The 2014R2 release of Delcam’s PowerMILL CAM software for high-speed and five-axis machining includes new simulation and customization tools to machine parts and tooling.

According to the company, the most important additions for five-axis machining are a new dialogue to track the position of the machine tool, and a new toolbar to simulate and adjust the configuration and tool axis of a 3+2 machine or any equipment with incremental rotary axes.

The new dialogue has a redesigned user interface giving improved presentation of data on the position of the machine tool, together with the limits set for each axis. It includes a slider to jog the machine components into position during the simulation and displays a warning if any axis limit is exceeded.

The new toolbar can be used to edit the tool axis and the orientation of the machine tool. This allows quick and easy updates to existing toolpaths with the new parameters. In addition, a new workplane that is aligned to the new axis and orientation can be created for subsequent programming operations.

Another addition that will be especially beneficial for five-axis programming is a new plug-in for PowerMILL that provides a graph of the linear and rotary axes of the machine during the simulation. Analysis of this graph allows users to locate any potential problems, such as sudden changes in direction or axis reversals that can adversely affect the surface finish. Adjusting the position of the part on the machine and running another simulation will often identify a solution to these problems, says Delcam.

In addition, a new method for creating composite curves has been added to PowerMILL that is based on similar functionality within Delcam’s PowerSHAPE CAD software. This allows adjacent arcs, lines, curves and surface edges to be merged into one composite curve, and so simplifies 2.5D programming and flowline machining.

PowerMILL 2014 R2 has seen improvements made to optimize the raster strategies, giving less fragmented toolpaths, without any overlaps. The software eliminates automatically any small, isolated segments that can leave marks on the part’s surface. Removing these short moves also reduces lifting of the tool. Cycle times can be reduced further by minimizing overlaps and so preventing over-machining in those areas.

Drilling has also seen numerous enhancements, including a separate strategy for each type of drilling cycle. New external threading and tapered threading options offer several settings to optimize the strategy. In addition, PowerMILL can scan the part to find any positions where holes intersect and then allows the break distance, feed rate and spindle speed to be adjusted through the intersections.

A series of improvements to Delcam’s Vortex high-efficiency area-clearance strategy is also included in the new release. Vortex gives fast, safe metal removal by allowing solid carbide tooling to cut with its full flute length so minimizing machining times. The main enhancement in PowerMILL 2014 R2 improves the ordering of the Vortex toolpaths to minimise lifts and air moves, and so increases overall efficiency.