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Delcam’s PowerMILL CAM software for high-speed and five-axis machining is being used in a Russian diesel plant.

In order to improve its competitiveness, the Penza Diesel Plant in Russia uses the latest high-technology production methods. These include programming the company’s advanced machine tools with Delcam’s PowerMILL CAM software for high-speed and five-axis machining.

The Penza plant, which is located between Moscow and Samara, was founded in 1949. The complete complex includes areas for casting, forging and pressing, machining, welding, assembly and maintenance, giving the plant the ability to produce all the elements of its products completely independently. In 2005, the factory acquired a Nakamura-Tome Super NTX high-performance turning and milling machining centre, for the production of the blisks for its turbochargers. A further five-axis machine, an OKK VP-600 5AX vertical machining centre, was added in 2010.  This is used for blisk manufacture and also for the production of moulds for precision casting of turbine blades and other components. Both machines are programmed exclusively with PowerMILL.

“We chose PowerMILL after we completed a number of pilot projects in cooperation with experts from the Centre of Computer Design within Penza State University,” said Andrey Sverchkov, deputy technical director at Penza Diesel Plant. “As a technologist by training and after having many years of experience using various CAM systems, it took me about a month of working with PowerMILL to gain an in-depth understanding of the program.” 

Sverchkov is still personally engaged in the development of many of the CNC programs in PowerMILL. “The main benefits are the speed with which I can generate even complex programs and the many opportunities to edit toolpaths manually to get exactly the results I need,” he claimed. “We also use the supporting CAD system, PowerMILL Modelling, which offers a variety of surface modelling techniques,” he added. “As a rule, we get CAD models of the finished products from designers in the Parasolid format. We undertake refinement of these designs to create an ‘operational’ 3D model that represents the shape of the casting. As well as using these models to develop the tooling designs to manufacture the parts, we also use them as stock models for all subsequent milling operations on the castings.” 

“The development of programs for machining of each new blisk requires about two days, taking into account the time spent on the construction of 3D models of the parts and the blanks. However, the various types of blisk may vary significantly, both in shape and size, and in the number of blades.  Similarly, developing the models and programs for machining of our moulds usually takes no more than two days,” claimed Sverchkov. “We compared this figure with the productivity of our colleagues in related businesses using other CADCAM systems and found that they were taking several times longer.”

More recently, in addition to traditional metal moulds for precision casting of large parts, the Penza plant has begun using the Delcam software for the production of master models in either plastic or wood for the manufacture of composite components. Again, the tooling design is first developed in PowerMILL Modelling and the models then milled with PowerMILL. This approach was used in the production of the exhaust system for a new generation of diesel engine.

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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