CodeWizard allows you to build up post processors and machine simulation layouts in a very process- and graphically-driven workflow. Here, showing machine tool model and graphical tree to illustrate moveable axes.
	EdgeCAM Simulator showing machine simulation with Mill/Turn machine.

This tenth major release of EdgeCAM sees development work in two key areas. Firstly, the incremental enhancement of the system in its bread and butter areas of production, 3-axis machining, and secondly a wide range of tools have been added to the system to support the programming and simulation of more complex machine tools, with particular focus on the use of 4- and 5-axis machines and the new breed of mill/turn hardware. But before we get onto that, I want to look at the updates made to the Code Wizard application.

Machine tool simulation

When using a CAM system, one of the most critical pieces of technology is the post processor. After all, it’s this that takes the toolpath created, verified and generated within the CAM system and outputs the G-code language files that are needed to drive any machine tool. Following the company’s concentration on easy to use and maintain systems, Pathtrace developed the Code Wizard application to provide a method for the user to create and tailor their own post processors, rather than relying on the outlay of large sums of consultancy cash for a custom written post. The latest version of Code Wizard is pretty damned impressive and allows the user to create the post in a very interactive, graphically-led manner. Essentially, you step through the five stages to define the working parameters of your machine tool – from basic machine tool parameters through to NC styles, preferences and number formats. This is all done in a true wizard-based environment which ensures you capture the data you need, in the correct place.

But alongside this, the system now allows you to recreate your machine tool in a much more useful and holistic manner. By implementing a machine tool modelling tool, alongside Post creation, you can also model your machine tool – luckily, in as much detail as you need. Yes, the system is supplied with a growing number of machine tools as standard (through a number of strategic relationships with the likes of Daewoo and Mori-Seiki), but the chances are that you’ll need to model them from scratch. With all areas of EdgeCAM, this is done in a graphic, interactive manner – but there are two methods available. In the first and most basic instance, you can model your machine tool using a parametric definition, which allows you to firstly select the type of machine you’re modelling then adapt the parameters that control the operation of that hardware. A basic 3D model is built up in the model window, and you can see exactly what you’re working with. You then have access to a hierarchical browser tree that gives a very clear description of how the various components interact.

	EdgeCAM workflow
	1 – A blade is being machining using a multi head mill turn machine. You can see the toolpath EdgeCAM has generated to cut the metal. A blade is being machining using a multi head mill turn machine. You can see the toolpath EdgeCAM has generated to cut the metal.
	2 – the new simulation tools are used to ensure that not only is the toolpath up to muster, but also that the machine operates safely within its limits.
	3 – The final blade part cut using the toolpaths generated and simulated within EdgeCAM.

This first pass provides you with a very basic, skeletal layout of how your system operates. For those working with basic 3-axis machines, this may suffice, but if you want something more fully defined (when working with more complex machines), then you can then use more detailed 3D models to create a more accurate representation of the actual machine and its components. Here, the CAD integration work that Pathtrace is well known for pays dividends, as you can either use the EdgeCAM part modeller, or import the part or assembly models from your workhorse CAD tool (including SolidWorks, Solid Edge, Inventor as well as STL) into EdgeCAM. Once they’re in the system, you output the models and paste them into the Model building environment and you can then use the same tree structure to assign which parts these represent and how they interact/behave. In the most extreme examples, users model all of the components of their machine tools, but when using these models for simulation, you might not need all of that data visible. To help with this, the system allows you to categorise the various components into commonly found groups (such as base, fixtures, guards etc) and the display of these can be toggled quickly from the UI.

Once your machine model is complete, this can then be used throughout the system as the basis for your toolpath programming activities. The benefit is that instead of just carrying out collision detection and gouge protection between the workpiece, the cutter (and cutter holder) and fixtures, you can ensure that all of your machine tool is considered in the simulation, verification and process optimisation workflows.

Production Machining

Alongside the machine tool building and 4/5 axis additions, EdgeCAM 10 sees work done on making production machining based on 3-axis machines more efficient and expanding the coverage. Firstly, the system now supports undercut machining. This allows you to take advantage of a new breed of cutters (specifically, the T-Slot and the fantastically named, Lollipop) to machine complex forms, and access any undercut areas, hence reducing the need for 4- and 5-axis indexing. To back this up, you can also now use 3D Curves as boundaries to confine machining to specific areas that need this special attention.

Another production machining update that takes advantage of the latest advances in cutter technology is plunge roughing – in this case, done through Pathtrace’s strategic relationships with cutter manufacturers Sandvik Coromant. This allows you to use a shell mill in a drilling cycle like approach to the rapid removal of material, where each plunge overlaps the previous one. Typically, it’s currently used in the machining of high-strength materials, such as titanium and the roughing of deeper cavities.

The final update I wanted to cover for production machining is the addition of rest profiling. This allows you to automatically take smaller radii cutters around areas which larger cutter couldn’t reach and is also useful for ensuring sharp edges are created when required.

4- and 5-axis machining

Another major concentration for new functionality is support for 4- and 5-axis machines, which is currently on preview to selected customers but is scheduled for full customer release in early 2006. This manifests itself in two ways. A full range of 4- and 5-axis strategies and options is available to the experienced user and those wanting to experiment with different options on specific jobs. But alongside this, the 4- and 5-axis technology has been distilled into specific operations that are much more user friendly and quicker to work through. These represent established workflows or operations that make use of 4/5 axis capabilities to solve specific problems – and these can be categorised into two areas – 4-axis Rotary and 5-axis Simultaneous.

The first is the use of a 4-axis machine to machine specific components, predominately cams and crankshafts, but it’s not restricted to these areas – it’s commonly used in the production of rotary dies (for cutting biscuits and such) and tooling for the Oil and Gas industry. The underlying toolpaths are driven using a very simple dialog which allows you to define parameters ranging from the mill type, cut distance, tolerance and offsets, through to the specific variable for this type of operation, such as the Run Tool option. This affords you control over exactly which area of the cutter is used to engage the work piece, whether that’s the front edge, the rear edge, the centre or a predefined offset. Alternatively, the same operation allows you control over the lag angle, which avoids centre cutting.

Meanwhile, the 5-axis simultaneous specific operations allow you to use similarly simple dialogs to create SWARF cutting toolpaths for finishing side walls, which are common in the aerospace field. There are additional operations for 5-axis surface finishing (with controls over lead, trail and lean angles) and 5-axis profiling (for slotting, de-flashing and trimming of sheet forms) for the likes of forgings or stamped forms or even composites. Other areas in which the EdgeCAM 5-axis technologies are applicable are complex drilling cycles (to reduce set-ups) and engine port machining.

System/Process integration

The final area I wanted to talk about was the continuing work that Pathtrace has done on the system’s integration front. Alongside the updating of the integration between EdgeCAM and the associated CAD systems (which currently include Solid Edge, Inventor, SolidWorks, Catia and Pro/Engineer), the team has been working on building better links with other commonly used CAE applications such as Tool Management and PDM. The first example is the link between Autodesk’s Vault and EdgeCAM. This allows the user to manage EdgeCAM data using the same version control and data management system that many Inventor users are already working with. Other developments include Tool Management where the company is working to integrate the cutter tool management areas of EdgeCAM with other widely used tool management systems such as TDM, FASYS and Wintool.

In conclusion

Pathtrace has always led the pack when it comes to CAD-integrated production machining technology and the latest EdgeCAM release shows that the work that the organisation has already done is continuing apace. The enhancements to the existing 3-axis operations mean that the user can further optimise their strategies to take use of the latest advances in cutter technology, as well as encapsulating rather complex operations into easy to use dialogs. The additions made with the introduction of some pretty heavy weight support for 4- and 5-axis machining technology mean that users that are in the production machining game can take advantage of the benefits for their core businesses, as well as pushing EdgeCAM into other areas where it’s not so well known. I find it interesting that the company isn’t trying to move into 4- and 5-axis led mould and die market, instead providing tools that both potential and existing user base can take advantage. Finally, the work done to bring machine simulation to the production machining users will undoubtedly benefit many users, particularly when you take on more complex machine tools. If you take a look at even the most modest mill/turn machine, it’s clear that there’s a massive potential for collision and over reach – and when you look at multiple turret machines or 4- and 5-axis machines in general, then the reality is that you do need to encompass the whole machine (or at least all the moving parts) in your simulation and verification process- otherwise things will definitely be going crunch in the night.

So, to conclude, EdgeCAM 10 looks to further enhance the company’s reputation as proving good solid CAM functionality that not only allows you to create the most efficient toolpaths possible whilst taking advantage of the latest technology, but in a system that’s easy to use and learn.