Delcam has added more five-axis machining functionality in the 2016 R2 release of its   FeatureCAM CAM programming software. Other enhancements include improved control and simulation capabilities for multi-axis machines, plus options to reduce both programming and machining times.

FeatureCAM was the world’s first feature-based programming software when it was launched in 1995. Constant development since then has ensured that the system has retained its leadership in programming speed and ease of use, while an increased range of strategies has been added to provide more efficient toolpaths that give greater productivity on a wider range of machinery, including turn/mill machines, five-axis mills and wire EDM equipment.

FeatureCAM 2016 R2 introduces the ability to machine features aligned to the Z axis by using the C axis, rather than by moving in the X and Y axis. This option, which is commonly known as polar milling or polar indexing, can be used in situations where the machine cannot travel beyond a certain linear point. Instead, the C axis can be used to rotate the part within the machining envelope. It can be most helpful when machining parts with a circular profile, when machining times can be reduced and surface finish improved.

Another addition to FeatureCAM’s flexible machine architecture provides support for the W-axis option in machine tools such as horizontal boring machines. This addition can be used to control and simulate moveable live spindles that can extend the travel limits of the Z axis to help avoid collisions.

The new release also includes an improvement to automatic tool selection – the inclusion of a check of the diameter of the tool shank. If the shank diameter is found to be larger than the diameter of the cutting portion of the tool, FeatureCAM will choose a tool of the appropriate length to avoid collisions of the shank with the part.

FeatureCAM 2016 R2 provides settings to position and index a turret within a part-handling feature when programming turn/mill machines. These settings can now be shown within the machine simulation, making it possible to pre-empt and fix potential collisions during part-handling operations.

Two options will allow more efficient machining. Firstly, relative plunge, which now supports two-axis spiral and zig-zag toolpaths, can be set to allow the tool to rapid to the plunge clearance location, rather than feeding to it. Secondly, curve sorting has been added to give better control of the order for machining multiple curves within a single feature. This can be set automatically using options including ascending or descending in X, Y or Z, or using the shortest path to achieve the quickest cycle time.

Machine design files can now be selected on a document level, making it easier to check visually which file is loaded. The same dialog also makes it quicker to edit the set-up location of the component and to change the machine-design file for the post-processor that is currently loaded.

Finally, FeatureCAM allows a post-processor document to be generated. This document helps users to understand the capabilities of the post-processor that is loaded currently.

Delcam has launched the 2015 R3 release of its FeatureCAM feature-based CAM software.  This includes a range of enhancements to give high-quality results on all types of machine tool, including complex mill-turn equipment and five-axis machining centres, while retaining the rapid programming times for which FeatureCAM is renowned.

FeatureCAM was the world’s first feature-based programming software when it was launched in 1995.  Constant development since then has ensured that the system has retained its leadership in programming speed and ease of use, while an increased range of strategies has been added to provide more efficient toolpaths that give greater productivity on a wider range of machinery, including mill-turn machines, five-axis mills and wire EDM equipment.

The most significant new option is the ability to duplicate the physical constraints of the machine tool in simulations in FeatureCAM.  Machine-tool limits can be added to the models to be used in the simulation for three-, four- and five-axis milling machines, for turning equipment, and for mill-turn machines, including those with multiple turrets and/or multiple spindles.  It is then possible to check that the chosen machine tool is capable of completing the proposed program for all types of equipment, from the simplest lathe to the most complex multi-tasking machine.

The simulation will pause whenever the program attempts to move the machine beyond the specified limits.  In many cases, simply changing the position of the part on the machine bed will allow the whole operation to be completed.  Alternatively, modifications to the fixturing or to the length of the cutting tools may be required.  Whatever changes are made, the computer simulation can then be repeated to check that the modified program will run successfully.  Proving out the program on the computer will save time and money on the machine tool, as well as checking that the part can be cut safely.

In another improvement to FeatureCAM simulations, more accurate representations can be created of shanks and holders.  These allow three-axis and five-axis collision checking to be undertaken more reliably.

Two enhancements have been made to five-axis machining with FeatureCAM.  Firstly, more control is available with the ability to set the C-axis orientation about the Z axis so helping to avoid machine collisions and to make the program more efficient by avoiding over-travel.  Secondly, support for five-axis operation is possible in 2D spiral operations, giving better control of the tool axis.  This can ensure uniform depth of cut and cross-section when engraving onto complex surfaces, including parts with undercuts.

Additional accessories that are supported in the new release include turning-head holders and mini turrets.  Turning-head holders allow turning to be undertaken on a milling machine, while mini turrets allow more flexible positioning of the tooling and faster tool changes.  In both cases, the new options can be simulated on the computer before being sent to the machine.

Delcam’s Illinois office presented the latest developments in the company’s PowerMILL CAM system for high-speed and five-axis machining and its FeatureCAM feature-based programming software at its annual update meeting earlier this month.

The meeting was held at Ingersoll Cutting Tools in Rockford and included live cutting demonstrations on Ingersoll’s Mori Seiki MV-65 and Toyoda UX570 CAT 40 machines. Both demonstrations showed the machining of a metal replica football, one programmed with PowerMILL and one with FeatureCAM. Recognizing the divided loyalties of the region’s Delcam customers, one was produced with a Chicago Bears theme while the other featured the Green Bay Packers. Part of the engraving process can be seen here – www.youtube.com/watch?v=ER8LR4-z4P0

The new release of PowerMILL includes improvements to the Vortex high-efficiency area-clearance strategy, expanded collision checking to also cover near misses, and more efficient raster finishing.

Vortex produces safe toolpaths with a much deeper cut by using a controlled engagement angle that maintains the optimum cutting conditions for the whole toolpath. As a result, higher feed rates and material-removal rates are possible, making the cutting time shorter by as much as 70%. Enhancements in PowerMILL 2015 will give even greater reductions in machining time with Vortex compared to conventional roughing.

Companies using four- or five-axis machines with trunnions or similar tilting tables will benefit from new options are now available to distribute PowerMILL’s toolpath points so that the machine’s gimbal-lock position is avoided and a smoother motion results.

As well as including the latest developments in the Vortex strategy, the 2015 version of FeatureCAM incorporates a range of enhancements in three-axis milling, two-axis and five-axis drilling, turning and turn-mill, and wire EDM to make the software even more powerful and easier to use.

FeatureCAM was the world’s first feature-based programming software when it was launched in 1995. Constant development since then has ensured that the system has retained its leadership in programming speed and ease of use, while an increased range of strategies has been added to provide more efficient toolpaths that give greater productivity on a wider range of machinery, including mill-turn machines, five-axis mills and wire EDM equipment.