PowerMILL

Specialist NC CAM software for the manufacture of the

complex shapes. PowerMILL 2011 makes the
programming of safe toolpaths easier than ever thanks to
new stock model engagement options that protect both the
cutting tool and the machine from excessive loading.
Present Version of Software-
The present version of software is PowerMILL 2011.
Having following features-
 Powerful
 efficient
 high-speed
 five-axis CAM machining
PowerMILL 2011 makes the programming of safe toolpaths easier than
ever thanks to new stock model engagement options that protect both the
cutting tool and the machine from excessive loading.

Name Of Developer- In 1965 Donald Welbourn, Director in Industrial

Co-operation at Cambridge University, had the vision to see the possibility
of using computers to assist pattern makers to solve the problems of
modeling difficult 3D shapes.

In July 1997, Delcam plc was floated on the Alternative Investment

Market (AIM). In preparation for this, Delcam UK was established to
spearhead UK sales and customer support. Overseas activities continued
to develop, with strong emphasis on joint ventures, especially in the
Americas, Europe and the Far East. Delcam now had more that seventy
sales offices worldwide and has a wholly owned subsidiary in the USA,
exploiting the country's massive complex manufacturing market.
The Power Solution
During 1998 DUCT was gradually replaced with a new incorporated range
of products, which covered the full manufacturing cycle from conceptual
design through to manufacture. Delcam’s Power Solution range of
products, which built upon the functionality of the DUCT suite, incorporated
the latest user interface technology and offered users many new benefits.
Delcam's commitment to providing the best tools for our customers lead to
the development of these individually 'Best of Breed' products, which were
developed to combine seamlessly and give a truly integrated solution.

Delcam's Power Solution Software

Delcam currently operates throughout the Americas, Europe, the Far East
and Australasia using a tight-knit network of regional headquarters and
sales offices. Regional Offices, for example Delcam Inc, a wholly owned
subsidiary in Canada, offer support and assistance to the numerous sales
offices within their area who are each able to concentrate on certain
markets and locations. Delcam has several wholly owned Sales offices
around the world, for example Delcam Malaysia offers the same service to
those Sales Partners in the Far East. This strong structure includes over a
hundred sales offices all working together to promote Delcam products and
offer local support and training to Delcam customers.
In addition to the development, sales and support of software, Delcam is
unique in being the only international CADCAM software supplier with its
own toolroom. Based alongside the company’s development headquarters
in Birmingham, UK, the centre houses some of the latest machining and
inspection technology from manufacturers such as Mecof, Anyak,
Matsuura, Bridgeport, Renishaw and POLI. The main aim of the facility is to
allow comprehensive real-world testing of software before it is released to
customers. However, it also operates as a working toolroom which is
profitable in it's own right.

Name OF Modules Of Sotware-

 Stock Model Engagement
 Fixed Tool Axis Angles
 Smart Selection for Machining
 Toolpath and Wireframe Transformation
 Tool Holder and Shank Definition
 Lead In Lead Out Feedrates
 Improved Toolpath Boundary Limiting
 Toolpath and Boundary Outside Block
 Block Enhancements
 Curve Editor Improvements
 Capability OF each Module Of Software-
Other enhancements include:-
 New editing capabilities to simplify the machining of duplicate items
 More versatile control of feedrates for leads and links
 Improved sketching
 Clearer dialogs for the complete range of strategies

 Stock Model Engagement  

 Stock Model Engagement is a fantastic new
option available within all finishing forms to
accurately control the optimum amount of stock
you wish to machine.
 Benefits of this new option include:-
 1.Avoids the tool damage that can occur when
machining excess stock
 2.Allows higher feedrates as excessive tool
engagement is eliminated
 3.Machining times are improved by removing
toolpath segments which machine very little, or no
material
   
 Fixed Tool Axis Angles  
 There is a new option inside the tool axis form to
lock the rotary axis of the machine tool to avoid
unnecessary tool axis motion.
 By reducing any unnecessary machine axis
motion, you will also see improvements to
surface finish and ultimately machining times.
 Fixed Angle control is available for all tool axis
definitions except for those with a tool axis of
Fixed Direction and Automatic.
   
  Smart Selection for Machining  
 Similar to the drilling methods functionality in
PowerMILL, Smart Selection allows you to
import data and automatically select
combinations of surfaces to machine based on
colour, level or model name. These selections can
be added to Thickness Sets and saved with a
toolpath template.
 Example ways to use this functionality include:-
1.Machine surfaces which are red or yellow
on Level 15
2.Ignore surfaces in model “XXX” which are
not green
   
 Toolpath and Wireframe Transformation  
 Toolpath transformation is now much simpler
and multiple transformations can be performed at
the same time.
 A new toolbar allows a choice of translation,
mirror, rotation or pattern transformation and a
preview picture allows the required
transformations to be viewed immediately.
 Similar functionality has been added in the Curve
Editor for Patterns and Boundaries.
   
 Tool Holder and Shank Definition  
 The tool holder and shank can now be defined
directly from a pattern.
 Complex tool assemblies can now be defined
quickly and easily by way of the PowerMILL
curve editor or via imported profiles.
 It is also possible to draw the shank and holder
when the tool is drawn on the cursor.
   
  Lead In Lead Out Feedrates  
 The Lead in & Lead out feedrates can now be
defined independently of the main cutting
feedrate.
 Slower material entry and exit will help to
improve tool life and minimise the risk of part
damage in brittle materials.
   
 Improved Toolpath Boundary Limiting  
 A significant improvement has been made to the
way toolpaths are limited to boundaries.
 Toolpaths are now trimmed using a 3D limiting
method, ensuring better and more accurate
results.

 Toolpath and Boundary Outside Block  

 Toolpaths and Boundaries can now be extended
beyond the block limits.
 This functionality will help to ensure that all parts
of the model are machined.

 Block Enhancements  
 There have been a couple of enhancements to the
block form
1.Reference Surfaces can now be considered
in the calculation for block size
2.The block or model can now be saved as a
DMT or STL file.
  Curve Editor Improvements  
 There are several improvements to the Curve
Editor toolbar:-
1.You can now create an arc which is
tangential to existing lines and arcs, as well as at
specific points using the Arc 3 Items button
2.Fillets can now be modified in two ways
3.You can now create a line which is tangent
to a curve
4.Also applicable to Patterns and Boundaries

Conclusion-
  Leading Global CAM Specialist
High Speed Machining- The ability to machine components in the shortest
possible time is an issue of ever increasing importance. Any development
in engineering which can give faster delivery, and at the same time improve
quality, must, therefore be given serious consideration by the toolmaker.
For many years Delcam has been at the leading edge in the development
of High Speed Machining (HSM) strategies. These use a combination of
techniques to ensure rapid delivery of high quality machined components.
There are many elements to efficient High Speed Machining including; the
cutting tool, the CNC machine, the material being cut not to mention the
use of a high quality CAM system.
Modern developments in cutting tool technology have led to a revolution in
the way CNC programmers now tackle jobs. These specialist tools have
totally different cutting characteristics to traditional tooling. Whereas
traditional programming methods would consider machining a component
from the top down, modern HSM tooling can sometimes prefer to cut from
the bottom up.
 PowerMILL leads the way with it's unique approaches to efficient area
clearance. The main requirements of these machining strategies are to
keep the load on the cutter as consistent as possible and to minimise any
sudden changes in the cutting direction. One of the basic changes in
strategy needed to achieve these conditions is the use of offset machining
for roughing rather than the traditional raster approach.

Multi Axis Machining- 5 Axis machining has been used in aerospace
applications for many years but it is only recently that the toolmaking
industry has shown similar interest. The main advantage of 5 Axis
machining is the ability to save time by machining complex shapes in a
single set-up. Additional benefit comes from allowing the use of shorter
cutters that permit more accurate machining.
Positional 5 Axis machining has long been available within PowerMILL.
With this technique, the head is oriented into a series of positions and
machining carried out as a set of discreet operations.
In addition to this, PowerMILL now offers continuous 5 Axis machining.
Continuous 5 Axis machining allows the user to create continuous 5 Axis
toolpaths across complex surface, solid and triangulated models. The
toolpaths are fully gouge checked and support a wide range of machining
strategies and all tool types.
“We can machine the surface in areas that would previously have been
impossible to access economically. In addition, difficult surfaces that would
have needed long series cutters are now simple. Easier access is allowing
us to use shorter tools resulting in improved surface finish and a reduction
in the number of post machining operations, including EDM.” David Gaskin,
AF Gaskin Ltd, UK.

Benefits of Positional 5 Axis Machining

 Ideal for machining deep cores and cavities
 Short cutters give increased accuracy and higher quality surface
finish
 Allows the machining of undercuts
 Significant time benefits through use of only one set up
Benefits of Continuous 5 Axis Machining
 Ideal for Profiling parts
 Ideal for machining deep corners and cavities
 Shorter cutters give increased accuracy and higher quality surface
finish
 Allows for machining with the flank or bottom of the tool
 Can be used with a full range of tool types
 Full gouge protection
 Can be used with models in STL format
Features and Functions
 Surface Finishing
 Swarf Milling
 Profiling
 Trimming:
 Pocketing
 Slotting
 Multi axis Drilling
 Integrated 5 Axis Post Processo

 Electrode Manufacture 

Power and flexibility

 Ease of use and rapid toolpath generation
 Ability to works with all tool types
 Powerful toolpath editing
 Totally customizable with macros, templates, Visual Basic and
HTML 

Confidence and reliability

 Animation and dynamic stock simulation
 Machine tool simulation
 Integrated toolpath verification
 Feedrate optimisation
References-

 http://www.powermill.com
 http://forum.delcam.com/viewforum.php?f=8
 http://www.mailers.delcam.com/customers/ams/PMILL2011.html
 http://en.wikipedia.org/wiki/Delcam#Parallel_Processing_in_PowerMILL_1
0:_A_White_Paper
 http://forum.featurecam.com/