SolidCAM brings high efficiency iMachining to Aero Engineering 2011

The new module delivers reductions in total machining time of up to 70%, using its knowledge-based algorithms that control the engagement angle of the tool and cutting feed to allow much deeper machining operations, using the full length of the tool in one pass. Especially useful for aerospace components, where exotic and difficult to cut materials, deep pockets, and the need to machine away a large proportion of the stock material are common features, iMachining will, it is claimed, enable engineers to achieve dramatically increased metal removal rates without introducing additional stresses into the component or cutting tool. Controlled by a Technology Wizard, the software considers the machine tool being used, the material being cut, and the entire geometry and material of the cutting tool. Specifically, it takes account of a range of factors, including the power of the machine, the maximum feed and speed available, the number of teeth on the tool and its helix angle. The user can then select the aggressiveness of machining to match the rigidity of the job and its fixturing. iMachining uses this information to generate smooth morphing toolpaths that avoid sudden direction changes, eliminate shock loading on the tool, and enable the maximum amount of material to be removed in a single pass, cutting at the full depth of the tool. Further algorithms within the software track where excess material is located and subdivide pockets as necessary. iMachining's unique channeling toolpaths then create areas that can be automatically machined with optimum efficiency, enabling the cutter to be kept in contact with the material for as long as possible at its full depth. Automatic rest machining operations follow. These remove any remaining excess material, utiklising the same advanced morphing toolpaths for high efficiency and low load machining. SolidCAM has already proved out the iMachining technology with a major aerospace supplier, cutting titanium and achieving a doubling of tool life, a 71% reduction in cycle time, and a greatly improved surface finish for long running existing components, generating significant savings in manufacturing costs. As well as iMachining, SolidCAM will be demonstrating its 5-axis machining and mill-turn technology. Both of these will be of interest to aerospace manufacturers who want to reduce the number of operations required to complete a component while, at the same time, improving the quality of the finished part.