© Copyright Delcam plc 2007. All other trademarks are the property of their respective owners

‘PowerMILL is much faster when

handling large files of complex

data, we can generate a better

finish and so produce a higher

quality part for the customer.’

Paul Mellor

Hyde Precision

‘All the time-consuming

maneuvering that goes with

cut-and-fit machining has been

eliminated. We can do in two

days what sometimes took

weeks.’

Jesse Haver

Hickham Industries

www.aerospace-cadcam.com

www.delcam.com

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

CADCAM software solutions for product development in the

manufacturing industry.

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

subsidiaries in North America, Europe and Asia. Delcam’s

software is used by more than 16,000 organisations in over

80 countries.

World Leading CADCAM SupplierFuture

Acquire CRISPIN Acquire IMCS (PartMaker)Acquire EGS (FeatureCAM)

15,000 Customers

3 Queens Awards(for Innovation and Export)

Company Flotation

Management Buyout

External Sales Begin

Division of Delta Metals

Cambridge University

00’s

90’s

80’s

70’s

Adaptive machining – an economic alternativeRepair of worn or damaged turbine blades using Delcam’s

unique adaptive machining process is an economic

alternative to machining new parts.

The Solution• The damaged area on the blade tips or leading edges

are repaired by applying a welding bead to the effected

area.

• Each blade is located in a precision fixture.

• The blade is then inspected on a CMM or by using

On Machine Verification (OMV) right on the machine

tool.

• Depending on the application and customer needs, a

unique ‘adapted’ model is generated using a

combination of fitting, both constrained and

unconstrained, as well as morphing technology. Key

geometric features can be preserved (such as aerofoil

chordal lengths, leading edge radii ratio, aerofoil

camber and twist).

• User defined CNC templates are now applied to the

adapted CAD model and output to the CNC machine

resulting in the welding bead being removed.

• Highly accurate blending of forms helps eliminate the

need for hand polishing

Blade Fixturing

Blade Inspection

Bla

de M

orphing

Machining Weld Bead

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

the confidence to tackle any job, regardless of complexity?

No matter what machining challenges you face, PowerMILL offers a new approach to solving your machining

problems. PowerMILL incorporates everything your company needs to increase productivity, improve quality and

reduce delivery times and so boost your profits.

‘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

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

draft?

• Needed to modify surfaces or add new ones, such as

split faces or 5-axis reference surfaces?

• Wanted to repair or change the way a surface is

trimmed?

• Struggled to define complex stock shapes including

castings or forgings?

• Been made to wait while the CAD office makes the

changes you need?

• automotive • press die • mould die • pattern making •

• aero engines • aerostructure • prototype • footwear • motorsport •

Adaptive Machining - solving complex problems

Machining with PowerMILL is simple when you know the component shape, stock shape, and datum

positions but how would you cope when these details are unknown? This often happens when machining large

or complex items, like aerostructures or press tools, or when repairing components such as turbine blades,

where repair is a more economic alternative than manufacturing new components.

The Problem

Turbine blades operate in extreme environments and therefore become distorted by heat and worn over time.

This significantly reduces engine performance.

Delcam’s in-house toolroomPr

obing W

orn Blade

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.

Manufacture and Overhaul of Turbine Components

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

• Guide vanes

www.portmachining.com

Machining Weld B

ead

With PowerMILL Modeller, modelling for manufacturing

operations can be completed quickly and efficiently, without

the need for a separate CAD system. Sketch geometry,

create and edit surfaces, repair common modelling

mistakes, and much more, all from within PowerMILL.

Being able to undertake model repair on the shop floor

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

work.

CheckInteractive model analysis tools identify potential

manufacturing problems before machining starts.

• Spot surfaces with gaps, overlaps or holes, find thin

walls and locate regions with undercuts.

• View the model as a colour-coded ‘map’ highlighting

small radii that are difficult to machine in either cavity

or core, or where electrodes may be required.

RepairPowerMILL’s unique repair toolkit lets you fix commonly

found modelling or translation problems.

• Repair gaps and holes by either interactively modifying

trim boundaries, or adding new surfaces.

• Remove duplicated geometry for greater efficiency.

ModifyPowerful 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.

• Adjust draft angles for easier part removal from the tool

• Identify features for spark-eroding and cap them with a

fill-in surface for easier cutting.

• Generate reference surfaces to control tool orientation

during 5-axis machining.

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

shape.

Intelligent RoughingPowerMILL uses an intelligent 3+2 machining strategy to

rough out the stock, using slices generated perpendicular

to the centre line along the port to provide additional reach

and access. Continuous 5-axis operations are only applied

where access or potential collisions prevent 3-axis

movements from being used. The benefit of this approach is

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.

Innovative finishingPlunge and Spiral strategies have been provided to finish

machine the ports. Both strategies make use of intelligent

stock engagement options which automatically adjust the

toolpaths to prevent surface mismatches being left on the

component by sudden changes in tool ‘push-off’.

Multi - Surface

Por

ts

Intelligent Spiral R

oughin

g

Spiral Finishing

Inte

llig

en

t Stock Engagement

Kenny Roberts KRV5 MotoGP Racing Engine

Fill-in Surfaces

Repair Trimm

in

g

Reference Surface Creation

Have you ever experienced bottlenecks in your manufacturing process? Have you ever had to wait for data from

the CADCAM department when you could be extracting and programming the electrodes yourself?

With ever decreasing lead times, it is essential you can operate as efficiently as possible. With Delcam Electrode,

you can eliminate bottlenecks by creating and machining your electrodes on the shop floor.

The process is simple while at the same time flexible. Within a few minutes electrodes can be automatically

extracted, holders attached, set-up sheets generated and toolpaths created.

Delcam Electrode benefits

Ease of use

• Use a dynamic wizard to

step through the electrode

creation process directly

within PowerMILL.

Quality

• Use a reliable process

to guarantee consistent

results.

Flexibility

• Organise multi-electrode jobs

• Save time by using Delcam

Electrode’s standard catalogue of blanks

and holders.

Savings

• Create electrodes on the shop floor instead of

adding to bottlenecks in the CAD/CAM Office.

• Save time by automatically creating set-up

sheets.

• Minimise costly mistakes by automating and

organising the process.

‘Toolpaths can be easily

generated and edited within

PowerMILL. The accuracy of the

toolpath and the interface is

intuitive - you can trust it. What

you see on the screen is what you

are going to get at the machine.’

Bill Reil

Reil Industrial

Enterprises

‘We looked at a number of systems

and PowerMILL seemed to be the

most straightforward for 5-axis

programming.

The software works in the way that

an engineer would work. Also,

the cutter path generation is

unbelievably quick.’

Paul Sollers

Goodrich Engine

Control Systems

Blade Roughing

Semi - Finishing

Blade Finishing

H

ub Finishing

Making complex operations simple is at the core of

PowerMILL’s philosophy. This has never been

demonstrated more clearly than in our options for

blades, blisks and impellers. PowerMILL’s automated

approach allows complex parts to be programmed

efficiently, with minimal user effort. Intelligent

collision avoidance ensures programs run safely,

with no infringements with the tool, holder,

fixturing or clamps.

Simplifying the Process

Dedicated strategies have been developed to guide you

through the complete process of machining your

component. The program’s knowledge of the stock

remaining ensures that bulk material is safely

removed before starting any finishing routines.

Fine Tuning Toolpaths

In addition to the dedicated strategies, toolpaths can

be enhanced with tool-axis editing, feedrate

optimisation and improved point distribution.

Intelligent point distribution along the toolpath ensures

programs are optimised for your machine control and

machine configuration, ensuring the smoothest surface

finish and highest accuracy.

www.5-axis-machining.com www.aerospace-cam.com

Helical Milling

Flat Machining

Drilling

Face Milling

Chamfer Machining

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.

Would you like to reduce your tool inventory?Using one tool to helically interpolate all holes

significantly reduces the need to fill your carousel with

multiple drills, while minimising tool changes cuts your

overall cycle time.

Are you over-machining your part?Have you ever witnessed your roughing toolpaths

over-machining areas? This can often be attributed to

poor roughing code that fails to consider flat regions of

the model. PowerMILL automatically identifies any flat

areas of the model then modifies the slice spacing to

optimise overall machining performance.

Is drilling giving you a headache?Drilling holes in PowerMILL could not be simpler. After

importing your part, PowerMILL identifies automatically

hole features and their orientations. They can then be

machined using pre-defined drilling methods.

Special attention is given to controlling the feed rate

automatically when approaching the bottom of the hole.

This is often needed to avoid damage to the cutter that

can occur with a sudden change in loading.

Improving Machine Motion, Cycle Times and Surface FinishControlling 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.

Automatic Collision AvoidancePowerMILL’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.

Total Control with Tool Axis EditingFor optimum control of your 5-axis machine, PowerMILL

allows the tool axis setting to be adjusted for individual

areas of the toolpath. This fine-tuning of a toolpath can

make a huge difference in the overall quality of the part and

allows the machine to run as smoothly as possible.

3 +

2 C

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Intelligent Corner Finishin

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Mach

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Lead / Lean Control

5-a

xis Trim

ming/Prototype Machining

‘To machine tool steel in excess of

52 Rockwell to a mirror finish

requires total confidence in

toolpaths and using PowerMILL’s

High Speed Machining strategies

gave me that confidence.’

Nick Buchok

Platinum Tool

Production machining has never been more challenging and shaving seconds off your machining time can be

the difference between making a profit or a loss.

But how often do you find yourself battling with your existing CAM system to get the toolpaths you want?

Worse still, how many times have you had to machine with toolpaths that you know are inefficient because

your system does not offer the strategies you need?

PowerMILL offers all the tools you need to gain complete control over your finished toolpaths.

So, you invested in a high speed CNC machine, new

tooling and balanced holders. You even had your

operators specially trained but you are still not realising

the HSM gains that were promised? What is going wrong?

High Speed Machining is not about running your

existing process a little faster. That just produces poor

quality parts or worse still, scrap, more quickly. The key

to success lies in maximising material removal rates while

maintaining tool life, surface finish and accuracy.

PowerMILL helps you meet this challenge by providing

innovative strategies to reduce tool loading and improve

stock engagement, and so machine directly into hardened

materials.

Opportunities to shorten delivery times, boost productivity,

and increase profitability make 5-axis machining very

appealing. But, having implemented this technology, are

you still experiencing surface quality issues, erratic

machine motion, and much longer programming times

than with your 3-axis machines?

PowerMILL offers a wide range of strategies to make

efficient 5-axis programming a reality. The combination of

power, flexibility and ease of use has enabled PowerMILL

to be used successfully in a wide variety of applications,

including:

• Blades and blisks

• Aerostructures

• Port machining

• Composite trimming

• Engraving of bottle moulds.

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

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

Additional benefits come from the use of shorter cutters

that permit faster, more accurate machining, with less

vibration. Cycle times and surface finish can be improved

dramatically by efficient control of the orientation of the

tool to the workpiece.

Machine symmetrical parts

Program one hand, then mirror the toolpaths while

maintaining climb direction.

Edit toolpaths

Remove or modify selected areas of a toolpath without

needing to recalculate from scratch.

Optimise leads and links

Smoothing the way the cutter enters and exits

material will improve tool life and surface finish.

Do you still have to machine costly prototypes before

committing to production with your 5-axis parts? Do

you find yourself laboriously examining a computer

simulation, looking for potential collisions manually?

Or are you being forced to invest in additional software

to verify your 5-axis toolpaths?

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

machining, making it more difficult to get it right first

time, every time, and more expensive when things go

wrong. PowerMILL solves this issue with fully

integrated simulation and collision detection, to ensure

that 5-axis machining can be programmed both safely

and efficiently. PowerMILL’s advanced simulation also

gives the operator extra confidence by predicting axis

reversals and surface quality, so ensuring parts are

machined accurately and on time.

At Delcam we make it our business to develop software that gives you the tools

you need to ensure your toolpaths are as efficient as possible.

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www.powermill.com

Innovative FinishingHigh speed fnishing requires constant tool loading and

the fewest possible sudden changes in direction. To meet

these priorities, a combination of strategies will usually be

needed.

Pattern FinishingDepending on the part shape, Raster, Radial or Spiral

strategies can be employed to provide maximum effciency.

Full control of the leads and links ensures smooth toolpath

transitions, improving both tool life and surface fnish.

3D Offset Finishing3D offset machining delivers an excellent surface fnish

because the step-over is varied to give a constant cusp

height, both on steep surfaces and shallow contoured

areas.

Spiral offset fnishing prevents ‘witness marks’, reduces

machining time and improves tool life since the tool stays

in constant contact with the model in one smooth spiral

motion.

Optimised and Interleaved Constant Z Finishing3D Offset and Constant Z fnishing can combine to

produce the best toolpaths to machine both the flatter and

steeper areas of the part. PowerMILL automatically

interleaves the toolpaths in the intermediate areas

between the two strategies and so ensures high surface

quality.

Parametric Offset MachiningParametric 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 fnish

and tool life.

High-effciency RoughingThe main requirements of high-effciency roughing are to

keep the load on the cutter as constant as possible and to

minimise any sudden changes in the cutting direction.

Raceline MachiningWith PowerMILL’s patented Raceline Machining, roughing

passes are progressively smoothed out as the toolpaths

move further from the main form. The resulting toolpaths

minimise any sudden changes in direction, allowing faster

machining with less wear on the cutter and reduced stress

on the machine tool.

Trochoidal MachiningPowerMILL automatically changes to a trochoidal

milling strategy when the cutter encounters large amounts

of stock. By implementing a trochoidal toolpath the radial

engagement on the tool is drastically reduced. This

improves tool life and prolongs the life of the machine tool.

Intelligent Stock RemovalPowerMILL intelligently removes small islands of residual

stock that can remain on your part due to a combination of

tool radii and step-over, by inserting a smooth extension

into the area.

Rest Roughing and SimulationUsing PowerMILL’s stock model and intelligent ordering

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.

Raceline Roughing

Troc

hoidal Roughing

Intelligent Stock Removal

Pattern Finishing - Radial

Interleaved Constan

t Z

ViewMILL Simulation

3D Offset Machining

Spira

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Finishing

Parametric Offse

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