Delcam will launch the 2016 version of its PowerMILL programming software for five-axis and high-speed machining at the Manufacturing & Engineering North East exhibition to be held at the Metro Radio Arena, Newcastle, on 8th and 9th July.

The main enhancement in PowerMILL 2016 will be 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 will save 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 will be able to 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’s PowerMILL CAM software was used by Manufax Engineering to create a highly efficient NC program to machine the tail-fin shear plate for the Bloodhound SuperSonic Car (SSC).  A complex, freeform aluminium component, the shear plate will form the interface between the tail-fin structure and the body of the vehicle for its attempt at the world land-speed record.

Based in Stockport, UK, Manufax is a major supplier to the aerospace, automotive, nuclear and agricultural industries, as well as supporting general precision-engineering businesses.  With several decades of experience, the company provides specialist tooling design and manufacture across all disciplines, including jigs and fixtures for airframe assembly, mould tools, automotive tooling and components for nuclear power generation.  Manufacturing is Manufax’s core business and the company has an excellent reputation for supplying its customers with a quality precision-engineering service.

A dedicated and multi-disciplined workforce has been trained to adapt to the unique and challenging projects undertaken at Manufax.  Both these criteria can certainly be applied to Bloodhound SSC, a jet- and rocket-powered car designed to go at 1,000 mph.  Manufax is no stranger to the Bloodhound SSC project, having produced the mounting frame for the HTP (High Test Peroxide) fuel tank, and an assembly jig that is being used to assemble and align the lower chassis, side rails and upper chassis.

The company’s Correa FP50 five-axis gantry-type machining centre was selected to produce the component in aircraft-grade aluminium.  CAD/CAM Projects Engineer, Mark Brittain, used PowerMILL to produce the five-axis NC program to machine the shear plate, with its very demanding geometric forms, from a single billet of aluminium.

At the suggestion of Tony Theaker, Area Manager for SGS Carbide Tool (UK), Mr. Brittain used the Vortex area-clearance strategy in PowerMILL and an SGS S-CARB APR three-flute roughing end-mill to rough the part in one operation.  Like Delcam, SGS is a partner in the Bloodhound project.

The combination of the Vortex strategy and the SGS tooling resulted in significant cycle time savings of over 40 per cent. “We were a little sceptical at first, as the cutting data being suggested for the S-CARB APR cutting tool was providing phenomenal results within PowerMILL,” Mr Brittain recalled.  “We could not afford to scrap the raw material so we set up a trial cut with a sample of the same grade of aluminium on the machining centre, and applied the speeds, feeds and depths of cut suggested by SGS.”

“The trial proved our trust in PowerMILL’s NC code and the cutting tool was well founded, continued Mark Brittain.  “They performed remarkably well together.   As well as giving the predicted time savings, the toolpath and the cutting action reduced any deflection of the thin walls of the rough machined part.”