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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.

During simulation, a user can create a list of “Stop At” events, such as “Collisions”, “Warnings”, “Tool changes”, or “End of each setup”, that can be managed interactively in the NC program dialog. The user can add, move, remove, or temporarily disable the events that pause the simulation. Other new features include:

Drag/drop files from Windows for quick setup.
Check cutting tool wear limits based on time, distance, and volume.
Constant gouge check simulation with very large design models is now 2X to 5X faster.
Automatically save a Reviewer file during the simulation session that incorporates all the functionality of NC Review mode in a stand-alone viewer that does not require a license.
Measure tool assembly components in the tool manager.
New CAD/CAM interface is available for Surfcam. Many other CAD/CAM interface improvements have been implemented.
SpacePilot Mouse/Navigator motion is improved.
Over 400 customer-driven enhancements and software change requests have been completed since version 7.2.

CGTech also offers VERICUT Composite Applications, machine-independent off-line programming and simulation software solutions for automated composite tape (ATL) and fiber-placement (AFP) CNC machines.

CGTech, 9000 Research Drive, Irvine, CA 92618, 949-753-1050, Fax: 949-753-1053, info@cgtech.com, cgtech.com.

INTEGRATED CAM SOFTWARE IN AUTODESK INVENTOR
InventorCAM 2014 from SolidCAM Inc. (Newtown, PA) is the leading integrated CAM for Autodesk Inventor, with software modules for all types of CNC applications, including the revolutionary, patented iMachining technology. As a Certified Autodesk Inventor Partner, InventorCAM seamlessly integrates inside the CAD system with full toolpath associativity with the Inventor model, automatically revising CAM toolpaths to keep up with any design changes. More than 100 new enhancements include iMachining 2D & 3D, 2.5D Milling, HSS, HSR/HSM, Sim 5X, Turning, Advanced Mill-Turn for multi-turret and multi-spindle machines, and the new module Solid Probe.

Newest features of InventorCAM are discussed by various shops that use it.

The powerful 2.5D Milling module adds more Toolbox roughing and finishing operations, while threading and engraving operations are enhanced. The HSS complementary module for surface machining is upgraded with new lead-in ramping options (see Figures 3-7).

Major enhancements to the Simultaneous 5 axis module include new tilting options and improvements to the SWARF, 5X Drill and Convert HSM to Sim 5X operation, which converts 3-axis machining to 5-axis machining.

The Port machining operation is a new and easy to use method for machining ports with lollipop milling tools. Four strategies will completely finish a port: Rouging, Rest Rough, Spiral and Plunge Finishing. For deburring and trimming, the new Contour 5-axis machining strategy tilts the tool along a chained 3D profile according to defined tilt lines, making it ideal for these processes.

The patented iMachining 2D module with its Technology Wizard provides the fastest cycle times, saving 70 percent machining time and more. Unmatched for hard material machining, it gives significantly longer tool life and offers outstanding small tool performance. The iMachining 3D module can automatically produce a complete, ready to run CNC program with optimal cutting conditions for 3D parts by using its expert Knowledge-based Technology Wizard, by roughing and rest roughing a complete 3D part, with true scallop on all slopes, all in a single operation.

iMachining 3D generates the toolpaths automatically and optimally for significant time savings. The 3D tool path automatically adjusts to avoid collisions between the holder and the updated stock at every stage. Without holder consideration, tools need to be long for safe machining. By taking the holder into account, engineers can use short rigid cutters. A new option provides step-up rest-rough after each step-down, leaving more room for tool holder avoidance so that more of the part can be machined in one operation.

SolidCAM Inc., 207 Pheasant Run, Newtown, PA 18940, 866-975-1115, infonorthamerica@solidcam.com, www.solidcam.com.

WORKFLOW GETS EVEN FASTER
Workflow tools in Edgecam 2014 R1 accelerated toolpath technology from Vero Software Limited (Gloucestershire, UK) get even faster in part setup with Machine Feature and stock and fixture management with Fixture Manager, giving additional control and saving even more time (see Figures 8-9).

A webinar walking through the new features in Edgecam 2014.

In other areas, a new Chamfering Cycle command supports 2D and 3D geometry to automatically deburr sharp edges without the requirement to prepare geometry. It fully supports cutter radius compensation as well as 3D chamfering. Surface machining cycles now have an added Support for 3D Normal Offset Output control to compensate for tool wear on 3D machining toolpaths for greater accuracy and control on tight tolerance components. A new design CPL datum marker has color-coded rotation bars and axis labeling for ‘rough and finish turn cycles’ for new or infrequent users.

An interactive editing tool for re-designing standard dialog boxes is now available. The ability to “Mask” the standard interface allows shops to pick which modifiers settings are displayed, empowering them to create command dialogs aligned to their preferred manufacturing methods.