Delcam launches 2016 FeatureCAM with new high-efficiency roughing

Delcam has launched the 2016 release of its FeatureCAM feature-based CAM software. This includes a range of enhancements, in particular more options for the Vortex high-efficiency area-clearance strategy, support for bar-fed mills, more efficient turning and user-interface improvements to make programming even easier and faster.

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FeatureCAM was the world’s first feature-based programming software when it was launched in 1995. Constant development since then has ensured that the system has retained its leadership in programming speed and ease of use, while an increased range of strategies has been added to provide more efficient toolpaths that give greater productivity on a wider range of machinery, including mill-turn machines, five-axis mills and wire EDM equipment.

The 2016 release includes a number of enhancements to the Vortex area-clearance strategy. Vortex gives the fastest safe metal removal from solid carbide tooling, in particular designs that give deeper cuts by using the full flute length as the cutting surface. It produces toolpaths with a controlled engagement angle and so maintains the optimum cutting conditions for the complete roughing cycle, giving faster machining and longer tool life.

The ability has now been added to adjust and fine tune the non-cutting moves of 2.5D and 3D Vortex toolpaths, with options to retract the tool and/or to increase the feedrate. These options can be set individually, or can be combined to achieve an optimum toolpath, with a reduced cycle time.

Other roughing improvements include the ability to take into account any remaining stock on the model during holder collision checking, ensuring that Z-level roughing toolpaths are completely free of tool-holder collisions.

Milling of inside or outside groove features has been upgraded with a number of improvements. These include support for different types of roughing links, wind-fan approach and retract moves for finishing, better gouge checking for plunges and retracts, and tool radius and partline cutter compensation support.

Support has been added to FeatureCAM for multi-tasking bar-fed milling machines, such as the Mazak Integrex I150, and the Willemen-Macodel 408T and 508T. Access to the back of the component is possible with an option to set the swivel angle of the machine, with additional cut-off operations now available that use milling tools.

Five-axis swarf machining has been made more flexible with a new option to control the upper and lower Z limits of a simultaneous five-axis swarf toolpath. This is useful if there are limitations on the tool length that can be used or if the stepdown needs to be varied for different segments of the toolpath.

For users of FeatureTURN, the selection of turning tools has been simplified with the ability to use a single tool in multiple orientations. This new automatic tool orientation categorises tooling into either outside-diameter or inside-diameter turning tools, so shortening the time taken to program parts and reducing the number of different tools required in the tool crib.

In addition, the engage angle can now be set for the lead-in approach move. By controlling the approach move in this way, smoother chip formation and lower cutting forces can be achieved.

FeatureCAM now allows the quick import and alignment of a variety of pre-defined vices and chucks into a machining project. The result is increased productivity, not only due to the speed of programming but also because collision checking is provided automatically during simulation.

Used in combination with PowerSHAPE, FeatureCAM now allows machining files to be selected and nested automatically in a single block to optimise stock material usage.

Interface improvements include the ability to create additional setups quickly during FeatureRECOGNITION, via a new button in the Feature Wizard. This reduces the overall programming time significantly.

In addition, items within the part view are now highlighted when the cursor hovers over them. At the same time, the items are also highlighted in the graphics screen, making it easier to find and select the desired items quickly.

Finally, Autodesk RealDWG has now been integrated into FeatureCAM, bringing with it increases in the speed of import of DWG files and support for DWG solid model import.

www.delcam.com

GC3225 and GC3210 – two new grades covering all cast iron turning operations

Sandvik Coromant has introduced two new grades for machining cast iron. GC3225 and GC3210 form a new insert grade chain covering all cast iron turning operations for both grey and nodular cast iron materials.

GC3225 for cast iron turning
GC3225 for cast iron turning

GC3225 is a first choice grade for the cast iron turning application area. It is designed to provide secure and trouble-free machining even in the most difficult conditions.

GC3210 is a grade with high flank wear resistance suitable for turning in all cast iron materials, in good to average machining conditions. It enhances reliability and productivity in intermittent cuts, high cutting speeds, wet or dry machining, machined surface or light cast skin.

To provide the edge-line security and wear resistance necessary to optimize performance, GC3225 and GC3210 feature a CVD coating combined with a fine-grained hard substrate. Additionally, their innovative design utilizes optimized micro-geometries to facilitate light cutting action, hence reducing cutting forces and improving tool life.

The results of tests conducted at customers have shown remarkable results. GC3225 has more to give when other inserts reach the end of their life. By using the insert in machining of nodular cast iron it was possible to increase tool life by 70% compared to a competitor grade. GC3210 has been tested in the machining of differential case covers with some outstanding results. After changing to GC3210 instead of a competitor grade, it was possible to increase tool life by 38%.

www.sandvik.coromant.com

Arburg at the Moldplas 2015

The Moldplas 2015 will be held in Batalha, Portugal from 28 to 31 October 2015. ARBURG will be presenting a complete range of plastic parts production – from one-off parts through to high-volume production – on Stand 3B04, Hall 3. The Freeformer for industrial additive manufacturing will be presented in Portugal for the first time. In the injection moulding area, there will be a demonstration of multi-component injection moulding of iPhone covers.

Industrial additive manufacturing: with the Freeformer and Arburg Plastic Freeforming, functional parts can be produced from qualified standard granulate without requiring a mould.
Industrial additive manufacturing: with the Freeformer and Arburg Plastic Freeforming, functional parts can be produced from qualified standard granulate without requiring a mould.

“The Freeformer will enable our customers to produce prototypes in the material of their choice, thereby achieving a significant reduction in development times. Moreover, it is also possible to produce fully functional parts in batches as small as a single unit,” says Martín Cayre, Managing Director of Arburg’s Spanish subsidiary.

Freeformer additively processes two components
The Moldplas 2015 will be the first time that the Freeformer and Arburg Plastic Freeforming (AKF) will be seen in Portugal. The Freeformer uses the patented “Arburg Plastic Freeforming” process to produce fully functional parts from qualified plastic granulates based on 3D CAD data, without the need for a mould. The granulate is first melted in a plasticising cylinder as with injection moulding. Plastic droplets are then applied layer-by-layer onto a moving part carrier via the nozzle of a stationary discharge unit, using high-frequency piezo technology at a specified duty cycle (60 to 200 Hertz).
The second discharge unit can be used for an additional component in order, for example, to produce a part in different colours, with special tactile qualities, or as a hard/soft combination. At the Moldplas, the second component will be used to produce a part with complex geometries using water-soluble supporting structures. Subsequently, the supporting structures are simply removed in a water bath.

Multi-component injection moulding
As an example of the automated production of high-volume parts, an electric two-component Allrounder 470 A will be used at the Moldplas 2015 to produce covers for an iPhone 6. This application will be realised with Portuguese partner Plasdan, which will provide a 1+1-cavity mould, special rotation technology and, in addition to the size 290 electric injection unit from Arburg, a second electric injection unit that can be retrofitted to existing machines. The two-colour iPhone covers, made in a hard-soft combination, are produced in a cycle time of 21 seconds. A Multilift Select robotic system is used to handle the moulded parts, which weigh around 15 g.

Alldrive high performance series
The Allrounder A has an energy requirement which is up to 50 per cent lower than for standard hydraulic machines. Servo drive energy recovery during braking also contributes to this saving. Short cycle times are achieved with the aid of the standard, servo-electrically driven independent main axes. Play-free, direct-acting spindle drives ensure maximum repeat accuracy and part quality. Low emissions thanks to liquid-cooled, encapsulated servo-electric drives are a further benefit. Convenient operation of the production sequence is ensured by means of the universal Selogica control system.

www.arburg.com

1st Trade Fair for Deburring and Polishing Technology from 13 to 15 October 2015 in Karlsruhe, Germany

More than 100 exhibitors from eleven countries will be on hand when the first DeburringEXPO opens its doors from the 13th through the 15th of October, 2015. They’ll present products and services for reliable and efficient deburring, rounding and polishing processes which have a decisive effect on manufacturing quality.

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Regardless of the industry sector and the manufacturing technology, deburring, rounding and polishing are indispensable steps in modern components production processes. And ever stricter quality and accuracy requirements have to be reliably fulfilled in the face of simultaneously rising cost pressure. DeburringEXPO, now being launched by fairXperts GmbH & Co. KG, does justice to this trend. The trade fair, taking place at the Karlsruhe Exhibition Centre from 13 to 15 October 2015, focuses exclusively on the issues of deburring, rounding and polishing for a broad range of industry sectors and materials. Consequently, it provides suppliers and users with a unique presentation and information platform, thus promoting a targeted exchange regarding products and services, and above all solutions. More than 100 exhibitors from eleven countries (status as of August 2015), including numerous market and innovation leaders, will take advantage of this opportunity. “Thanks to the great interest demonstrated by exhibiting companies, visitors from vehicle manufacturing, drive and transmission technology, aviation and aerospace, machinery manufacturing, medical engineering, sanitary, clock making, the tool and die industry, fluid engineering, hydraulics, precision engineering, microtechnology and other sectors will be awaited by comprehensive and representative offerings, about which they can gather information in a targeted fashion on a single day”, explains Hartmut Herdin, managing director of fairXperts.

Premiere with Numerous Firsts
Numerous firsts, which will be showcased at the premiere in all trade fair segments, are further indication that DeburringEXPO is being received as an important industry meeting place right from the start. These include, for example, a model for predicting and minimising burrs. It makes a considerable contribution to ensuring reliable and economically efficient deburring processes. A new process will also be presented which makes it possible for the first time to deburr cross-holes with nearly any diameter ratio and with intersection angles of significantly less than 90° in an automated fashion within the machining process with a defined cutter. Highlights will also include the innovative and easy-to-automate cavitation deburring process by means of which ultrasonically induced cavitation is used for targeted deburring of external and internal component surfaces with minimal energy consumption. The exhibitors will also present new and further developments in the fields of thermal energy machining (TEM), electrochemical machining (ECM), precision electrochemical machining (PECM), abrasive flow machining, vibratory grinding, brush deburring and blasting with solid and liquid media. One of the event’s focal points will cover solutions for the automation of deburring, rounding and polishing processes, in order to significantly enhance their reproducibility and economic efficiency. Measuring technology for process monitoring and quality control are further areas within which the exhibitors at DeburringEXPO will present new and further developed systems.

www.deburring-expo.com

New MachineWorks Software to be Unveiled at EMO MILANO

Version 7.4 has been specifically written to tackle the toughest software challenges faced by developers of CAM products and manufacturers of CNC controllers and machine tools. MachineWorks’ unprecedented development includes much improved surface quality and much greater accuracy.

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This is not just another release“, says Mike Nicholson, Sales & Marketing Director of MachineWorks, “Years of research have made possible some of the advances that we can see today in 7.4, like for example a completely new approach to 5-axis simulation that provides a real leap forward

New 5-Axis Algorithm

MachineWorks has created a new method to resolve an old problem. The new algorithm for 5-axis swept volume generation allows more flexible quality optimisation, which further enhances the finishing surface accuracy.

New Sampling Technology

The enhanced engine creates images with improved surface detail, even on close ups, providing a highly accurate graphic representation at all times on sampling technology.

Hybrid Manufacturing Simulation

Both additive and subtractive processes can now be carried out in a single CNC environment. MachineWorks can deliver a seamless simulation for both the material deposition and the material removal as part of the machining steps of the hybrid manufacturing process.

MachineWorks Ltd, will be disclosing the latest release at EMO MILANO 2015 in Hall 4, Stand C27.

www.machineworks.com