Wednesday, September 12, 2007

CAM software behind gearboxes in Caterham Seven

The company chosen by Caterham to design and make the gearboxes for the new Caterham Seven, Nova Racing Transmissions, uses hyperMILL computer-aided manufacturing (CAM) software from Open Mind

Motorsport enthusiasts will be aware that the new Caterham Seven car launched at the Birmingham Motor Show last year (2000) was powered by a Honda Blackbird 1100cc motorcycle engine with an integral, six-speed sequential gearbox modified to allow the car to reverse. The company chosen by Caterham to design and make the gearboxes, Nova Racing Transmissions, uses hyperMILL computer-aided manufacturing (CAM) software from Open Mind to assist in programming the machines which produce the gearbox parts.

This article was originally published on Engineeringtalk on 2 May 2001 at 8.00am (UK)
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Former motorcycle champion, Steve Parrish, recently demonstrated that the gearbox works very well in reverse when he reached a record 85 mph going backwards in a Caterham Seven at Bruntingthorpe Proving Ground, Leicestershire.

More and more, racing cars are being powered by motorcycle engines owing to their responsiveness and high power-to-weight ratio, a trend which has increased the contract gearbox side of Nova's business to around 50 per cent of turnover within the past 12 months.

Graham Dyson established Nova in Crowland, near Peterborough, in 1989 having spent most of his career in racing engine and transmission design.

He was joined in 1999 by engineering director Martin Ford-Dunn, who was instrumental in progressing the company from conventional draughting to computer-aided design (CAD).

Autodesk Mechanical Desktop was selected as Martin was familiar with this 3D design system from his days with the design consultancy, Ricardo.
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Millennium Angel made with high-tech CAM approach
Computer-aided manufacturing (CAM) software company, Open Mind, has assisted in creating a two metre high representation of Icarus, called the Millennium Angel

CAM package integrates with Inventor 7
With its Hypermill CAM software, Open Mind has become one of the first CAM solution providers to receive official certification for Autodesk's latest CAD system release, Inventor 7

Press tool maker automates the job
With the help of Open Mind's Hyperfact CAM software, High Wycombe press tool specialist JP Engineering (HW) is able to develop CNC part programs automatically from tool designs

However, the procedure then was to create 2D drawings from the model and program the cutter paths manually.

This was a laborious process entailing the calculation and transfer of very large numbers of points and it was easy to make mistakes.

Martin knew that the CAM end of the process needed to be automated as well and spent a year on the internet researching the options.
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It became clear that if the CAM software was able to work within the CAD environment rather than separately from it as a stand-alone application, then considerable benefits would accrue.

Nova was producing complex components requiring multiple drawings and it was difficult to keep track of their release numbers.

By having the CAM package resident within the CAD system, it is possible to keep a single drawing going throughout the entire process from concept through all the design iterations to programming and manufacture.

There were only two CAM products capable of doing this at the time.

HyperMILL was selected partly owing to its extensive user base, indicating that sufficient debugging of the software had already taken place.

Price and responsiveness to the enquiry were also important, but paramount was ease of use.

ToolBox UK, a premier Autodesk System Center and Open Mind Partner, demonstrated the integration of Autodesk Mechanical Desktop with hyperMILL and its ease of use.

They also provided a high level of support and training from their High Wycombe offices.

Martin bought the 2D version of hyperMILL to keep the cost down, as the 3D package could not be justified at the time (although Nova intends to upgrade in the near future).

It is noteworthy that this advanced software is offered as a 2D entry-level system.

Currently, sections are taken through the solid CAD model and hyperMILL works on the 2D data to build up the cutter paths required to machine the prismatic part.

Programs are downloaded by DNC link to the Heidenhain control on a Bridgeport CNC mill and the Fanuc CNC system driving a Leadwell vertical machining centre.

There is a further CNC mill in the design office for rapid prototyping.

Nova makes motorcycle gearboxes and other components such as dry sump kits, dry clutch conversions, rev-up boxes and transaxles in relatively small volumes, so rapid design and machine tool programming is essential to maintain profitability.

'What used to take two days to program is now done in an hour,' says Martin.

'We recently designed a new gearbox for a mid-engine kit car and had manufactured it within a month of releasing the first drawing for manufacture.' 'Moreover a lot of what we program now could not have been attempted at all manually.

CAD/CAM has greatly increased both our design flexibility and our manufacturing capability.'

High-speed and 5-axis machining on CAM software

The latest release of Delcam's Powermill machining software, Powermill 3.1, includes a range of enhancements including additional features for high-speed machining and 5-axis machining

The latest release of Delcam's Powermill machining software, Powermill 3.1, includes a range of enhancements for all manufacturing operations. However, priority has been given to additional features for high-speed machining and 5-axis machining. Delcam is already ranked as the most successful international supplier of NC software and services to the toolmaking industry by US consulting and market research firm CIMdata.

This article was originally published on Engineeringtalk on 16 May 2001 at 8.00am (UK)
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The company expects that this new version will further consolidate its leading position.

Powermill has had a reputation as the most advanced software for high-speed machining for many years.

Powermill 3.1 sees the introduction of another unique Delcam machining strategy - spiral offset finishing.

This technique combines the benefits of spiral and 3D offset strategies to give more consistent tool loadings during high-speed finishing and so allow faster machining rates without risking damage to the cutter.

It also gives an improved surface finish and so minimises any need for hand finishing.
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Inspection software receives new features
Delcam's PowerInspect inspection software is compatible with the AIMS metrology system used by leading aerospace companies, such as Boeing and Lockheed Martin

Inspection software is made for Renishaw's Revo
Delcam has developed a special version of its PowerInspect inspection software for use with Renishaw's revolutionary Revo measuring head and probe system

Inspection software gains multi-axis option
Delcam PowerInspect's new multi-axis option allows companies with four, five or six-axis equipment will be able to undertake comprehensive verification of their parts on their machine tools

One of Powermill's great advantages for high-speed machining has always been its exceptionally fast calculation and re-calculation times.

For Powermill 3.1, Delcam has continued to make calculation times faster throughout the program.

Of particular note are the improved speeds with 3D offset, projection and rotary machining.
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In addition, corners in constant-Z finishing are now handled more efficiently, while the calculation speed and quality of corner machining toolpaths have both been improved.

Powermill 3.1 includes a considerable increase in the five-axis machining capabilities within the program.

New routines have been added for the calculation of gouge-free leads and links as the machine tool moves between the various surfaces within a part.

These will enable the generation of safe toolpaths for five-axis machining through a point or to a point, and for automatic adjustment of tilt angles for both lead and lag.

Until now, 5-axis machining been used mainly in the aerospace industry and has had limited application in toolmaking.

Powermill's new features will encourage the use of 5-axis machining in mould and die manufacture by allowing the machining of complex shapes in a single set-up, so saving time, and by enabling shorter cutters to be used in deep cavities, so giving increased machining speed and accuracy.

Powermill 3.1 offers a more efficient method for setting Z-levels for roughing of flat areas.

Other systems offer the option to add Z-levels manually that match flat areas.

This can be difficult, especially since the user must remember to include allowances for stock to be left on and machining tolerances.

Powermill automatically sets the Z-heights to match flat areas, with due allowance for stock and tolerances.

The program can then automatically fill in additional Z-heights with the required step-down to give the minimum number of slices without exceeding the safe cutting depth of the tool.

Once this process has been completed, the user still has the option to add any extra Z-heights, if required.

Like other CAM programs, earlier versions of Powermill would simply refuse to process CAD files including poorly-defined surfaces, for example, those with trimming errors, without highlighting the exact source of the problem.

In contrast, Powermill 3.1 takes any unsatisfactory surfaces within a model and automatically places them on a separate level.

The user can then quickly and easily identify these surfaces.

He can choose to delete them if, for example, they are duplicates or are so small that they are within the machining tolerance.

Alternatively, the surfaces can be exported back into a modelling package, such as Delcam's Powershape, for the errors to be corrected.

A number of other changes will make Powermill 3.1 even easier to use.

Training of new programmers has been improved through the incorporation of on-line tutorials.

These include 'show me' buttons to help new or inexperienced users find the appropriate commands within the software.

In addition, enhancements to the user interface have simplified the creation and management of a tooling database.

'As software developers, we are always faced with demands both to increase the capabilities of the program and to make it easier to use,' commented Delcam's CAD Development Director, Steve Hobbs.

'With Powermill 3.1, we believe that we have achieved both of these apparently contradictory aims

Free CD-based guide to high-speed machining

Delcam's new free CD-based guide to high-speed machining contains details of the newer strategies now recommended for high-speed machining, together with guidance on selecting the most appropriate

Delcam, developer of Powermill, the world's leading multi-axis machining software, has released a free guide to high-speed machining. The guide, which is issued in CD format, contains details of the newer strategies now recommended for high-speed machining, together with guidance on the selection of the most appropriate strategies for a particular manufacturing operation.

This article was originally published on Engineeringtalk on 29 May 2001 at 8.00am (UK)
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The guide, which has been prepared in association with cutting tool specialists, H.R.

Pearce, Mitsubishi Carbide and Sandvik, highlights that there is much more to HSM than simply making the spindle turn faster and emphasises the need for a completely new approach to machining.

A range of examples is described in depth, with details of the machining strategies used and videos of the cutting process.

To obtain a copy of Delcam's guide to high-speed machining, please e-mail marketing@delcam.com

Tuesday, September 4, 2007

Directly machine Parasolid design models

EdgeCAM Solid Machinist for Parasolid from Pathtrace allows users to directly machine Parasolid design models such as Solid Edge, SolidWorks and other leading CAD systems

EdgeCAM Solid Machinist for Parasolid from Pathtrace is a major breakthrough that bridges the CAD to CAM barrier allowing users to directly machine Parasolid design models such as Solid Edge, SolidWorks and other leading CAD systems inside EdgeCAM's dynamic environment. Mould and toolmakers and production machine tool programmers are able to accept solid model design data directly from any leading Parasolid-based CAD system.

This article was originally published on Engineeringtalk on 26 May 2000 at 8.00am (UK)
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This direct acceptance overcomes problems where translators can strip out 'intelligence' such as topology feature data and dimensional information from the original model.

EdgeCAM Solid Machinist for Parasolid provides a major step forward in flexibility and productivity for both the production departments and programmers working in the mould, tool and die industries.

In particular, where customer design offices are using SolidWorks, Solid Edge, or other Parasolid-based CAD software, EdgeCAM Solid Machinist for Parasolid is able to provide a 'universal' solution.
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Through an innovative Solid Machinist feature, operator input can be reduced by utilising Automatic Feature Recognition (AFR), which will automatically locate and present the user with the machinable features.

EdgeCAM Solid Machinist for Parasolid will also recognise a previously programmed part model, automatically detach any modified features and update the toolpath accordingly.

The EdgeCAM Solid Machinist for Parasolid capability to machine solid model design data from any CAD system opens up new levels of flexibility in CAD and CAM.

With the latest developments investment costs and software updating can be reduced when the machinist company is faced with different customers using a variety of CAD systems.

Normally, the machinist is faced with two problems - purchasing a CAM system from the same CAD supplier used by the customer in order to obtain full compatibility, or risk data loss by using 'universal' translators such as IGES or DXF.

The disadvantage of using a translator is that it does not understand features or dimensions.

It will not comprehend, for instance, whether a circle is really a pocket, or an island.

For maximum flexibility, CAM programmers and machinists need the capability and independence to handle CAD files directly and efficiently.

Here, EdgeCAM Solid Machinist for Parasolid's ability to process Parasolid models enables the user to manipulate the intelligent files ready to output the relevant CNC code.

EdgeCAM Solid Machinist for Parasolid can also recognise a part model previously programmed that has, for instance, a raised issue from design.

From that model, it will automatically identify features that have been modified through its AFR capability.

AFR then presents the operator with the machinable features, thus reducing operator input, ready for updating the CNC code to accommodate the change.

Delcam still No.1 for mould, tool and die industry

Delcam has been confirmed as the leading international supplier of manufacturing software to the mould, tool and die industry in the latest publication from CIMdata

Delcam has been confirmed as the leading international supplier of manufacturing software to the mould, tool and die industry in the latest publication from renowned US consulting and market research firm CIMdata. The company was also one of the fastest growing manufacturing software suppliers to all industries during 1999.

This article was originally published on Engineeringtalk on 1 June 2000 at 8.00am (UK)
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The report, NC Software and Related Services Market Assessment, names Delcam as the leading supplier to the toolmaking industry in both North America and in Europe, and places the company third in the Asia-Pacific region behind Graphic Products and Hitachi Zosen, two Japanese suppliers that dominate their home market.

Delcam is the only supplier that appears in the top three rankings in all three geographic areas.

Delcam was also the largest specialist supplier of manufacturing software to the automotive industry.
Further reading

Delcam to host aerospace conference
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Watson expands professional services
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This sector is dominated by suppliers of integrated design, data management and manufacturing systems, such as CATIA from Dassault and Unigraphics.

Delcam is, however, a bigger supplier of CAM software to the automotive industry than SDRC, despite the latter's position as the preferred supplier to Ford.

Delcam's record sales in 1999 made it one of the fastest growing suppliers.

The company's end-user payments increased by 20%, almost three times the 6.8% growth recorded for the total market.

Of the leading ten developers, Delcam's growth was second only to Unigraphics, which showed an exceptional increase due, in part, to the company's acquisition of another major supplier, Applicon.

Delcam is forecast to show further gains in market share during this year.

Commenting on the results, Delcam's Managing Director Hugh Humphreys said, 'I am delighted that our position has been confirmed as the leading supplier of NC software and services to the toolmaking industry.

However, we need to ensure that we continue to increase our market share in the future.

To this end, we will be delivering a major upgrade to our PowerMILL machining software in the summer.

This will give our customers even greater flexibility and productivity in all their machining operations.'

CAM Technology to market EdgeCAM Start

Pathtrace of Reading has appointed CAM Technology of Hinckley as the first UK organisation to market EdgeCAM Start, the software developer's entry-level CAM software

This new marketing venture, will provide high levels of personal service and support, with an entry level CAM software product based on the top-selling EdgeCAM off-line programming software. While the pricing structure of EdgeCAM Start will be very competitive, it will carry the same comprehensive support and backing as any other Pathtrace product.

This article was originally published on Engineeringtalk on 12 June 2000 at 8.00am (UK)
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CAM Technology has been set up by Andy Rose, who has some 13 years' experience in the CADCAM business dealing at all levels from problem solving and application engineering, to sales and financial justification.

Jackie Groves, Sales Director of Pathtrace said: 'The EdgeCAM product has been very successful due to its strong production engineering roots.

It is also gaining significant sales in the mould and die sector.

The EdgeCAM Start product and CAM Technology are ideally suited to ensure the success of a low-cost CAM system, combining the high capability and productivity with the personal touch to fully support first-time users.' EdgeCAM Start provides five proven modules covering three-axis milling, two-axis turning, RS232 communications, NC editor and remote communications.

The price has been kept as low as possible to ensure levels of support and make the software attractive to first time CAM users and small production machine shops.

To ensure the customer is totally familiar with the product, a full support package, which will include training, installation and commissioning, much of it on a personal, 'hand-holding' basis, is available if required.

EdgeCAM Start can be easily upgraded at any time without a price penalty to full EdgeCAM specification which is now installed at well over 16,000 users worldwide.

Saturday, September 1, 2007

Stored tooling data improves CAM efficiency

Technology Assistant is the latest productivity enhancing feature to be included with EdgeCAM, Pathtrace's off-line programming software

This all-new, major extension of the EdgeCAM Toolstore allows operators to achieve considerable gains in cutting efficiency by utilising stored tooling and materials data for selection of the most appropriate tool and automatically optimise speeds and feeds. Provided by the industry's leading tooling suppliers, the stored tooling data helps ensure that tool life and reliability are maximised, surface finish and quality are consistent and cycle times are kept to a minimum.

This article was originally published on Engineeringtalk on 20 June 2000 at 8.00am (UK)
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The result: higher productivity, lower scrap and significantly lower machining costs.

Raf Lobato, System development director of Pathtrace outlines the thinking behind the Technology Assistant: 'When programming a part, most machine operators will rely on speeds and feeds that they feel most comfortable with - typically, the ones they've always used.

To the detriment of the process, they are not always the most suitable for the task.' He continues, 'To find the correct settings would normally require searching through tooling catalogues or reference books.

Technology Assistant provides the operator the information he requires, at his fingertips.

No searching, no trial and error.' In common with EdgeCAM development, the user interface for Technology Assistant is straightforward.

The screen is split vertically in two with material data displayed on the left and tooling information on the right.

This simple layout encourages the user to quickly match the correct tooling with the material.

A prime consideration to users is that Technology Assistant can be customised to suit their requirements which extends the programming/machine shop user friendly capability.

Data can be added or deleted and the screens adapted to hide obsolete material, for instance.

In addition, the inclusion of a 'free format' printable notepad having full interactivity with Microsoft Word, this allows useful information to be stored and reports and support documents generated.