There are indeed several CAM solution providers and it is not just true for India alone. The CAM market is fragmented and I see some consolidation in the industry now. However, the key factor in our line of business is people and support. We have been in India as a direct office for the past 16 years and arguably are the leading CAM supplier in the country. Through a dedicated and pro-active team that we have across 14 offices in the country, we are constantly in touch with our customers to understand their key requirements and pain areas. This helps us being more responsive and adaptive to their needs. We also invest heavily in R&D.

Please share with us the growth trends of die and mould industry in India – and what are the key drivers of this industry in the manufacturing sector?
The die and mould industry in India has had a steady growth largely, but has also seen its share of slowdowns as well. To a large extent the die and mould industry has based its growth on the automotive sector and therefore the result relies more importantly on automotive growth in the country (or across the globe for that matter) than anything else. However, this is soon changing with organisations investing in new technology and continuously innovating – rather than being just mould or tool suppliers. The OEs too are doing their bit by involving tool making companies in their development plans so that the entire chain becomes efficient. According to me, competence, delivery schedules and impeccable quality are the three most important drivers of this industry in the manufacturing sector.

What will be the impact of programmes like Make in India, Digital India and Smart Cities project on the die and mould industry?
Programs like Make in India, Digital India and Smart Cities are envisioned to transform the country and each of these will result in a better quality of life for citizens. Naturally, the die and mould industry will play a key role in helping these programs to be efficient through innovative product/tool designs, material selection and durability, aesthetics and functional quality of the end products – and these factors are true for all of the above programs for building a brand – India.

The above programs are also expected to bring in investments, newer technologies, budding scientists and engineers, veteran industrialists and the Government towards a common goal of building brand India. This is an opportunity that comes with a privilege and the die & mould industry can take a leadership role in transforming change from the roots.

Do you think SMEs in India are ready to adopt high end technologies like CAM?
SMEs in India have been adopting high end technologies like CAM and CNC machines for a long time now. It is now time to think beyond these and look at the ever changing consumer needs, changing materials and the methods of producing these new age materials. I feel that we have reached a stage where companies start investing not only in high end technologies, but also in employees, knowledge and analytical capital. This will help SMEs transform into larger and more responsive organisations.

Tell us about the growth of your company and your growth expectations in the next financial year…
We have been growing double digit YoY for the past 16 years now. We now supply to a diverse portfolio of customer industries as well as products. I am very positive of our continued growth in the coming FY as well.

Delcam will demonstrate the latest releases in its range of CADCAM software for mouldmakers at the Die & Mould International exhibition to be held in Bangalore, India, from 6th to 9th April. New releases will be on show of the modelling-for-manufacture CAD system, PowerSHAPE, the PowerMILL CAM system for high-speed and five-axis machining, and the PowerINSPECT inspection software.

The 2016 release of PowerSHAPE Pro software will help users to complete complex tooling designs more quickly and more easily. In addition, a combination of new, more efficient, code and the extension of multi-threaded calculations to many commonly-used tasks will make the software significantly faster than any previous version.

One key enhancement allows groups of features to be copied between two solids in a single operation. While the features do not need to be of the same type, the most common application is expected to be in copying patterns of holes from one solid to another, for example, from one mould plate to any other plate in the mould stack.

The main enhancement in PowerMILL 2016 is the ability to mirror complete machining projects in one operation and to maintain automatically the machining characteristics, for example to specify automatically whether climb or conventional milling should be used in each section of the toolpath. Previously, only individual toolpaths could be mirrored.

Automatic mirroring saves considerable time whenever tooling is needed to produce right- and left-hand versions of a part. It will also be faster to program the machining of moulds for symmetrical objects since it will be possible to program one half of the core or cavity and then mirror the toolpaths to generate the complete program.

A new PowerMILL module for creating ribs in tooling makes it much easier and safer to program the machining of cavities for narrow ribs, even when the cutter’s length is much greater than its diameter. Using the dedicated rib-machining strategy gives a better surface finish than using a standard finish-machining option and also improves efficiency by limiting the number of air moves.

The latest release of PowerINSPECT makes it easier to complete fast and accurate inspection of complex assemblies, including mould tools. The main improvement for users of CNC CMMs is the addition of support for MCR20 and FCR25 probe change racks. PowerINSPECT can now incorporate probe changes into fully-automated measurement sequences.

The new version also includes automatic feature extraction for point-cloud batch inspection, easier navigation of the history tree, better control over RPS alignments and new options for collision checking.

Commenting on the event, Vineet Seth, Delcam’s Managing Director for South Asia & Middle East, said, “We have been participating in the TAGMA Die & Mould exhibition for over a decade now. It is interesting to note that, over the period, many of our die-mould customers have diversified their businesses into emerging markets like automotive component manufacturing, aerospace component manufacturing, composites manufacturing, automation products, healthcare components etc. This has been possible due to their wide experience in precision manufacturing as well as their willingness to invest in technology products that offer reliability, flexibility and speed. I’m really looking forward to the event in Bangalore, as this region offers a mix of all of the aforementioned emerging markets. The exhibition will allow us to share with visitors, the benefits of investing in our Advanced Manufacturing Solutions software that is renowned for being reliable, easy-to-use, robust and fast.”

Parker Aero Tooling Solutions, a rapidly expanding aerospace toolmaker, has changed to Delcam’s PowerMILL CAM software to remove a programming bottleneck that was limiting the company’s productivity.

The company, which has been based in Accrington in the North-West of England for over forty years and is now in its second generation of family ownership, produces a wide range of tooling, including jigs and fixtures, exclusively for the aerospace industry.  It has been closely involved in designing and manufacturing tooling for many of the world’s most prestigious aircraft programmes, including all Airbus platforms, plus the Eclipse and Honda VLJ programmes.  Virtually all of the tooling is made as a ‘one-off’ so developing the most efficient machining approach for each project involves a steep learning curve.

Most of the staff are time-served toolmakers with a wealth of aerospace knowledge, and their skills and expertise are needed on almost every job.  In addition, Managing Director, Mike Parker, puts a strong emphasis on encouraging direct interaction between his staff and his customers.  “We have built up a detailed knowledge of our customers’ equipment so we can make tooling that will be easy for them to install and efficient for them to use,” he claimed.

“We have always designed our tooling with the same CADCAM system that is used by most of our customers, and have been happy with that aspect of the software,” said Mr. Parker.  “However, we have ten machines, including several five-axis machining centres, all demanding programs.  We were experiencing a serious bottleneck with our two seats of the machining software as we couldn’t supply toolpaths quickly enough.”

Mr. Parker investigated a number of alternative CAM programs before deciding on PowerMILL.  The software provided a complete machining package that covers all the bases for the range of projects at G. Parker Aero Tooling Solutions, plus the price was very competitive.  In addition, the company was already using Delcam’s PowerINSPECT inspection software and had been impressed with both the software and the support provided.

Even though the staff have only been using PowerMILL for a few months, the effects have been dramatic.  “We have effectively doubled our programming capacity with the three seats of PowerMILL because the software is so much easier to use,” reported Mr. Parker.

Craig Cooke, Production Manager, had used an alternative CAM system for all his working life but hasn’t found anything that PowerMILL can’t do.  “All four people that we have trained in PowerMILL have been very motivated.  Of course, introducing new software has seen some difficulties but nothing insurmountable,” he said.

A key benefit of PowerMILL for G. Parker Aero Tooling Solutions is that it is purely a machining package so it is much easier to introduce onto the shop floor.  “It is much simpler to exchange knowledge between the different users because it is so much easier to use,” said Mr. Cooke.

“The calculation times are around 25% faster, which, along with the ease of use, means we can generate programs more quickly,” he continued.  “Stock models are much easier to use in PowerMILL so we are able to reduce air cutting and shorten machining times with rest machining.  We had always struggled with creating undercuts but programming for disc cutters is extremely quick in PowerMILL.  The surface finish we get now is very good; it is extremely smooth with no faceting.  This has reduced polishing time by an average of 20%.”

Operator Robbie Cooke has also been impressed with the Delcam software.  “PowerMILL is very graphical with pictures to tell you what the system is going to do,” he explained.  “The measuring tools for angles and undercuts help me to choose the best strategy and cutting tools to use, while the automation in the software means that I can complete programs more quickly.  I’ve only been using the software for a few months so the simulation tools are really valuable.  They make it easy to see if you are going wrong and to put it right.  They also give me the confidence to put jobs onto the machine straight away.  I’ve already programmed all sorts of jobs – press tools, jigs, fixtures and so on.  PowerMILL handles it all.”

The productivity boost from introducing PowerMILL has come at an important time for G. Parker Aero Tooling Solutions.  “Business is pretty good,” claimed Mr. Parker.  “We already have enough projects lined up to make 2016 a better year than 2015.  We have plans to add more five-axis machines as they always seem to be fully booked and we will be recruiting two more apprentices.  Extra training, including more PowerMILL courses, is also planned for the existing staff to make them more flexible so we are able to take on more projects.”

An investment in a new Mazak machining centre convinced Neil and Gareth Williams, Joint Managing Directors of Halesowen-based Hockley Pattern, that the time had come to move up to Delcam’s PowerMILL CAM software for five-axis and high-speed machining.

One of the UK’s leading toolmakers for the aerospace and automotive industries, Hockley Pattern specialises in turnkey tooling packages for the production of composite components, together with all the associated jigs and fixtures for trimming, drilling, checking, assembling and bonding those parts. The company boasts an impressive list of clients in both sectors, having supplied the likes of Airbus, Bombardier, Rolls Royce, Spirit Aerostructures, Triumph Structures, GE Aviation, GKN, Bentley, BMW and Jaguar Land Rover.

The company was founded by Neil and Gareth’s father in 1979 and is now jointly managed by the two brothers. Since moving to its current site in Halesowen six years ago, it has doubled its turnover, increased its workforce to 53 people and now has the strongest order book since it started trading.

The brothers decided to invest in a Mazak VTC 800 five-axis machining centre to expand the company’s existing machining capacity, in particular to accommodate a large tooling order from Airbus. They believed the machine would be ideally suited to the production of the large, complex tooling required in a variety of different materials by the aerospace industry. However, he was less confident in the capabilities of the company’s CAM system.

“We were making a significant investment in a machine that had the potential to process difficult-to-machine materials, much more quickly and to exceptionally high tolerances,” remembered Neil Williams. “There didn’t seem to be much point in making that investment without a CAM system that could help us take full advantage of the machine’s capabilities. We had been thinking about switching to Delcam software for some time and the new five-axis machine meant it was definitely time to make the change.”

“Our aim is always to keep on improving and developing our manufacturing procedures to ensure that we can support all of our customers’ needs,” continued Mr. Williams. “Even during the last recession, we kept on investing in new equipment. This not only ensures that we stay competitive, it also means that we can continue to deliver the highest quality tooling.”

As CNC Manager, Darren Laker was responsible for supervising the transition to the new software. “We had one programmer that had used PowerMILL in a previous job, which meant we could start using the software almost immediately,” he recalled. “However, he had only used the software for three-axis programming so Delcam put one of its experts on-site for an intense session in five-axis operation. Similarly, we had on-site support when we needed to add some extra options for the new machine to the standard post-processor.”

The benefits of the change soon became apparent. “With our previous software, the tool wouldn’t always be retracted far enough from the job so we had to check everything really carefully before we sent toolpaths to the machine or we would risk gouging the part,” said Mr. Laker. “With PowerMILL, we haven’t seen any similar problems. I’m sure the reliability comes from the fact that Delcam has its own manufacturing facility where it can test its software on real jobs.”

“Programming our drilling routines has become much faster,” he added. “With PowerMILL, you can detect all the holes in a model and group them by size automatically ready for drilling. Previously, we had to select, measure and program each hole individually. This took far longer and there was always a chance of missing a hole in our more complex parts.”

PowerMILL’s built-in CAD tools are also a big help, for example, when programmers want to add run-off surfaces to models or to cap holes before generating milling toolpaths. Models don’t have to be sent back to the CAD office for modification, which could cause delays, especially at the weekends when there wouldn’t be any CAD staff on-site.

Even though Mr. Laker knows that there is plenty more to come as his team becomes more familiar with PowerMILL, he is already convinced that the change was the right decision. “Most people I talk to about our business ask if I use Delcam software,” he claimed. “I’m very pleased that I can now say “Yes” because of the credibility that comes from being a Delcam user.”

CAM developer Delcam and tooling supplier Technicut have partnered to produce a novel method for blisk machining that delivers remarkable savings in both time and cost. The new method covers the machining of the blisk from start to finish and combines new tooling concepts from Technicut with advanced machining strategies in Delcam’s PowerMILL software for the rough, semi-finish and finish machining of integrally bladed rotors.

A video of the new process can be seen on the Delcam AMS channel on YouTube, In this example, the cycle time was reduced to 35 hours, less than half the time that would have been needed using conventional methods, while the costs for milling were reduced by 45%. The initial billet was 804 mm diameter Ti6-4 titanium, while the completed blisk had 31 blades, each 84mm in length with a root radius of 4mm and scallop height of 10µm.

Blisks are used increasingly in place of a series of individual blades fixed into a central hub. They offer advantages in weight, efficiency and through-life servicing but are challenging to manufacture because of their highly complex shapes and the hardness of the materials used, usually titanium or nickel alloys.

As with most machining projects, the new blisk machining method comprises roughing, semi-finishing and finishing operations. The initial rough machining operation cuts between the blades with a series of slotting cuts using Technicut’s new Titan X-Treme Ripper endmill. As well as removing the bulk of the material between the blades, this operation relieves any stresses in the billet introduced during the forging process.

Both the semi-finishing and finishing operations on the individual blades are then undertaken in a series of vertical sections, working from the tip downwards. The lower sections are left in the rough state to maintain the stiffness of the blade in the area being machined and so to minimise push-off of the blade tip by the cutter.

In addition to the specific toolpaths for blisk machining in PowerMILL, the key to the new method is the use of barrel cutters from Technicut for both semi-finishing and finishing. The tooling designs incorporate a much larger radius on the cutting surface that the ball-nose cutters that would normally be used and so can achieve the same cusp height with a stepdown up to three or four times as large. This larger stepdown means fewer cutting passes are needed to achieve the target smoothness in the surface, meaning that machining times can be reduced significantly.

Delcam has launched the 2016 version of its PowerMILL programming software for five-axis and high-speed machining.

The main enhancement in the new release is the ability to mirror complete machining projects in one operation and to maintain automatically the machining characteristics, for example to choose automatically whether climb or conventional milling should be used in each section of the toolpath. Previously, only individual toolpaths could be mirrored.

Automatic mirroring saves considerable time whenever right- and left-hand versions are needed of a part or tool. It will also be faster to program the machining of symmetrical objects since it will be possible to program one half and then mirror the toolpaths to complete the program.

To ensure that the mirroring has performed as expected, the new option can be used with the ability, introduced in PowerMILL 2015 R2, to undertake complete verification of a project for machine-tool issues such as collisions. Comprehensive verification can be performed, including ensuring that the machine tool is capable of running the mirrored toolpaths, as well as checking for both machine-tool collisions and tooling collisions.

PowerMILL 2015 R2 also saw the introduction of the ability to simulate machine-tool movements as tool changes are executed. The capability has been enhanced in the 2016 release by allowing more complex tool changes to be simulated, in particular those involving a carousel mechanism.

Other improvements to simulation in PowerMILL 2016 include a new form to print out the position of the cutting-tool tip during simulation, an auto-translucency option that will allow viewing of the table attach point at all times, and the ability to draw translucently the safe areas for rapid moves.

Development work has continued on the optional modules for PowerMILL as well as to the main program. In particular, a new, more efficient strategy to machine single blades has been developed for the Blades, Blisks & Impellors module, and a constant-Z machining option has been added to the module for programming the machining of ribs into tooling.

Delcam will demonstrate the 2016 version of its PowerMILL  programming software for five-axis and high-speed machining on booth C05 in Hall 4 at the EMO exhibition to be held in Milan from 5th to 10th October.

The main enhancement in PowerMILL 2016 is the ability to mirror complete machining projects in one operation and to maintain automatically the machining characteristics, for example to choose automatically whether climb or conventional milling should be used.  Previously, only individual toolpaths could be mirrored.

Automatic mirroring saves considerable time whenever right- and left-hand versions are needed of a part or tool.  It will also be faster to program the machining of symmetrical objects since it will be possible to program one half and then mirror the toolpaths to complete the program.

To ensure that the mirroring has performed as expected, the new option can be used with the ability, introduced in PowerMILL 2015 R2, to undertake complete verification of a project for machine-tool issues such as collisions.  Comprehensive verification can be performed, including ensuring that the machine tool is capable of running the mirrored toolpaths, as well as checking for both machine-tool collisions and tooling collisions.

PowerMILL 2015 R2 also saw the introduction of the ability to simulate machine-tool movements as tool changes are executed.  The capability has been enhanced in the 2016 release by allowing more complex tool changes to be simulated, in particular those involving a carousel mechanism.

Other improvements to simulation in PowerMILL 2016 include a new form to print out the position of the cutting-tool tip during simulation, an auto-translucency option that will allow viewing of the table attach point at all times, and the ability to draw translucently the safe areas for rapid moves.

Development work has continued on the optional modules for PowerMILL as well as to the main program.  In particular, a new, more efficient strategy to machine single blades has been developed for the Blades, Blisks & Impellors module, and a constant-Z machining option has been added to the module for programming the machining of ribs into tooling.

Delcam has launched the 2016 version of its PowerMILL programming software for five-axis and high-speed machining.

The main enhancement in the new release is the ability to mirror complete machining projects in one operation and to maintain automatically the machining characteristics, for example to choose automatically whether climb or conventional milling should be used in each section of the toolpath. Previously, only individual toolpaths could be mirrored.

Automatic mirroring saves considerable time whenever right- and left-hand versions are needed of a part or tool. It will also be faster to program the machining of symmetrical objects since it will be possible to program one half and then mirror the toolpaths to complete the program.

To ensure that the mirroring has performed as expected, the new option can be used with the ability, introduced in PowerMILL 2015 R2, to undertake complete verification of a project for machine-tool issues such as collisions. Comprehensive verification can be performed, including ensuring that the machine tool is capable of running the mirrored toolpaths, as well as checking for both machine-tool collisions and tooling collisions.

PowerMILL 2015 R2 also saw the introduction of the ability to simulate machine-tool movements as tool changes are executed. The capability has been enhanced in the 2016 release by allowing more complex tool changes to be simulated, in particular those involving a carousel mechanism.

Other improvements to simulation in PowerMILL 2016 include a new form to print out the position of the cutting-tool tip during simulation, an auto-translucency option that will allow viewing of the table attach point at all times, and the ability to draw translucently the safe areas for rapid moves.

Development work has continued on the optional modules for PowerMILL as well as to the main program. In particular, a new, more efficient strategy to machine single blades has been developed for the Blades, Blisks & Impellors module, and a constant-Z machining option has been added to the module for programming the machining of ribs into tooling.

A combination of Autodesk’s Maya design software, Delcam’s PowerMILL Robot programming system and a KUKA robot allows special effects company, Artem, to bring amazing projects to life. A video showing the process used is on Delcam.TV at www.delcam.tv/artem

Artem provides special effects of all types from giant puppets to small film props from its base in West London. “We get involved in all sorts of technology, the most recent being robot machining and 3D printing,” explained Artem CEO, Mike Kelt. “Much more is done on a computer now than has ever been done in the past when it used to be very much an industry based on hand skills.”

“One of the challenges is dealing with clients who aren’t entirely sure what they want,” added Mr. Kelt, “so you have to tell them what you think they want and get them to approve things. If you can do the design on a computer with Maya and send them an image that’s rendered, then they can go “yeah that’s it”, and we can carry on with the design and manufacturing process.”

The team at Artem explained how the process develops, starting with modelmaker, Jim Bones. “My main job is to pose the figure,” he said. “I sit down with the sculptor and we’ll tweak everything to get it all in the right positions. Importing a RIG model on Maya is a massive advantage as it comes with all these handles. I can just grab them and pose every little bit of the model. It’s all very easy to use.”

“We often start with the photograph and position the Maya RIG model to look like the photograph,” continued Andrew Freeman, Digital Sculpture and CNC Supervisor: “Then we can export the model from Maya into another software, a sculpting package, that’s going to allow us to fine tune the model, add on the clothing, change the muscles to give the look that the client wants. Once the design has been approved, we can start chopping the pieces up and putting them into the Delcam software to prepare them for cutting on the robot.”

The programs for the robot are developed by Design Engineer, Ken White. “We import the part designs into PowerMILL Robot as a series of STL files,” he stated. “For each element, we create roughing and finishing passes which we then simulate to see how they machine. Once I am happy, the toolpaths are output as G-code to the KUKA robot for machining.”

“Because we are using STL files, creating boundaries is very important to be able to get to certain areas of the model,” he added. “The robot allows us to machine very large pieces so keeping the number of parts to as few as possible. We are able to use the software to see how the robot is going to cut the material and to see the finish we are going to get, while the software also lets us see how the robot will react in the cell and make sure that it is not going to do something silly.”

“I see a really bright future for Delcam with this company – we’re delighted with the robot and the software,” concluded Mr. Freeman. “We are going to try and extend the software to the other machines now. For me, PowerMILL is very easy to use and it’s very good at what it does.”