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CAD/CAM Machining Software: The Latest Trends and Advances

Nothing is changing faster or more profoundly than the software used to design and machine parts. To help shops keep up with the latest competitive advances being introduced on the shop floor, here is a report on some of the newest CAD/CAM software.

Posted: January 24, 2014

Figure 1. CAMWorks 2014 uses toolpath simulation for an effective review: The tool vectors for the toolpaths can be viewed during Step-through simulation, making it easier to review 5-axis toolpaths. Shops can use a WIP (work-in-process) model as a start-up stock when simulating sections of a toolpath to shorten the review time.

Figure 2.VERICUT 7.3 is now 5X to 10X (or more) faster in Collision Checking Speed when the NC program moves the simulated machine into potential collision conditions. Enhanced collision algorithms remove the need to adjust complex machine models to improve performance.

Figure 3. The powerful iMachining 3D Milling solution includes the High Speed Roughing (HSR) and High Speed Machining (HSM) modules with new algorithms that provide additional strategies and benefits, including Hybrid Machining, faster multi-core calculation that uses the full power of a computer’s processors, and smoother surface finishes.

Figure 4. InventorCAM Sim 5X has three new powerful operations, while the new Multi-blade machining operation easily handles impellers and bladed disks with multiple strategies for efficiently roughing and finishing every part of these complex shapes.

Figure 5. The InventorCAM Advanced Mill-Turn module handles any type of multi-turret and multi-spindle CNC machine and sets the standard for easy programming of these complicated machines. The Machine control operation MCO, balanced roughing, multi-turret synchronization and full machine tool simulation are all extensively improved.

Figure 6. InventorCAM iMachining 3D, combined with its full-depth step-down, intelligent step-up localized machining and smart positioning, achieves the shortest optimal cycle time for roughing and semi-finishing of molds and complex 3D parts. It is easy to mill prismatic parts which include hundreds of pockets and islands in one operation, without the need for defining geometry chains from the solid model of the part and the solid model of the stock.

Figure 7. The new InventorCAM Solid Probe module does the setup, performs part measurement cycles during machining, supports tool presetters and tool breakage detection. Machining operations and Probe operations are intermixed in the CAM manager, with both using the same geometry. Should the solid model change, both the machining and probe operations automatically synchronize to the new design, keeping full associativity between product development and product manufacture.

Figure 8. Edgecam 2014 R1 Machine Feature command interactively selects a feature on a component, which is then machined. The user can elect to only rough, finish, or rough and finish, with full control over their manufacturing order without the need to apply full automation.

Figure 9. Edgecam 2014 R1 Fixture Manager sees the introduction of chucks and collets that can be used for milling and turning, automatically filters valid and invalid fixtures based on component size, and offers a dynamic placement preview before it is placed on to the component.

Figure 10. RhinoCAM-MILL, RhinoCAM-TURN, RhinoCAM-NEST and RhinoCAM-ART all run integrated inside the Rhino 5 CAD program of RhinoCAM 2014 and can be bought and licensed independent of each other.

Figure 11. The VisualMILL, VisualTURN, VisualNEST, and VisualART modules of VisualCAD/CAM 2014 are significantly enhanced and improved to provide shops with a seamlessly integrated complete manufacturing platform.

Figure 12. To accommodate the motorsports industry, where engine performance is frequently increased by optimizing flow through ports, manifolds and throttle bodies with specialized machining, the 5-Axis Porting option in GibbsCAM 5-Axis increases the efficiency of programming and machining any parts with openings that change profile and curvature from end to end.

Faster multicore and embedded processors are combining with cloud-based innovations to increase the capabilities and expand the boundaries of CAD/CAM software far beyond the origins of its traditional work envelope. Shops are hard pressed to keep up with all of the competitive advances in machining alone, where each day introduces a new toolpath creation, a new simulation of multitask machining on a part, a new program that performs more simultaneous operations than ever before in one machine setup – all accessible and monitored from anywhere through new mobile applications.

In quality assurance, CAD/CAM is moving deeper into the footprint of part inspection and surface finish measurement. In part design, CAD/CAM integrates FEA capabilities to test and predict how certain materials machined on a prototype will perform before anything is actually built. To help shops stay informed and maintain their edge in machining capabilities, here are some of the latest advances in CAD/CAM applications.

END-TO-END SEAMLESS INTEGRATION
Geometric Americas Inc. (Scottsdale, AZ) offers their CAMWorks® 2014 intuitive solids-based CNC programming solution. With the addition of true G-code simulation, CAMWorks is the most complete fully integrated end-to-end CAD/CAM solution, from the initial part design to creating a CNC program to full machine simulation. This reduces data redundancy and saves valuable shop floor time (see Figure 1).

http://youtu.be/L5jfwLcXpqc
Demonstration of how CAMWorks 2014 Makes Significant Progress On Using WIP STL Models.

Along with support for SolidWorks® 2014, CAMWorks 2014 accelerates design-to-part time by improving the productivity of CNC programmers with the addition of a number of enhancements, including:

Turn feature definition enhancement: Turn profiles are now fully associated with the model they are extracted from, making them fully associative to the sketches. This first in the feature-based machining world makes program changes very quick and efficient. Particularly beneficial in mill-turn operations is the selection of turn profiles by specifying the angle at which the profile has to be extracted.

Increased automation in CNC programming: Adding 39 APIs to the current suite helps reduce repetitive activities and provides a solid foundation for shops that want to customize or automate their systems to accelerate CNC programming output.

Sub-spindle operations simplified: The addition of more pre-programmed routines that are configurable to the shop’s need increases flexibility in the sub-spindle operations.

CAMWorks introduces a free iPad app for mobility-inclined users of the CAMWorksView App for iPad/iPhone/iPod that views, reviews and annotates 3D WIP models and assemblies, tool paths and relevant operation data on the go, anywhere from the shop floor to the design room, without the need of an additional CAMWorks license.

CAMWorks 2014 provides certified Mori-APT CL code to drive DMG Mori (Hoffman Estates, IL) NMV Series, NH(X) Series, NV(X) Series, NL(X) Series and NT Series of mill, turn, and mill-turn machines using the Manufacturing Suite Post Processor that eliminates the need for custom post-processors. Shops must get Manufacturing Suite from DMG Mori, while the Mori-APT CL output add-in is available from Geometric, which has also enhanced its video instructions set that serves as a useful reference guide for self-paced learning to supplement the training needs.

Geometric Americas, Inc., 15974 North 77th Street, Suite 103, Scottsdale, AZ 85260, 480-367-0132, Fax: 480-367-0420, inquiries@camworks.com, www.geometricglobal.com/products.

MACHINE SIMULATION AND OPTIMIZATION
CGTech (Irvine, CA) now ships version 7.3 of their VERICUT® CNC machine simulation and optimization software that meet the needs of all types of shops – from the small job shop with simple parts to the OEM and Tier 1 supplier that is regularly pushing the limits of CNC technology. VERICUT is CNC machine simulation, verification and optimization software that eliminates the process of manually proving out NC programs (see Figure 2).

http://youtu.be/GJxrhE3-2Sg
An overview of the new features of the latest CNC simulation, verification and optimization software features in VERICUT 7.3.

It reduces scrap loss and rework and optimizes NC programs to save time and produce higher quality surface finishes by simulating DMG Mori, Mazak, Makino, Matsuura, Hermle, DIXI, Chiron and other CNC machine tools. The software runs standalone but can be integrated with Catia, NX, Creo Parametric, MasterCAM, PowerMill, EdgeCAM, hyperMILL, Esprit, GibbsCAM, and Surfcam CAM systems.

The 7.3 user interface is very customizable. A user will notice all-new icons, available in multiple sizes. There are several user-selectable color themes. Every window and icon can be optionally displayed or hidden. User-configurable “Favorites” further simplify setting up a simulation session. “Favorites” can consist of commonly used folders and files, and each item can be drag/dropped into a project. To help objects stand out in the machine simulation scene, an “Edge Display” option analyzes models on-the-fly and finds and displays their edges, all without affecting simulation speed.