‘PowerMILL is much faster when

‘All the time-consuming

handling large files of complex
maneuvering that goes with
data, we can generate a better
cut-and-fit machining has been
finish and so produce a higher
eliminated. We can do in two
quality part for the customer.’
days what sometimes took
weeks.’ Paul Mellor
Hyde Precision
Jesse Haver
Hickham Industries

www.aerospace-cadcam.com

© Copyright Delcam plc 2007. All other trademarks are the property of their respective owners www.delcam.com
 Blade
Adaptive machining – an economic alternative Fix
tu
Repair of worn or damaged turbine blades using Delcam’s ri
n

g
unique adaptive machining process is an economic
alternative to machining new parts.

Delcam is one of the world’s leading suppliers of advanced

The Solution
CADCAM software solutions for product development in the
• The damaged area on the blade tips or leading edges
manufacturing industry. are repaired by applying a welding bead to the effected
area.
The company has grown steadily since being founded in
1977 after initial development work at Cambridge
University, UK. It is now the largest developer of product
design and manufacturing software in the UK with Blade Insp
ec
tio
subsidiaries in North America, Europe and Asia. Delcam’s n
software is used by more than 16,000 organisations in over
80 countries.

• Each blade is located in a precision fixture.

• The blade is then inspected on a CMM or by using
Future World Leading CADCAM Supplier
On Machine Verification (OMV) right on the machine
tool.

ng
Acquire CRISPIN
p hi
Acquire IMCS (PartMaker) or

M
Acquire EGS (FeatureCAM)

e
ad
Bl
15,000 Customers

00’s 3 Queens Awards

(for Innovation and Export)

90’s Company Flotation

• Depending on the application and customer needs, a

Management Buyout ining We
Mach ld
unique ‘adapted’ model is generated using a Be
ad
combination of fitting, both constrained and

80’s unconstrained, as well as morphing technology. Key

External Sales Begin
geometric features can be preserved (such as aerofoil
chordal lengths, leading edge radii ratio, aerofoil

Division of Delta Metals camber and twist).

• User defined CNC templates are now applied to the
adapted CAD model and output to the CNC machine

70’s Cambridge University resulting in the welding bead being removed.

• Highly accurate blending of forms helps eliminate the
need for hand polishing
‘Since we began using Delcam
software to program our 5-axis
machines, we have reduced our
manufacturing times by more
than half, with a typical reduction
for port machining down from 40
hours to 15 hours.‘
John Manchester
Operations Director at Zytek
www.portmachining.com
Successful machining is about more than just cutting.
How often have you had to make changes to your
customers’ data before you could begin programming?
• Had to fix problems like gaps and holes or insufficient
What do you want from a CAM system? A program that is easy to use? One that always delivers efficient and
reliable results? One that works the way you want to rather than forcing you to change your methods? Gives you draft?
the confidence to tackle any job, regardless of complexity?
• Needed to modify surfaces or add new ones, such as
split faces or 5-axis reference surfaces?
Adaptive Machining - solving complex problems
• Wanted to repair or change the way a surface is
Machining with PowerMILL is simple when you know the component shape, stock shape, and datum No matter what machining challenges you face, PowerMILL offers a new approach to solving your machining
trimmed?
positions but how would you cope when these details are unknown? This often happens when machining large problems. PowerMILL incorporates everything your company needs to increase productivity, improve quality and
• Struggled to define complex stock shapes including
or complex items, like aerostructures or press tools, or when repairing components such as turbine blades, reduce delivery times and so boost your profits.
castings or forgings?
where repair is a more economic alternative than manufacturing new components.
• Been made to wait while the CAD office makes the
changes you need?
The Problem
Turbine blades operate in extreme environments and therefore become distorted by heat and worn over time.
This significantly reduces engine performance. Blade
orn
W
ng
bi
Manufacture and Overhaul of Turbine Components ro
P
Repairing high-value blades for jet engines, power generation
and marine industries is a complex challenge.
Applications
The process allows blade tips and leading edges
to be repaired in a range of applications ranging from;
• Compressor blades
• Turbine blades
• Fan blades and Machi
nin
g
• Guide vanes W
el
d
Be
ad
• automotive • press die • mould die • pattern making •
• aero engines • aerostructure • prototype • footwear • motorsport •
Delcam’s in-house toolroom
CMM measurements or On Machine Verification (OMV),
reverse engineering and morphing of nominal CAD data can
automate the complex process of generating specific CNC
toolpaths adapted to each individual part.
 Port Machining is a dedicated solution for the machining of
tubular parts. Although this module has been developed for
machining of engine ports, it can also be used to machine
shrouded blisks, shrouded impellers or any other hollow
With PowerMILL Modeller, modelling for manufacturing
shape.
operations can be completed quickly and efficiently, without
the need for a separate CAD system. Sketch geometry,
create and edit surfaces, repair common modelling

ts
mistakes, and much more, all from within PowerMILL.

or
P
ce
fa
Being able to undertake model repair on the shop floor Multi - Sur
means that any problems can be fixed as soon as they are
identified. This eliminates delays that would inevitably
occur if the data had to be sent back and forth to the CAD
office, as well as minimising the interruptions to its design
Fi

work.
ll-
in

Su
rfa
ces

Check

g
Interactive model analysis tools identify potential

in
Intelligent Roughing

gh
manufacturing problems before machining starts.
PowerMILL uses an intelligent 3+2 machining strategy to o

u
Int lR
rough out the stock, using slices generated perpendicular elligent Spira
• Spot surfaces with gaps, overlaps or holes, find thin to the centre line along the port to provide additional reach
walls and locate regions with undercuts. and access. Continuous 5-axis operations are only applied
• View the model as a colour-coded ‘map’ highlighting where access or potential collisions prevent 3-axis
small radii that are difficult to machine in either cavity movements from being used. The benefit of this approach is
or core, or where electrodes may be required. that PowerMILL can fully utilise HSM routines to quickly and
safely remove as much material as possible. By maximising
the use of 3+2 machining, the rigidity of workpiece holding
and machine can be maintained.
Repair g
k Engagem in
oc sh
PowerMILL’s unique repair toolkit lets you fix commonly St en Spiral F ini
t t

en
found modelling or translation problems.

llig
Inte
g

in • Repair gaps and holes by either interactively modifying

m
Repair Trim trim boundaries, or adding new surfaces.
• Remove duplicated geometry for greater efficiency.
KRV5 MotoGP
rence Surface rts Ra
fe be cin
Re Cr Ro g
ea y
ti e nn En
on K
gi
ne
Modify
Powerful modelling tools allow you to quickly make any
modelling for manufacture changes to the part.

• Add or change fillets to simplify machining and optimise

processing times.
Innovative finishing
Plunge and Spiral strategies have been provided to finish
• Adjust draft angles for easier part removal from the tool
machine the ports. Both strategies make use of intelligent
• Identify features for spark-eroding and cap them with a
stock engagement options which automatically adjust the
fill-in surface for easier cutting.
toolpaths to prevent surface mismatches being left on the
• Generate reference surfaces to control tool orientation component by sudden changes in tool ‘push-off’.
during 5-axis machining.
‘We looked at a number of systems ‘Toolpaths can be easily
and PowerMILL seemed to be the generated and edited within
most straightforward for 5-axis PowerMILL. The accuracy of the
Have you ever experienced bottlenecks in your manufacturing process? Have you ever had to wait for data from
programming. toolpath and the interface is
the CADCAM department when you could be extracting and programming the electrodes yourself?
The software works in the way that intuitive - you can trust it. What
With ever decreasing lead times, it is essential you can operate as efficiently as possible. With Delcam Electrode,
an engineer would work. Also, you see on the screen is what you
you can eliminate bottlenecks by creating and machining your electrodes on the shop floor.
the cutter path generation is are going to get at the machine.’
The process is simple while at the same time flexible. Within a few minutes electrodes can be automatically
unbelievably quick.’ e Roughi
Making complex operations simple is at the core of
B lad n g PowerMILL’s philosophy. This has never been extracted, holders attached, set-up sheets generated and toolpaths created. Bill Reil
demonstrated more clearly than in our options for Reil Industrial
Paul Sollers
blades, blisks and impellers. PowerMILL’s automated Enterprises
Goodrich Engine
approach allows complex parts to be programmed
Control Systems Delcam Electrode benefits
efficiently, with minimal user effort. Intelligent
collision avoidance ensures programs run safely,
Ease of use
with no infringements with the tool, holder,
• Use a dynamic wizard to
fixturing or clamps.
- Finishi step through the electrode
mi ng
Se
creation process directly
within PowerMILL.
Simplifying the Process
Dedicated strategies have been developed to guide you
Quality
through the complete process of machining your
• Use a reliable process
component. The program’s knowledge of the stock
to guarantee consistent
remaining ensures that bulk material is safely
results.
removed before starting any finishing routines.

Flexibility
de Finishi
Bla ng • Organise multi-electrode jobs
• Save time by using Delcam
Fine Tuning Toolpaths
Electrode’s standard catalogue of blanks
In addition to the dedicated strategies, toolpaths can
and holders.
be enhanced with tool-axis editing, feedrate
optimisation and improved point distribution.
Savings
Intelligent point distribution along the toolpath ensures
• Create electrodes on the shop floor instead of
inishin programs are optimised for your machine control and
H ub F g adding to bottlenecks in the CAD/CAM Office.
machine configuration, ensuring the smoothest surface
• Save time by automatically creating set-up
finish and highest accuracy.
sheets.
• Minimise costly mistakes by automating and
organising the process.

www.5-axis-machining.com www.aerospace-cam.com
 e Milling
Fac Many components, no matter how complex, require
basic machining operations, such as facing,
chamfering and drilling. PowerMILL is best known
for its innovative high-speed and multi-axis
machining toolpaths, so its powerful 2D machining
functionality can often be overlooked.
Improving Machine Motion, Cycle Times and
Surface Finish
Controlling what happens at the head of the machine as well
as the tool contact point is critical if successful 5-axis
machining is to be achieved. Poor tool-axis control will
produce erratic machine motion, uneven surface finish,
premature tool wear or, worst of all, collisions. PowerMILL’s
unrivalled tool axis control ensures unbeatable results in
5-axis machining.

Hel
ica
lM
ill
in
g

Would you like to reduce your tool inventory?

Using one tool to helically interpolate all holes Le
ad
/L l
significantly reduces the need to fill your carousel with ean Contro
multiple drills, while minimising tool changes cuts your
ining
Mach overall cycle time.
at
Fl

5-ax
is
g

Tr
Are you over-machining your part? in

im
n m
in

i
Have you ever witnessed your roughing toolpaths

ch
g/ ng
Pr ni

Ma
oto i
over-machining areas? This can often be attributed to type Mach

poor roughing code that fails to consider flat regions of
Drilling the model. PowerMILL automatically identifies any flat
areas of the model then modifies the slice spacing to
optimise overall machining performance.
Swarf
Automatic Collision Avoidance
PowerMILL’s collision avoidance tools
automatically tilt the cutter away from obstacles
by a specified clearance. Once clear of the
obstacle, the tool returns to the original
cutting angle. In addition to avoiding
obstacles, this is also useful when
machining undercut regions.

ligent Cor
Intel ne
Is drilling giving you a headache? rF
in
Drilling holes in PowerMILL could not be simpler. After

is
Chamf importing your part, PowerMILL identifies automatically

hi
er

3+
Ma

ng
ch hole features and their orientations. They can then be Total Control with Tool Axis Editing
i

2C
machined using pre-defined drilling methods. For optimum control of your 5-axis machine, PowerMILL
n

o
in

allows the tool axis setting to be adjusted for individual er

rn
g

Fi
Special attention is given to controlling the feed rate areas of the toolpath. This fine-tuning of a toolpath can nis
hing
automatically when approaching the bottom of the hole. make a huge difference in the overall quality of the part and
This is often needed to avoid damage to the cutter that allows the machine to run as smoothly as possible.
can occur with a sudden change in loading.
‘To machine tool steel in excess of So, you invested in a high speed CNC machine, new
tooling and balanced holders. You even had your
52 Rockwell to a mirror finish operators specially trained but you are still not realising

requires total confidence in the HSM gains that were promised? What is going wrong?

toolpaths and using PowerMILL’s High Speed Machining is not about running your

High Speed Machining strategies existing process a little faster. That just produces poor
quality parts or worse still, scrap, more quickly. The key
gave me that confidence.’ ion to success lies in maximising material removal rates while
Opportunities to shorten delivery times, boost productivity, at
fic
ri maintaining tool life, surface finish and accuracy.
and increase profitability make 5-axis machining very Production machining has never been more challenging and shaving seconds off your machining time can be

Ve
Nick Buchok

n
io
appealing. But, having implemented this technology, are the difference between making a profit or a loss.
Platinum Tool

lis
PowerMILL helps you meet this challenge by providing

ol
you still experiencing surface quality issues, erratic

Intelligent C
innovative strategies to reduce tool loading and improve
machine motion, and much longer programming times But how often do you find yourself battling with your existing CAM system to get the toolpaths you want?
stock engagement, and so machine directly into hardened
than with your 3-axis machines? Worse still, how many times have you had to machine with toolpaths that you know are inefficient because
materials.
your system does not offer the strategies you need?
PowerMILL offers a wide range of strategies to make
efficient 5-axis programming a reality. The combination of PowerMILL offers all the tools you need to gain complete control over your finished toolpaths.
power, flexibility and ease of use has enabled PowerMILL
to be used successfully in a wide variety of applications, Machine symmetrical parts
including: Do you still have to machine costly prototypes before Program one hand, then mirror the toolpaths while
committing to production with your 5-axis parts? Do maintaining climb direction.
• Blades and blisks you find yourself laboriously examining a computer n
io
h s at
• Aerostructures is
simulation, looking for potential collisions manually? at im
o lp pt
• Port machining Or are you being forced to invest in additional software To s
O
ro
r nk
Li
• Composite trimming to verify your 5-axis toolpaths? M
ir &
a ds
• Engraving of bottle moulds. Le

sh

Ac
Optimise leads and links

i
Fin
The main advantage of 5-axis machining is the ability to

tu
al S
Smoothing the way the cutter enters and exits

urface
save time by machining complex shapes in a single set-up.

urface Fin
material will improve tool life and surface finish.
Additional benefits come from the use of shorter cutters

ed S
that permit faster, more accurate machining, with less Intera

ict
ct
iv

ish
vibration. Cycle times and surface finish can be improved
d
e

re
ol

P
dramatically by efficient control of the orientation of the
To

Toolp
m

at
tool to the workpiece. h
nu

There’s no disputing the added complexity of multi-axis

ti

la
P
by machining, making it more difficult to get it right first
i ed Edit
p pl time, every time, and more expensive when things go ing
e Su
Imag
wrong. PowerMILL solves this issue with fully Edit toolpaths

integrated simulation and collision detection, to ensure Remove or modify selected areas of a toolpath without

that 5-axis machining can be programmed both safely needing to recalculate from scratch.

and efficiently. PowerMILL’s advanced simulation also

gives the operator extra confidence by predicting axis
reversals and surface quality, so ensuring parts are At Delcam we make it our business to develop software that gives you the tools

machined accurately and on time. you need to ensure your toolpaths are as efficient as possible.
www.powermill.com
 Raceline Roug
h in High-efficiency Roughing Innovative Finishing
g
The main requirements of high-efficiency roughing are to High speed finishing requires constant tool loading and
keep the load on the cutter as constant as possible and to the fewest possible sudden changes in direction. To meet
minimise any sudden changes in the cutting direction. these priorities, a combination of strategies will usually be
needed.

Pa
tte
Offset Machin

rn
Raceline Machining Pattern Finishing ni 3D in

Fi
sh g
With PowerMILL’s patented Raceline Machining, roughing Depending on the part shape, Raster, Radial or Spiral in
g-
Radial
passes are progressively smoothed out as the toolpaths strategies can be employed to provide maximum efficiency.
move further from the main form. The resulting toolpaths Full control of the leads and links ensures smooth toolpath
minimise any sudden changes in direction, allowing faster transitions, improving both tool life and surface finish.
machining with less wear on the cutter and reduced stress
ng
ughi on the machine tool.
Ro
d al
oi
ch
o
Tr

3D Offset Finishing
3D offset machining delivers an excellent surface finish
because the step-over is varied to give a constant cusp

Spi
Trochoidal Machining height, both on steep surfaces and shallow contoured

ra
PowerMILL automatically changes to a trochoidal areas.

l3
milling strategy when the cutter encounters large amounts

D
ff

O
of stock. By implementing a trochoidal toolpath the radial Spiral offset finishing prevents ‘witness marks’, reduces se
tM
engagement on the tool is drastically reduced. This machining time and improves tool life since the tool stays ach
ini ng
improves tool life and prolongs the life of the machine tool. in constant contact with the model in one smooth spiral
motion.
lligent St
Inte oc
k
Re
m
ov
al

Intelligent Stock Removal Optimised and Interleaved Constant Z Finishing

tZ
PowerMILL intelligently removes small islands of residual 3D Offset and Constant Z finishing can combine to

an
stock that can remain on your part due to a combination of produce the best toolpaths to machine both the flatter and

st
n
tool radii and step-over, by inserting a smooth extension steeper areas of the part. PowerMILL automatically Co g
e d in
into the area. interleaves the toolpaths in the intermediate areas Interleav ish
Fin
between the two strategies and so ensures high surface
Par
ViewMILL quality. am
Sim et
ul ri
at c

O
io

ffs
n

et
Rest Roughing and Simulation

Mac
Using PowerMILL’s stock model and intelligent ordering Parametric Offset Machining

ensures constant cutting and minimises wasteful air
moves. At any time, you can simulate and visualise any
stock remaining to aid subsequent choices of strategy and
cutter size.
hining
Parametric Offset machining intelligently morphs toolpaths
across a surface with a varying rather than constant
step-over. This strategy covers the complete area without
any sharp changes in direction, so improving surface finish
and tool life.