PowerMILL made even more eﬃcient - Delcam · PowerMILL 2105 produces smoother toolpaths on...

ISSUE 3 2014

For more news, go to www.delcam.com and www.delcam.tv

P6/7FeatureCAM made even easierNew options fordrilling, milling,turning, turn-mill and wire EDM

P8/9Cut machiningtimes with VortexThree case studiesshow savingspossible with Vortexarea clearance

P3PowerSHAPE 2015launchedImprovements to directmodelling, surfacemodelling and reverseengineering

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The 2015 version of Delcam’s PowerMILL CAM system for high-speed and five-axis machining includesimprovements to the Vortex high-efficiency area-clearance strategy, more flexible collision checking toalso cover near misses, and more efficient raster finishing.Vortex produces safe toolpaths with a muchdeeper cut by using a controlled engagementangle that maintains the optimum cuttingconditions for the whole toolpath. As a result,higher feed rates and material-removal rates arepossible, making the cutting time shorter by asmuch as 70%. In addition, cutting is undertakenat a more consistent volume-removal rate and at a near constant feed rate, so extending tool life and protecting the machine.

Two enhancements in PowerMILL 2015 will give even greater reductions in machining timewith Vortex compared to conventional roughing.The first change allows toolpaths to approachthe part from outside the stock at the cuttingheight for open pockets or in areas where earliercuts have made this possible. Previously, allentry moves had to be made by plunging ontothe surface or by ramping into the material.

The second change allows an increased feedrate to be set for non-cutting moves. The default

value is set at double the rate for the cuttingmoves but this can be altered as required foreach machine tool. The extra time that can besaved depends on the shape of the part but an additional saving of around 20% should beexpected above the earlier releases of Vortex.

Another problem in previous versions ofPowerMILL was that unnecessary lifts could beadded to area-clearance toolpaths when thecutter moved outside the stock or close to its

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For full details on the new options in PowerMILL2015, visit the LearningZone at lz.powermill.com

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Two enhancements inPowerMILL 2015 will give evengreater reductions in machiningtime with Vortex compared to conventional roughing.

edge. Changes to the roughing algorithm havenow reduced the number of lifts per toolpathslice to the minimum needed and so made area clearance much more efficient.

Companies using PowerMILL for either positionalor continuous five-axis machining will benefitfrom improvements to the collision checkingwithin the software. Firstly, collision checking has been changed so that warnings can also be flagged for near misses. The user can nowspecify a clearance value and, when the machinetool comes within this value, it will turn yellow incolour to highlight a near miss. Collisions will stillbe shown by a change of colour to red.

Secondly, the display showing the list ofcollisions, and now near misses as well, hasbeen updated to be easier to read, making itsimpler to extrapolate the coordinates at thesepoints. For near misses, the clearance distanceis shown in the display, with the distance shownas zero for collisions.

PowerMILL madeeven more efficient

Collision detection in PowerMILL2015 will also show near misses

0924 DEL News 3 2014_AW Q9_Layout 1 14/08/2014 15:26

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A clearer form for strategyselection makes navigation easier when choosing whichstrategy to use. It is also easier to create folders of strategies and to add and remove strategies.

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Another improvement will help companies using four- or five-axis machines with trunnionsor similar tilting tables. Previous PowerMILLtoolpaths could exhibit unwanted changes of azimuth as the cutting tool approached aposition vertical to the part. This would slowdown the machine, often to the extent that a witness mark would be left on the surface. New options are now available to specify theinformation used by PowerMILL to distribute the toolpath points so that the machine’sgimbal-lock position is avoided and a smoothermotion results.

Raster finishing has also been improved inPowerMILL 2015, with the software now able to set automatically the most appropriate anglefor each region of the part. In previous versions,the user had to select each area and specify theangle manually. The new option, which providesthe same functionality that already existed forsteep-and-shallow finishing and face milling, is most beneficial when finishing a series ofpockets aligned in different directions.

A number of improvements have been made to the PowerMILL interface. Most important is a clearer form for the strategy selector thatmakes navigation easier when choosing whichstrategy to use. It has also been made easier to create folders of strategies, for example, those most suitable for a particular machine tool, material or type of part, and to add andremove strategies from those folders.

Finally, three new curve-creation options havebeen added to the curve editor – ellipse, spiraland helix. These options can be used to createpatterns or boundaries when generatingtoolpaths.

PowerMILL 2105 producessmoother toolpaths onmachines with tilting tables

PowerMILL made even more efficientcontinued

The most appropriate raster machining angle for each region is now selected automatically

Impcrossstandardises on DelcamUK precision engineering specialist,Impcross, has standardised onDelcam software for its futuredesign and programming needs.The order for multiple seats ofPowerSHAPE, PowerMILL andFeatureCAM was confirmed duringthe recent MACH exhibition.Impcross, which is based in Stroud inGloucestershire, has grown into a world-classcentre of precision engineering over more than twenty years. It makes high-precisioncomponents in an array of materials for theaerospace, automotive, autosport, military andpetro-chemical industries. The company hasbuilt up a wide range of equipment, includingeleven three- and five-axis Matsuura mills, twoDMG DMU five-axis machining centres, andturning and turn-mill equipment from Hitachi-Seiki, Mori-Seiki, MHP and Romi, plus high-precision grinding and jig-boring machines.

“At Impcross, we focus on providing ourcustomers with a winning blend of accuracy and excellence,” claimed Operations Manager,Steven Arnold. “We offer quality, speed andcompetitive pricing to all our customers, whetherthey are ordering a one-off prototype or a largerun of components.”

“Despite our status as one of the UK’s leadingcentres for precision engineering, we know thatwe cannot afford to be complacent and so put a big emphasis on our continuous improvementphilosophy,” added Mr. Arnold. “With our newDelcam software, our production engineeringand programming departments are fullyequipped to produce even the most complexparts on our five-axis and turn-mill equipment.”

“In all the sectors we supply, the pressure for cost reduction is ever present but we also needto maintain our exacting standards and quick lead times without compromise. We believe thatDelcam offers the best CADCAM software on the market and look forward to continuing thegrowth of our business with Delcam by our side.”

Steven Arnold (centre left) and Martin Phelps (centre right)of Impcross with Alan Gardner (left) and Steve Creron onthe Delcam stand at MACH


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Once the particular group has been selected, all thefeatures within it can beedited simultaneously. Forexample, all holes having a diameter of 5mm can havetheir diameter increased to10mm in one operation.

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Modelling and reverseengineering enhancedThe 2015 version of PowerSHAPE Pro includes improvements indirect modelling, surface modelling and reverse engineering, plussupport for data from Creaform HandySCAN handheld scanners.Full details are on www.powershape.com The improvements in direct modelling buildon the introduction of the Smart FeatureManager and the Smart Feature Selector inrecent releases. The Smart Feature Managerallows users to identify all the features, such asfillets, slots, bosses etc, within a solid in a singleoperation and so makes the analysis of theimported data easier and faster. The SmartFeature Selector then allows multiple similarfeatures to be found and selected using either a specific value or a range of values.

Once the particular group has been selected, all the features within it can be editedsimultaneously. For example, all holes having a diameter of 5mm can have their diameterincreased to 10mm in one operation.

This new functionality will speed the preparationof models for manufacturing significantly. Forexample, one common problem in productdesigns that are to be moulded or cast is thatfillet sizes are set so small that they restrict theflow of material. The Smart Feature Selector canbe used to identify any fillets below the requiredradius and then all the fillets found can beincreased to the desired minimum sizesimultaneously.

Another potential application is in tidying upmodels created by reverse engineering, wherefeatures that are intended to be identical, suchas a series of holes, will often show smallvariations. In such cases, all the items within a specified tolerance band can be selected and then all adjusted together to the sameprecise size.

One of PowerSHAPE Pro’s great strengths hasalways been its surface modelling capabilities,giving the user the ability to create any shapethey can imagine. These capabilities have beenfurther improved with new dynamic point editing.Multiple points, either along a single curve orpicked from multiple curves, can now beselected and moved, with real-time updating of the model. This makes styling of free-formshapes easier and quicker, and also speeds upmodelling-for-manufacture tasks like removingundercuts from tooling designs.

Another strong area for PowerSHAPE Pro thathas also been made faster and easier is theability to morph a complete model into a newshape. One key application for this option is incompensating for springback in press tools orwarpage in moulded products. The user canalter CAD directly based on scan data from asample part collected as a point cloud or as atriangle mesh, with a choice between eitherupdating the CAD model of the part to matchthe as-produced item or adjusting the toolingdesign so that it can produce parts matching the original CAD data.

Another important application of morphing is in updating parts that need to be repaired butthat have changed their shape during use. A typical example is turbine blades that havebeen distorted by heat so that their shape nolonger matches the CAD data used for theirmanufacture. Again, the original CAD data canbe adjusted to match scan data captured fromthe actual part.

The main enhancement to PowerSHAPE Pro’sreverse engineering functionality is a moreautomated method for capturing cross-sectionsthrough a mesh. The software now fits lines andfillets to the cross-section where it can, with theuser able to control the tolerance used. Thismethod uses the mesh as a guide instead of

treating it as exact geometry, with the priority ofcapturing the design intent rather than ensuringa precise fit to the scan data.

Points selected from multiple curves can beselected and moved with real-time updates

A number of fillets of different radii can bealtered simultaneously to a new size or aset of holes can be resized in one operation

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Multiple points, either along a single curve or picked frommultiple curves, can now beselected and moved, withreal-time updating of themodel. This makes styling of free-form shapes easierand quicker, and also speedsup modelling-for-manufacturetasks like removing undercutsfrom tooling designs.


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This program certifies that FeatureCAMsoftware applications have been tested byAutodesk engineers to ensure that they meet the highest standards set for strength, qualityand interoperability with the latest version of Inventor, the industry’s leading DigitalPrototyping software that enables engineers to design, visualise and simulate products before they are built.

“Increased interoperability offers huge benefits to our customers who use Autodesk Inventor

as they can open Inventor parts seamlessly inFeatureCAM, with no loss of data or concernsabout translation errors,” said Tom McCollough,Vice President of Development for FeatureCAM.“The certification program gives our customersthe added confidence of knowing thatFeatureCAM has been rigorously tested byAutodesk and found to perform to the higheststandards.”

“Delcam has prioritised interoperability withInventor and worked with the certificationprogram for many years,” added Carl White,senior director, manufacturing engineering at Autodesk. “Our ongoing work with Delcam to more closely integrate our portfolios movingforward will be highly beneficial to ourmanufacturing customers looking to machineInventor models with Delcam’s range ofprogramming software.”

Delcam’s FeatureCAM range offeature-based CAM softwareproducts has been certified bythe Autodesk Inventor CertifiedApplication Program for AutodeskInventor 2015 mechanical designand engineering software. SinceAutodesk’s acquisition of Delcamin February, the two companieshave been working together tomore closely integrate theirtechnology, and this certificationis the first step in this process.

FeatureCAM certified forAutodesk Inventor 2015

The latest release of Delcam’s FeatureCAM CAM system has been certified for use with Autodesk Inventor 2015

MWP Best CADCAM AwardDelcam’s Vortex high-efficiency area-clearance strategy was the winner in the Best CADCAM or ControlSystem category at the MWP Advanced Manufacturing Awards presented at the Awards Dinner at theHilton Birmingham Metropole on Tuesday 8th April.In selecting Vortex for the Award, thejudges commented, “The winner has developed a method of controlling the tool’s angle ofengagement, which optimises the tool speed,extends tool life and produces a faster overall cycle time.”

Winning the Award was the highlight of an extremelysuccessful week at the MACH exhibition for Delcam.As well as taking many orders at the exhibition,Delcam engineers carried out demonstrations to more than 250 companies that were looking to invest in more powerful CADCAM software.

A video from the exhibition has been added toDelcam.TV, showing Delcam software drivingequipment from machine-tool manufacturers CMSIndustries, Roeders, and XYZ Machine Tools, togetherwith interviews with company representatives on their partnerships with Delcam. To view the video,please go to www.delcam.tv/MACH2014

Steve Finn, Managing Director of DMG Mori UK (left), presents the Award to Steve Creron, General Manager of Delcam UK(centre left), and Delcam Marketing Manager, Peter Dickin (centre right), watched by compère Marcus Brigstocke


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ArtCAM in the Mariinsky Theatre

ArtCAM is being used by the workshops at St. Petersburg’s Mariinsky Theatre toproduce spectacular scenery for operasand other productions.The world-famous Mariinsky Theatre was built in 1860.Since then, it has become an integral part of Russian culture thathas given debuts to many of the great opera singers, as well asbeing one of the main architectural attractions in St. Petersburg.

“All of our scenery has always been complex and uniquelydetailed so the cost of its production was quite high,”remembered Head of Department at the Theatre, Inessa V. Almazova. “The Theatre’s management set us the task ofdeveloping modern and efficient manufacturing techniques thatwould greatly reduce the financial cost of the scenery.”

“A few years ago, the supplier of our large-format printers showed us equipment to cutsheet-metal parts on a milling machine. Weacquired a three-axis milling machine, designedfor cutting soft sheet material: wood, plywood,plastic, foams, etc.”

“The same supplier advised us to use ArtCAMfor the programming. We were soon able todevelop programs for the milling machine and,later, for laser cutting. In August 2013, wepurchased a new three-axis milling machine with an indexable 4th axis to expand ourmanufacturing capabilities. Again, we usedArtCAM for the programming.”

Despite the fact that the Theatre has mastereddigital technology, the role of the designers hasremained central to the process of creating eachnew set of scenery. Before staging a new opera,artists and modellers use AutoCAD to createfrom paper sketches detailed models at a 1:20scale of each scene in the production and all ofits scenery.

Production of these models is a very complexand time-consuming task as they must containall the fine details that will appear in the final full-scale designs. In addition, the designer musttake into account not only the aesthetic aspectsbut also the technical requirements to allow achange of scenery during the production, and to provide a sequence of assembly anddisassembly for transport and storage.

The opera Boris Godunov was one of many productions atthe Mariinsky Theatre to feature scenery made with ArtCAM

The CNC router and ArtCAM have reducedthe cost of scenery significantly

The results of the work of designers andtechnologists are two-dimensional vectordrawings, with an accompanying description of each part. The data is then transmitteddigitally to ArtCAM so the programmer candevelop an efficient layout of the variouselements in the block of material and create the programs for the CNC router.

Once the director of the production hasapproved the scenery designs, they areproduced at full scale. This is one of the mainadvantages of the digital approach since the1:20 CAD model can be resized quickly to thesize to be used in the Theatre. Similarly, ArtCAMmakes it easy to duplicate parts of the design or to create their mirror copies.

These techniques mean the new scenery can be produced much more quickly. Even moreimportantly, the CNC router and ArtCAM havereduced significantly the financial costs ofcreating scenery and so allowed the MariinskyTheatre to recoup the cost of purchasing theequipment many times over.

Additive manufacturing projectDelcam is part of a consortium of UK companies being led by GKN Aerospace in a 3½ year, £13.4million research and development programme called Horizon (AM) that builds on GKN Aerospace’sextensive and fast-developing capability in additive manufacturing.The Horizon (AM) team includes GKNAerospace, Renishaw, Delcam, and theUniversities of Sheffield and Warwick. Theprogramme is backed by the UK’s AerospaceTechnology Institute (ATI) and funded jointly byindustry and the UK Government’s TechnologyStrategy Board (TSB).

The project is part of a major investment of £154million in research projects to keep the UK as aworld leader in aerospace innovation that wasannounced by the Deputy Prime Minister, NickClegg, during his visit to the 2014 FarnboroughInternational Air Show.

Horizon (AM) will take a number of promisingadditive manufacturing (AM) techniques fromresearch and development through to viableproduction processes, able to create

components that could be as much as 50 percent lighter than their conventional counterparts,with complex geometries that cannot bemanufactured cost-effectively today. These newprocesses will unlock innovations in low-drag,high-performance wing designs and in lighter,even more efficient engine systems – and lead to dramatic reductions in aircraft fuelconsumption and emissions.

The programme will focus initially on using AMtechniques to create near-net shape parts whichrequire minimal subsequent machining. This willdramatically improve the ‘buy-to-fly’ ratio of the parts by reducing the considerable cost intime and material wastage associated with theconventional machining of metal forgings orbillets. With material wastage as high as 90 percent for some parts, a significant reduction herewill also provide major environmental benefits.

Within the project, Delcam will work with GKN Aerospace on an integrated solution tocombine additive and subtractive technologiesseamlessly. This approach will allow companiesto benefit from both the geometrical freedomoffered by AM and the surface finish andaccuracy that is possible with subtractivemanufacturing.

Horizon was one of a number of projectsannounced by the UKDeputy Prime Minister,Nick Clegg, during his visitto the 2014 FarnboroughInternational Air Show


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Programming of complex partshas been made easier and morereliable with the addition ofautomatic collision checking of the tool shank and holder for both three-axis roughing and finishing toolpaths.

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More powerful and easier to useTwo new versions of FeatureCAM have been released in recent months. Both the 2014 R3 and the2015 releases focus on making the software even more powerful and even easier to use, so allowingcustomers to produce programs for all types of machine tool more quickly and, therefore, to deliverhigh-quality parts in shorter lead times.

General enhancementsOne new command that will boostFeatureCAM’s productivity allows entire parts or projects to be mirrored more easily thanbefore. The option supports parts to be milledwith multiple set-ups, including 2.5D, 3D and3+2-axis configurations. Both ‘Move’ and ‘Copy’options are available to reflect all the featureswithin the part or project relative to a choice of a particular plane, line or axis in which to mirror.

Continuous enhancements have been made to the FeatureCAM user interface to improveease of use. One simple improvement in the new release makes tool windows respond to the machine choice. Tools now appear in the window in an orientation that matches howthe tool will be used on the machine, eliminatingany mental disconnect when selecting thedesired tools for particular operations.

Another change allows the picking of the bottom radius of solid faces through curvatureanalysis. This greatly improves interactive feature recognition by removing the need to take measurements of the part to identify thebottom radius.

Five-axis programming of multiple holes has alsobeen made easier in FeatureCAM 2015. It is nowpossible to create patterns of holes of a similarsize with regular positioning. Any subsequent

changes to the program can then be made for all the holes in the pattern in one operation,rather than having to edit the toolpathsseparately for each individual hole.

Three-axis millingMore control is available when creating z-levelroughing toolpaths, with a new option toestablish pre-drill locations for the toolpath. This can be done through the use of single-pointpositions or curve-point positions to define theplunge locations.

Five-axis drilling of patterns of holes has beenmade quicker and easier

Entire parts or projects can be mirrored moreeasily than before

Collision checking isnow undertaken for thetool shank and holder,as well as the cutter

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Continuous enhancementshave been made to theFeatureCAM user interfaceto improve ease of use.

‘Thread Mill Hole’ eliminatesthe need to create holes,pockets or sides, and threadfeatures as separate items Programming of complex parts has been made

easier and more reliable with the addition ofautomatic collision checking of the tool shankand holder, as well as the cutter, for both three-axis roughing and finishing toolpaths. If a gouge is detected, the toolpath can then be recalculated with any segments that willcause a gouge clipped away.

Removing these segments of the toolpath willleave an area of unmachined stock that will needto be removed with a longer tool. This extratoolpath can be calculated using a stock modelof material remaining after the shorter tool hasbeen used to ensure there is no re-machining of stock that has already been removed.

The latest FeatureCAM also allows easierprogramming of families of parts. Working withthe part library, the software matches the namesof features within the part library with user-created curves relating to those features. Thismakes the programming of subsequent parts in the family much easier and faster.

The availability of a wide range of post-processors has always been a key benefit ofFeatureCAM, together with the ability for users to customise their posts. In the latest releases,post variables can be assigned user-definednames. This allows users to see quickly exactlywhich post variables are configured for use witha particular post-processor and to understandtheir intended use. This change will beparticularly valuable when programmers need to understand customisations in posts that have been made by other users.

DrillingFeatureCAM now includes a new hole type,‘Thread Mill Hole’, which eliminates the need tocreate holes, pockets or sides, and threadfeatures as separate items. It can be used eitherwith holes created with the ‘Hole’ feature orthose that have been identified with ‘FeatureRecognition’. A range of preset threads forstandard depths of drilling and thread depthscan be applied or users can customise their own thread combinations.


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FeatureCAM provides full-machine simulation and post-processing for the rotating sub-spindleon the Mori Seiki NTX1000 turn-mill equipment

FeatureCAM now has the ability to manage multiplepart-catchers on turn-mill equipment

Stock models can be usedin conjunction with othergeometry to give morecontrol over the toolpath

As part of this development, an additionalfunction, called ‘maximum machine stock’, hasbeen added that removes direct moves whereclipping has occurred. These direct moves canleave witness marks on the part so their removalimproves surface finish.

Another improvement in three-axis machiningallows stock models to be used in conjunctionwith other geometry, such as the part surfacedimensions, solid models, the stock dimensionsand boundary curves. This addition gives bettercontrol over the area to be machined by eachtoolpath and so gives more efficient machiningby allowing the user to confine toolpaths tospecific regions and to minimise air-cutting byreferencing the stock model.

Turning and turn-millA series of improvements have been introducedto make turning with FeatureCAM more efficient.The software now produces toolpaths that rapidup and over previously machined diameters,rather than feeding along them. This reduces the overall cycle time and avoids dragging of the tool.

‘Pinch and follow’ turning can now be chosenwhen machining components using the ‘face’ or ‘back-face’ cycles. Using this method givesbetter results since having the tools cut inopposing directions to each other means thatthe cutting forces are better balanced.

Two additions have been made that allowFeatureCAM to provide programs for a widerrange of turning and turn-mill machine tools.Firstly, support has been added for the use oftravelling steady rests to give increased flexibilitywhen turning very long parts. Secondly,FeatureCAM now has the ability to managemultiple part-catchers on turn-mill equipment.Machines with multiple part-catchers include the Nakamura WT-150, NTJX and NTMX, all ofwhich have part-catchers for the main spindleand a separate part-gripper for the sub-spindle.

FeatureCAM also provides full-machinesimulation and post-processing for the rotatingsub-spindle on the Mori Seiki NTX1000 turn-millequipment. The user has full control over theangle of the sub-spindle, with the softwareinserting automatically an operation on eachchannel so that the lower turret is positionedcorrectly prior to the movement of the sub-spindle.

Wire EDMFor users of wire EDM, FeatureCAM nowprovides an expanded wire-cut database tosupport multiple machines with varying formatsand methods of operation, with the ability tospecify nozzle type and fluid type as well asmaterial type and thickness, wire type anddiameter, and EDM machine. This gives moreflexibility by providing the option to store andapply a greater variety of different parameters.

Clay-millingvideo

The video, which is located atwww.delcam.tv/claydesignprocess, covers the complete clay design and manufacturingprocess using Autodesk’s Alias software forstyling, followed by machining and inspection on a Stiefelmayer CMM programmed withDelcam software.

The combination of a CMM and machiningsoftware is intended primarily for use inautomotive styling but could also haveapplications in other sectors that use claymodels for design reviews, such as the marineindustry. When operated with PowerINSPECTand the clay-milling software, CMMs can beused as multi-purpose tools for measurement,digitising, marking out and milling.

Depending on the size of the CMM, designerscan machine a complete car body or sections of the design. If required, the design can be re-machined following design reviews usingdigitised curves or scan data.

The software has been developed specifically for the production of styling models andcomprises a number of templates for themachining techniques that are needed in theseapplications, such as raster machining, Z-levelarea clearance and rest finishing. The full rangeof PowerMILL strategies is available in thebackground so additional templates can becreated if required, either by an expert user inthe company or by Delcam’s support team.

The clay-milling software can be used togetherwith PowerINSPECT’s marking-out option forrefining or completing clay models. This utilityenables curves created within PowerINSPECT to be used to guide a marking-out tool on ameasuring device or layout machine. Time-saving features make it easy for users to displaythe details of digitised curves, to switch betweencurves, and to select, edit and mark out pointswithin the curves.

A video has been added to Delcam.TV demonstratingDelcam’s software for clay milling with CMMs

A video has been added to theDelcam.tv online video channeldemonstrating software for claymilling of styling models withcoordinate measuring machines.


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give us the cutter paths we require. Delcamallows us to be on the machine cutting a lotquicker that the alternative software solutionsbecause we’re able to reduce our programmingtimes.”

“We also use On-Machine Verification withPowerINSPECT so, when we are getting near to finishing a part, we can probe the surfacesand machine adaptively, if required, to ensurethat we get good geometrical tolerance.”

“We’re focused constantly on reducing costs,mainly through looking at cycle time reductions,”continued Mr. Farnsworth. “We need tounderstand the limitations of any process in order to challenge traditional productionmethods and then apply new technicaldevelopments in machining strategies, as well as in tooling and machine tools.”

The machining for the Bloodhound SSC is a change from the usual work at the AMRC,where 95% of the projects are involved with the aerospace industry.

“AMRC has always been a strong advocate of the Bloodhound project, not only because it is an exciting engineering challenge to go at1,000 miles an hour but also because it is anopportunity to bring young engineers through bygetting children interested in engineering,” saidMr. Farnsworth. “We’ve recently opened ourtraining centre with 250 apprentices comingthrough that each year. The Bloodhound projecthas a lovely synergy with that initiative.”

The AMRC used the Vortex high-efficiency area-clearance strategyto machine components for theBloodhound SSC

Promolding is a partner in the EU-funded projectFaBiMed (Fabrication and Functionalization of BioMedical Microdevices) to improve anddevelop new manufacturing techniques, basedon micro-moulding, specifically for biomedicalmicro-devices. The project aims to reduce the cost of mass production of diagnosis andtherapeutic micro-devices which have commonproblems of small batch sizes, frequentdemands for customisation, and micron-scalegeometric features.

The FaBiMed project has received funding fromthe European Union’s Seventh FrameworkProgramme for research, technologicaldevelopment and demonstration under grantagreement No 608901. For more informationabout the FaBiMed project, please visithttp://www.fabimed.eu.

Bloodhound partproduction at AMRC

PowerMILL is being used by the AMRC (University of SheffieldAdvanced Manufacturing ResearchCentre with Boeing) to produce a series of components for theBloodhound SuperSonic Car project.To see the full story, go towww.delcam.tv/bloodhound-amrc

Machining tim

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The plate was roughed in 45minutes, whereas conventionalarea clearance would have takenclose to nine hours, a saving inthe machining time of 90%.

Delcam’s Vortex high-efficiencyarea-clearance strategy produceda saving of 90% in the timeneeded to machine the core platefor an injection mould at Dutchcompany, Promolding BV.Promolding (www.promolding.nl) is aninnovative company that transforms high-performance polymer technology into industrialapplications. It offers its customers a completeservice from product design, via material andprocess development, to manufacturing,including automation. The company is veryactive in the use of new and high-tech materials,such as biodegradable materials and technicalplastics with extra properties including electricalconductivity and heat conductivity, as well asnew technologies for mould production.

Bloodhound SSC aims to set a new worldland speed record of 1,000mph in South Africain 2016. Delcam is both an SME Sponsor,supporting the project with its manufacturingsoftware and expertise, and a Product Sponsor,producing components for the record-breakingvehicle in its Advanced Manufacturing Facility.The AMRC is one of several Delcam customersand technical partners that are using thecompany’s CADCAM software to manufactureparts for the ultimate jet- and rocket-poweredracing car.

One particularly challenging part machined at the AMRC was for the front suspension sub-assembly of the Bloodhound SSC. On firstlooking at the model, it appeared that the partwould be extremely difficult and complex tomachine because it included deep pockets withsmall internal corners. However, these problemswere overcome easily by using the Vortex high-efficiency area-clearance strategy in PowerMILLto rough out the pockets. As a result, the AMRCwas able to produce the finished part within thetight time constraints demanded by the project.

The work for the Bloodhound SSC continued along relationship between Delcam and theAMRC. “We’ve dealt with Delcam for seven oreight years now,” commented Matt Farnsworth,the Aero Structures Platform Group Leader.“Delcam offers us a lot of functionality in terms ofthe programming capability within the software.In addition, we like its ability to give us rapidprogramming, so reducing the time it takes to


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With Vortex, it is possible touse a much deeper cut and soremove a larger quantity ofmaterial with each pass. Thereis also a significant reductionin the wear seen on the tool.

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Using Vortex in Delcam for SolidWorks cut the machiningtime for this mould base by 90%

The students regularly participate incompetitions organised by SAE (Society ofAutomotive Engineers) between Institutions ofHigher Education. The target of each team is todesign and build a prototype, off-road, single-seat car, for marketing to enthusiastic amateursrather than professional drivers. Thecompetitions let engineering students participatein real examples of project development, with all the activities involved, to provide a practicalapplication of the theoretical knowledge theyhave acquired in the classroom.

Since being founded in 2001, the USP team hasimproved its results year by year, winning morethan thirty awards in various categories includingthe national championship in 2009 and 2012,and 9th overall in the finals in South Carolina,USA, in 2010.

Left- and right-hand versions of the transmissioncover were produced on machines at SandvikBrasil. Using the Vortex strategy enabled bothparts to be machined in three and a half hours.Similar parts had already been machined inDecember 2012, also using PowerMILL, thesame cutters and the same machines, when the machining took thirteen hours. This meantthat Vortex achieved a reduction of 73% inmachining time.

“With conventional roughing, it is necessary tolimit the depth of cut and step-over of the tool to approximately 70% of its diameter,” explained

Alexandre Magdalon from Seacam. “With Vortex,it is possible to use a much deeper cut and soremove a larger quantity of material with eachpass. There is also a significant reduction in the wear seen on the tool.”

“We were very grateful to Sandvik for the helpgiven to us during the tests,” he continued. “A technical partner like Sandvik was essential to complete this project so successfully becausethe staff are specialists in cutting tools, with vastexperience in all kinds of machining, as well ashaving a productivity centre with high-qualitymachining centres.”

According Mr. Luis Angelo Veloso, a CAMApplications Specialist at SEACAM, “The use of Vortex strategy is very simple and intuitive; the only challenge is to set the optimum cuttingparameters for safe machining. For this, I reliedon the long experience of the technicians ofSandvik. Together, we were able to achieve this incredible result.”

A 73% reduction in machining time for transmissioncover was achieved by using Vortex

me cut by 90%

Promolding is a work-package leader,responsible for mould design and manufacturingas well as for the injection moulding of themicro-devices. One of its tasks within the project is to manufacture several experimentaltest moulds. Promolding manufactures itsmoulds in-house using a five-axis DMG DMU 60monoBLOCK machine and has used Delcam forSolidWorks to program the machine for severalyears.

CNC machinist at Promolding, Arjan Markus, felt that the core plate of one injection mouldwould be a perfect test for the new roughingstrategy. The mould plate was to be machinedfrom tool steel and featured two cores, each48mm high.

Mr. Markus was able to program the part withoutdifficulty using the knowledge of Vortex he hadgained at a recent Dutch Delcam user meetinghosted at Seco/Jabro. The 48mm height wasmachined in two layers, although Mr. Markus felt confident that it could have been machinedin one go if the cutting length of the tool hadbeen long enough.

The plate was roughed in 45 minutes, whereasconventional area clearance would have takenclose to nine hours, a saving in the machiningtime of 90%. The same afternoon, Mr. Markusreported his experience back to Delcam: “Today,I machined about 2,750 sq cm of tool steel in 45 min using Vortex in DFS. In one word:unbelievable! I am definitely going to use thismethod again! The cutting sounded beautiful,the swarf was perfectly consistent and the toollooked unused.” Subsequently, he machined thecore and several other components of the mouldusing the same technique.

Reducedmachining time

Delcam’s Brazilian reseller, Seacam, worked together with Sandvik Brasil to machine aluminium transmission covers for a car being developed by students from the University of São Paulo State. A reduction of 73% was achieved in the machining time by using Vortex.


10 | ISSUE 3 2014

MTAChallengevictoryArtCAM was used by CharlieSmith of Sedbergh School tocreate his innovative ‘SOLA’water-heating stove for outdoorexpeditions, the winning entry in the Manufacturing TechnologyAssociation’s annual Technology,Design and Innovation (TDI)Challenge in the competition forthe 17-19 age group.Charlie’s victory is the latest result ofDelcam’s close partnership with the SedberghSchool, an independent co-educational schoolbased in Cumbria. Delcam sponsored theinstallation of a state-of-the-art Roland MDX540at the school, with the company’s David Stokeshelping students with a variety of projects,including Charlie’s successful entry.

Open to all Technology and Design students, thenationwide MTA TDI competition is split into twoage groups: 14-16 years old and 17-19 yearsold. The 12 finalists, who all impressed thejudges with their engineering talent, were chosenby the MTA’s Education and Training committee.The final judging and the award ceremony tookplace on 9th July at the Yamazaki MazakEuropean Headquarters in Worcester.

Charlie Smith with his ‘SOLA’ water-heating stove that won the MTATechnology, Design and Innovation Challenge for 17-19 year-olds

Development stafftrained at SecoDelcam is putting members of its development team through the Seco Technical Education Programme (STEP) to update theirunderstanding of the latest developments in cutting-tool technology.The knowledge gained should ensure that the CAM software theyproduce reflects these developments and so gives the maximumbenefit to Delcam’s customers.

“The potential problem in all CAM softwaredevelopment is that the toolpaths produced bythe system may be mathematically correct butmay not consider other practical limitations,”explained Charles Jones, the Delcam ApplicationEngineer who is coordinating the training withSeco. “We need to ensure that our developershave an understanding of real-world machining,as well as their programming skills, so that theycan produce software that performs on themachine tool just as well as it does on thecomputer.”

“Delcam may have the largest developmentteam in the CAM industry but we also need toensure that the programs they produce will allowour customers to take full advantage of themuch faster machining that is possible with thelatest cutting-tool technology,” added Mr. Jones.“Having our on-site machining facility plays animportant part in giving our developers a realappreciation of the challenges faced by ourcustomers; the training provided by Seco willadd significantly to their knowledge of theconcepts that underpin the process of creatingmachined components.”

STEP is offered as a series of modules tofamiliarise Seco’s customers with the latest

tooling systems and metal-cutting techniquesand so achieve maximum machiningproductivity. Without this in-depth understandingof the new technologies in the market, manycustomers find the decision-making processmore and more difficult as the range of toolingsystems expands. Courses can be designed tocover customer-specific requirements, so thatmachine operators, manufacturing engineers,programmers, and company owners can beginto understand the simplest way to choose thecorrect tooling and machining strategy.

Graham Brown of Seco (centre) with the latest group of Delcamstaff to be trained on the Seco Technical Education Programme

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We need to ensure that our developers have anunderstanding of real-worldmachining, as well as theirprogramming skills, so that they can produce softwarethat performs on the machinetool just as well as it does on the computer.


ISSUE 3 2014 | 11

The PowerSHAPE videos include one demonstrating how the Solid Doctor can be used to repair CAD data

Design and machining video tips A series of videos have beenadded to Delcam’s YouTubechannel showing tips for users of PowerSHAPE,PowerMILL and FeatureCAM.These latest additions bring thetotal number of videos to over1,200 on Delcam’s AdvancedManufacturing Solutionschannel on YouTube.

The PowerSHAPE playlist of tips comprisesfive videos. These cover the use of the SolidDoctor and PowerSHAPE’s trim-region editingtools for data repair, an introduction to the use of the Smart Surfacer for surface creation, plusexamples of creating a blend between threesurfaces and of separating the internal andexternal surfaces in a solid model.

To see the playlist, go towww.youtube.com/playlist?list=PLDuUAqDYm_rbfjnW9FNPayXvymkaOniJ5

The FeatureCAM playlist includes a video showing howto use Delcam’s Vortex high-efficiency area-clearancestrategy on mill-turn equipment

The playlist for PowerMILL includes five videosdemonstrating a variety of machining methodsfor items including cavities, open pockets, sidewalls and upstands. A sixth video shows how toapply parameters from one toolpath to othertoolpaths.

The PowerMILL playlist is atwww.youtube.com/playlist?list=PLDuUAqDYm_rYBlqkFnyEhpVgg7hAYfK1o

10 videos make up the FeatureCAM playlist.These include two examples of the use ofDelcam’s award-winning area-clearancestrategy, Vortex, one in a milling example andone in a turn-mill project. Other demonstrationsshow how to use stock models in 2.5Dmachining, a comparison of automatic andinteractive feature recognition, selection offeatures by colour or type, parametric surfacemachining and programming from 2D DXF data.

The full playlist for FeatureCAM is atwww.youtube.com/playlist?list=PLDuUAqDYm_rZ1vLjFFnGmb_XS0AKzMHXW

Delcam’s Marketing Manager, Peter Dickin,explained that the demonstrations were originallypart of the material presented at the company’sUK Technical Update Days, which are held eachyear at locations around the country. “Wethought that the videos would be helpful both toour UK customers who were unable to attendthe meetings and to our internationalcustomers,” he said. “If they prove popular, wewill look into adding more material after thisyear’s series of events in October.”

Mold Builderof the Year

CS Tool Engineering designs and builds injection and compression moulds

Delcam is pleased to congratulate customer Don Snow,Operations Manager at CS Tool Engineering, Inc., on beingnamed the 2014 Mold Builder of the Year by the AmericanMold Builders Association (AMBA). CS Tool Engineering,based in Cedar Springs, Michigan, has used PowerSHAPE,PowerMILL and PowerINSPECT for more than ten years.Mr. Snow received his award during theAMBA’s Annual Conference, which was held inMilwaukee, WI, from 14th to 16th May. He wasrecognised for his long-term commitment to theindustry, to the AMBA and to the developmentof an in-house apprenticeship programme, inwhich he takes an active part in conductingtraining sessions. Working with Ferris StateUniversity, the Kent Career Technical Center,Grand Rapids Community College and theWhitehall Township Tooling Coalition, Mr. Snow

continues to promote the industry and keep thetraining facilities aware of the need for skilledworkers. He also has worked extensively withthe Michigan Economic DevelopmentCommittee to create more advertising for thetool and die trade on the state’s own website.

Founded in 1967, CS Tool Engineering hasalways been a company that promotes qualityand customer service in everything it designsand manufactures. CS Tool Engineering

specialises in building injection mould toolsprimarily for the automotive industry and has ahigh experience level with automotive interiorand exterior trim components. The company,which also designs and builds largecompression forming moulds for headliners andpackage trays, offers full project managementfrom start of concept through textured sampleparts, as well as mould flow analysis withAutodesk’s Moldflow software.


12 | ISSUE 3 2014

New release of DentMILLThe 2014 R2 release of Delcam’s DentMILLsoftware for the milling of dental implantrestorations provides a new mechanism for receiving parts from Delcam’sOrderManager system, more control when using multi-holder fixtures and new options for non-uniform scaling of items. Smaller enhancements includeimproved library management and easierset-up for 3+2 machining.

DentMILL is now linked to Delcam’sOrderManager workflow management software so that the new part library is updatedautomatically once a new order is received.OrderManager then manages the whole processfrom the initial order through to manufacturingand final dispatch. At all stages users canmaintain a ‘real-time’ view of the centre’s totalorder status. The improvements in the 2014 R2 release provide a quicker, slicker and moreintelligent mechanism for transferring newrestorations into DentMILL from OrderManager,thus making the whole process more efficientand saving time.

Multi-holder fixtures allow individual restorationsto be machined from discrete blocks of material,rather than machining multiple items from a

single block. DentMILL 2014 R2 gives usersmore control when using this type of fixture. For example, if similar types of restoration arebeing produced in all the positions, the same set of strategies can be applied to the completegroup. Alternatively, individual machiningapproaches can be used to calculate thetoolpaths if each item is of a different type.

In addition, the machining sequence can be setup so that all operations with a particular toolacross the various items can be completed insequence before moving to the next cutter, soreducing tooling changes. If preferred, eachrestoration can be machined completely beforemoving to the next item.

DentMILL has always offered an option to scalemodels to compensate for shrinkage of materialsduring the sintering process. This option hasbeen made more powerful with the ability toundertake non-uniform 3D scaling, allowingmore accurate scaling to give better-fittingrestorations.

Data import has also been enhanced to improvethe import of models from many different openand closed systems, an important area for anopen system like DentMILL. In particular, morevariants of 3Shape parts can now be read intothe software.

DentMILL now gives users more control when using multi-holder fixtures

OrthoMODELupgradedThe 2014 R3 version of Delcam’s OrthoMODEL software forthe design of custom orthotic insoles includes the ability todisplay multiple 2D images and a 3D model simultaneously,and a range of improvements to the user interface to simplifyworkflow and reduce design times. For further details, pleasego to lz.orthotics-cadcam.comThe new version represents a big leapforward in bringing together 2D image data and 3D scan data. When both types of data are presented together, users are better able todecide upon the features required in the orthotic.

OrthoMODEL enables multiple 2D images to beimported and overlaid onto the 3D scan data.This ability creates a dynamic environmentwhere users can interpret the informationrepresented by the 2D images in situ over the 3D model.

The extra dimension that OrthoMODEL offers isin allowing multiple images to be displayed at thesame time. For example, the user can overlay

the photographic image of the plantar surfaceand an image from a pressure system, and beable to see the data from both whilst overlaid onthe 3D scan. The ability to vary the transparency of the scan, images and orthotic allows a fullappreciation of how the various elements worktogether to influence the overall design. As aresult, more informed decisions can be made as to the prescriptive requirements and on whereany additions may need to be located, such as adepression to relieve a skin lesion or region ofhigh pressure.

Also new to this version is a dramaticallyupdated user interface. A new image page to

capture, import and present multiple images,plus extra display utilities on the alignment anddesign pages, make for a better user experienceand enable decisions on the orthotic design tobe made quickly and accurately.

The system has also been updated to allowusers who purchase a Delcam iQube scanner tosend orders that contain either scan data or thefinished design through to a range of on-line labsthat can fulfil the manufacture. This allows usersto embrace the digital design world without theneed for a CNC mill or router.

OrthoMODEL now has the ability to display multiple 2D imageson the 3D model of the orthotic


ISSUE 3 2014 | 13

CRISPIN Ortho for orthopaedic footwearDelcam CRISPIN has launched a new version of its Engineer Pro software specifically for themanufacture of orthopaedicfootwear. Engineer Ortho includesall the options for 2D patterndevelopment from Engineer Proand so allows bespoke footweardesigns to be created in theshortest possible time.

One key tool in Engineer Ortho is the multi-point transformation function that makes it easyto transform the style lines of an existing patternto match a new last. This allows existing shoedesigns to be transferred directly onto anyindividual last developed to match the patient’sfoot.

If parts have been developed as well as the stylelines, then the same operation will adapt theirshapes to the new last as well. While the piecesare unlikely to be produced exactly as requiredfor manufacture, the adjustments necessary will

take, at most, one tenth of the time needed todevelop the equivalent parts from scratch.

The time savings will be especially beneficialwhen the patient is suffering from a non-staticcondition, for example, progressive deteriorationresulting from diabetes. In these cases, newfootwear will be needed on a regular basis, with each pair needing to be redesigned based on new lasts.

If a completely new design is required, Engineer Ortho offers the full range of patterndevelopment tools available in Engineer Pro,

including all the time-saving enhancements inthe recently released 2014 version. For example,simple parts can be created with a single click in a closed area and adjoining regions can then be added to the piece with a click in theneighbouring area. In addition, if a part has amirrored boundary, the features will be mirroredautomatically.

Once the piece area has been finalised, edgedetails can be added around the part simply bydragging and dropping designs from the libraryof edge templates.

Engineer Ortho allows existing pattern designsto be transferred directly onto any individuallast developed to match the patient’s foot

Additive Manufacturingof 3D orthotic insolesDelcam is embracing the new eraof mass customisation by applyingAdditive Manufacturing (AM) to thedesign and manufacture ofcustom orthotic soles.

Delcam first looked at AM for the orthoticsand prosthetics industry back in 2010, workingwith Adrian Bowyer of Bath University using aRepRap device to print custom PLA insoles.More recently, the Healthcare team has beenable to transfer surface data from Delcam’sorthotics solution software, OrthoMODEL, intoArtCAM. By combining the functionality of thesetwo software packages, Delcam has been ableto generate and print a series of conceptdesigns which demonstrate some of thepossibilities for AM in the production of

orthotics.

The process started by creating theorthotic designs within OrthoMODELand then importing them into ArtCAMwhere additional product featureswere added. These includedstructural ribs for strength, high-resolution 3D reliefs foraesthetics, and textures andaeration holes for potentialclinical benefits.

Delcam is aware of a wide range of potentialcustomers who are embracing the advances inthe AM sector. The new materials and increaseddesign freedom offered by AM are expanding thecreative opportunities of designers, allowingmass customisation to be offered together withbespoke requests. Delcam is investing itsresources into providing a flexible design solutionfor its customers.

AM does not replace the faster and moreeconomical subtractive milling but it does opensome new and interesting doors. For example,by 3D printing an orthotic, the practitioner is ableto design the ideal custom insole unhindered bythe restrictions of conventional manufacturing.

Chris Lawrie, Healthcare Business DevelopmentManager at Delcam, believes, “In a world wherewaste reduction is increasingly on people’sagendas, AM certainly offers potential to be the ‘greener’ choice in the future. We are awarethat machine prices are coming down, but thereal change will come first from faster printingtechnologies and then from an increase in thechoice of functional materials.”

A combination of OrthoMODELand ArtCAM can produceorthotics designs suitable forAdditive Manufacturing


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Having access to FeatureCAM isreally beneficial because it is ableto read files from any of our designsoftware and is able to outputtoolpaths ready to cut parts on any of our machining equipment.

14 | ISSUE 3 2014

Autodesk opened its Pier 9 facility inSeptember 2013 to support the company’svision of helping everyone to imagine, designand create a better world. The 27,000 squarefoot site is located a short walk from thecompany’s San Francisco headquarters.

“Pier 9 is a very interesting facility because it has traditional Autodesk software alongside an incredible workshop,” explained GonzaloMartinez, Director of Strategic Research atAutodesk. “It has a whole floor for additivemanufacturing, plus we have a metal shop and a wood shop on the site. The best part of thewhole concept is that it lets people experimenthere. They have access to the tools that weprovide – both the software and the hardware –to see what they can do.”

Jeremy Malan, Applications Engineer at Delcam,was responsible for installing FeatureCAM at Pier9. “It’s not every day that you can come out to a machine shop overlooking the bay, especiallysuch a great facility,” he remembered.

“Pier 9 does have a lot of people that arelearning machining for the first time so it’s reallyhelpful that FeatureCAM is one of the easiest-to-learn software programs out there,” he added.

“With FeatureCAM, even new users are able toidentify very quickly the kind of feature that theyare trying to make and how they are going to dothat on the machine.”

“I love what FeatureCAM does because, atAutodesk, we’ve always been very good withdesign tools, and visualisation and simulationtools, but we were not really connected to whatI’d call fabrication,” said Mr. Martinez. “Havingaccess to FeatureCAM is really beneficialbecause it is able to read files from any of ourdesign software and is able to output toolpathsready to cut parts on any of our machiningequipment.”

“I really looked forward to testing FeatureCAM on our Mori-Seiki machine, which is our mostcomplex being a mill-turn with two turrets andfive-axis capabilities,” he continued. “There arealways multiple axes moving around but, withFeatureCAM, I can make sure that nothing iscolliding and that the machine is workingcorrectly.”

“The support that I have received from theDelcam team has been an A+ from day one. I’m so pleased that we have Delcam; not onlythe technology, but the people as well. Thepeople are so extremely knowledgeable aboutthe industry that it makes this journey beautiful.”

The most complex machine at Pier 9is a Mori-Seiki mill-turn

FeatureCAM at Pier 9

Autodesk has added FeatureCAM for its Autodesk Workshop at Pier 9 in San Francisco. FeatureCAMwill be used to program all the CNC equipment at the facility, including a DMS five-axis router and aMori Seiki mill-turn machine.

To see more about how Autodesk is using FeatureCAM, please go to www.delcam.tv/pier9

FeatureCAM will be used to program all the machinesat Pier 9, including this DMS five-axis router


JaguarSchoolChallengeTwo staff from Delcam’sBirmingham headquarters,Andrew Whitten and RichardPedley, have been helpingnearby Holy Family PrimarySchool with the Jaguar PrimarySchool Challenge. The twoteams entered by Holy FamilyPrimary and mentored byAndrew and Richard won 1st and 2nd place in theBirmingham regional finals.The Jaguar Primary School Challenge ispart of the UK F1 in Schools programme, which is sponsored by Delcam’s parentcompany, Autodesk. It is open to students aged 5-11 years old and involves designing and manufacturing the fastest car possible,emulating the design and engineering processesemployed by real engineering companies, such as Jaguar Cars. The children also have to produce a display to promote their team,create merchandising and give a five-minutepresentation on their car.

Alison Lloyd, one of the teachers at the school,said, “We certainly wouldn’t have enteredwithout the help we received from Andrew andRichard. The children said it was one of thehappiest days of their lives, so we played a partin giving them that achievement.”

The winning design by theRacing Rebels from HolyFamily Primary School

ISSUE 3 2014 | 15

PartMaker Modeling The 2014 version of PartMaker Modeling features a host of excitingnew enhancements, including the Radial Cut Wizard for creatingcylindrically-wrapped part features as well as improved direct-modelling and feature-recognition functionality using PowerSHAPE’sSmart Feature Manager.The new and unique Radial CutWizard allows very quick and intuitivecreation of solid cut features oncylindrical surfaces. This functionalityis particularly helpful for creating“wrapped” features on cylinders that typically require cylindricalinterpolation programming whenthey are machined.

Additionally, PartMaker Modelingnow includes automatedfunctionality for snapping bothgeometry and solid features to existing faces. This makes creating both milled and drilled features, such as hexes, flats and holes of any orientation, much faster than previous versions.

A number of enhancements have been made to the software’s direct-modelling functionality for altering “dumb” solid models or 3D modelswith no feature history that have been created in other solid-modelling systems. Oneparticularly helpful new direct-modelling option is

the Merge Faces command. This allows anumber of coincident but separate faces to bemerged into a single face automatically, whichmakes altering or removing features attached tothese faces much faster and more automated.

PartMaker Modeling 2014 also has significantlyimproved functionality for extruding multipleregions with hollow shapes automatically.

Tackling the skills gapDelcam’s PartMaker Division issupporting an initiative by one of its customers, Precision Plusfrom Elkhorn, Wisconsin, totackle the skills gap in NorthAmerican manufacturing.Precision Plus is an ISO 9001:2008registered contract manufacturer of precisionturned components. The company specialises in Swiss-type turning and uses PartMaker toprogram more than twenty Tsugami machines to produce complex parts for electrical,aerospace, medical, dental and hydraulic/pneumatic applications. To see how Precision Plus uses PartMaker, visitwww.partmaker.com/video/precisionplus

President and owner, Mike Reader, has built upa team of skilled manufacturing men and womenwith many years of experience. His team has theknowledge and expertise to see a product fromconcept to reality, working closely with thecustomers’ engineering and production teams toproduce high-quality, cost-effective components.

Like many other company presidents, Mr.Reader is a strong believer in continuouseducation of his staff to ensure that his companycan continue to flourish in the new globaleconomy. However, he has gone further thanmost by hiring a former school principal, Barry

Butters, to run his education and apprenticeshipprogramme.

As well as training current Precision Plus staff,Mr. Reader is aggressively attacking the skillsgap in manufacturing by opening the classroomon his company’s site to a group of apprenticesmade up of highly motivated students from localhigh schools. They will be trained to use Inventorsoftware donated by Autodesk as well as thePartMaker CAM program supplied by Delcam.

Both Autodesk and PartMaker supported therecent opening ceremony for the new trainingfacilities. “Together with our software partners,Autodesk and Delcam/Partmaker, we are rollingout training programmes to develop the nextgeneration of elite manufacturing and applicationengineers,” explained Mr. Reader. “We will usethe new classroom as the focus of our efforts towork with local school districts to close the skillsgap and to enlighten young people about whatmanufacturing is today and the careeropportunities it offers.”

PartMaker Modeling 2014 includes the Smart FeatureManager, giving improved feature recognition

The new classroom at Precision Plus will be used fortraining staff and students in PartMaker CAM software


16 | ISSUE 3 2014

For more news, go towww.delcam.comwww.delcam.tv

www.delcam.comNews.Delcam is written and produced by Delcam, Small Heath Business Park, Birmingham B10 0HJ, UK.

Tel: +44 (0)121 766 5544 | Fax: +44 (0)121 766 5511 | Email: [email protected]

© Copyright Delcam 2014. All trademarks are the property of their respective owners.

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Delcam Electrode can nowprovide scripts for Exeron andJDMA EPX equipment as well as the previously supportedAgieCharmilles (Agievision and CT Millennium controls),Makino EDM, Mitsubishi Electric, ONA EDM, OPS-Ingersoll,Sodick and Zimmer & Kreim.

A range of enhancements has been added to the DelcamElectrode integrated solution for the design, machining andinspection of electrodes, and the range of EDM equipmentsupported by the software has been extended. For fulldetails, please visit www.delcam-electrode.com

Delcam Electrode combines PowerSHAPE,PowerMILL and PowerINSPECT to give acompletely integrated solution for the design,machining and inspection of electrodes. At theheart of the Delcam solution is a novel file format– the .Trode file. This contains all the informationfor each electrode project, including not only theelectrode design but also the machining andinspection information, plus the set-up sheets for its manufacture and use.

In the 2014 version, the .Trode file is compatiblewith Windows Explorer. This new option allowselectrode geometry, set-up sheets and scriptfiles to be viewed directly from the .Trode fileusing Windows Explorer with a single click onthe desired item.

Data management has also been simplified withthe option to output an electrode schedule fromthe software. The data can be output in HTML,Excel or CSV format as a table describing eachelectrode required and its key data, such asblank size, undersize value, material etc. Thisoption will, of course, be of most value whenlarge numbers of electrodes are required in aproject, for example, for a complex mould tool.

The system has also benefitted from a numberof new options introduced into the PowerSHAPEdesign software which provides the CADelement of the overall solution; in particular, the new option to merge fragmented faces into a single, continuous surface and so producecleaner, simpler electrode geometry. Thissimplification makes subsequent operations,such as adding draft to complex regions of themodel, much easier and also improves theoperation of many of the direct-modelling tools in the software.

Delcam Electrode can now provide scripts forExeron and JDMA EPX equipment as well as thepreviously supported AgieCharmilles (Agievisionand CT Millennium controls), Makino EDM,Mitsubishi Electric, ONA EDM, OPS-Ingersoll,Sodick and Zimmer & Kreim.

Scripts are the EDM equivalent of CAMprograms for machine tools. They provide anautomated process for the programming of themachine, instead of users having to programmanually from a set-up sheet. The automatedprocess is much easier and quicker, especiallywhen a number of electrodes are being used on

Delcam Electrode integrates the design,machining and inspection of electrodes

Electrode solutionenhanced

the same component. Furthermore, the directlink removes the human error that could alwaysbe possible with manual programming.

In the 2014 version, the script files are updatedautomatically based on information gatheredduring the inspection with PowerINSPECT. The new script file can then provide accurateprocess information to the EDM machine,avoiding the need for manual updates.

In addition, data from Delcam Electrode can nowbe output to the CERTA shop-floor managementsoftware.


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