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PowerMILL brochure - .PDF file.

At the AIRTEC exhibition in Frankfurt on 28–30 October 2014, Delcam will promote its range of software and services for the aerospace manufacturing and MRO industries. These services can help aerospace companies whenever they need to increase productivity, to reduce lead times or to improve quality and consistency.

The range of support from Delcam Professional Services is mainly intended to help any company whose own engineering resource is needed to maintain its existing operations. The services provided can vary from supplying extra design and programming resources when existing staff are overloaded, through to developing dedicated software to automate existing manufacturing methods or to establishing completely new turnkey processes for the manufacture of novel designs.

Recent developments using Delcam software include the programming, with Delcam’s adaptive machining technology, of a new hybrid machine from Hamuel Maschinenbau for the remanufacturing of high-value metal components, such as turbine blades, and a novel five-axis machining method, programmed with the company’s PowerMILL CAM system, for the creation of ‘fir-tree’ profiles in components for turbo machinery.

The Hamuel hybrid machine combines five technologies in one unit: five-axis CNC milling, laser cladding, robot polishing, inspection and laser marking. Any of these processes can be combined, as required by the particular project. The equipment costs a fraction of the price of a multi-machine repair cell, and saves floor space.

Using a hybrid machine, it is possible to remove the damaged area of a turbine blade by milling off the worn material and then build the material back up using the cladding technology. A second machining operation, using high-speed five-axis milling, then produces the final shape, with a smooth transition between the original part and the new material. Polishing and laser marking can be undertaken to complete the component, if required. In-cycle part inspection, using Delcam’s adaptive machining software, provides feedback to orientate the parts, assess defects, and ensure accuracy throughout the various stages.

The novel method for the creation of ‘fir-tree’ profiles was developed in partnership with Iruba, a German provider of engineered solutions, and machine-tool manufacturer Hermle. It allows these complex shapes to be produced on milling machines, such as the Hermle C60 five-axis machining centre, rather than having to use specialist broaching equipment.

The use of PowerMILL’s trochoidal strategies to program the operation gives a number of benefits, in particular high material removal rates with lower, and more consistent, cutting forces.

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Delcam supplies software and services that help manufacturing companies to maximise their profitability by increasing productivity, improving quality and reducing lead times. The company is the world's largest specialist supplier of computer-aided machining software, with its PowerMILL, FeatureCAM, Partmaker and ArtCAM programs making up the most comprehensive range of CAM systems from any developer.

This broad selection allows Delcam to offer a CAM system capable of machining virtually any product, in any material on any type of equipment. Delcam also develops product design, tooling design and quality control programs. The unique Tribrid Modelling approach to design incorporates solid modelling, surface modelling and triangle modelling in a single program, enabling complete design and reverse engineering projects to be undertaken without transferring data between software.

Delcam's Powerinspect offers fast, reliable comparison of parts, prototypes and tooling against CAD data on all types of inspection equipment and even on machine tools. This versatility has made it the world's leading hardware-independent inspection software. Related programs are available for checking machine tool set-up and part location. Delcam software is used in over 80 countries worldwide by around 40,000 organisations, from large multi-nationals to small sub-contractors, in industries including aerospace, automotive, dental, engineering, footwear, medical and toolmaking.

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