with autodesk’s hsmworks 2014, users get an easy-to … module that offers users seamlessly...

March 2014 | ManufacturingEngineeringMedia.com 95

In the manufacturing world, users of CAD and CAM software

constantly seek out the fastest, most efficient ways of program-

ming machine tools that cut, bend and shape metals and other

materials into finished components. With today’s more integrated

desktop CAM software that run within solid modeling applications

such as Dassault SolidWorks, Siemens Solid Edge or Autodesk

Inventor, users get more affordable, easy-to-use systems that have

been gaining traction in recent years as designers seek tighter links

between design and manufacturing.

When CAD giant Autodesk Inc. (San Rafael, CA) moved last

November to buy CAM-centric software developer Delcam plc

(Birmingham, UK) for $286 million, it was one of the larger CAM

industry acquisitions in recent memory, signaling the potential for big

changes in the highly fragmented CAM market. Autodesk, creator of

the ubiquitous AutoCAD and a $2.3-billion business, has acquired a

host of software technology in the past year or more, mostly in design

and simulation, including Allpoint Systems LLC, Firehole Technologies

Inc., Tinkercad Inc., and Virtual Shape Research GmbH.

With Autodesk’s HSMWorks 2014, users get an easy-to-use, affordable integrated CAD/CAM solution.

Blurring the Lines Between CAD and CAMWith more integrated CAM, cloud-based options, better simulation and multitasking tools, users gain more choices in CAD/CAM programming

Patrick WaurzyniakSenior Editor

CAD/CAM Software

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With the Delcam deal, which was finalized in early

February, Autodesk is attempting to move designers and

manufacturers closer together using better Design-for-

Manufacturing solutions (see our Software Update Pass-

word interview with Carl White, Autodesk’s senior director,

manufacturing engineering, in the February 2014 issue of

Manufacturing Engineering).

More Integrated CAM Solutions

After acquiring CAM developer

HSMWorks in 2012, Autodesk last

November released an updated

HSMWorks 2014. That integrated CAM

solution forms the core of the company’s

new cloud-based CAM 360, a product

introduced in December at Autodesk

University in Las Vegas. Integrated CAM

solutions have always been highly popu-

lar with job shops, said Anthony Graves,

CAM product manager, Autodesk Inc.

(San Rafael, CA), but the less-expensive

integrated CAM packages are now much

more capable of competing with major

developers’ stand-alone CAM systems.

“Given the option of an integrated solution, people

opt for an integrated CAM solution.”

“The single biggest shift in CAM

has been a move to integrated CAM

for mainstream desktop users,” said

Graves, who previously worked with

CIMCO and the Copenhagen, Denmark-

based HSMWorks development team.

“We heard from end users what they

were looking for in a CAM solution as

far as usability, and we recognized that

designers and engineers were more and

more becoming involved in the manu-

facturing process, if not directly involved

in the prototyping process on CNC

machines because of this whole push of

Design-for-Manufacturability.”

During the development of HSMWorks,

Graves said “we needed to understand

96 ManufacturingEngineeringMedia.com | March 2014

CAD/CAM Software

how we design better products, and part of that is under-

standing how products are made. Companies were literally

forcing these two groups of users, who had previously been

divided by this invisible wall, to work together to come up with

better solutions and better products and more economically

manufacturable products.”

Given the option of an integrated solution, Graves noted,

people opt for an integrated CAM solution because they can

learn the system faster, it’s easier to do cross-training, and

data exchange and data management are much smoother.

When developing HSMWorks “we said if we could do this right

and come up with a seamlessly integrated solution that offers

users this transparent workflow where they can’t tell where the

CAD tools end and the CAM tools begin, we are going to pave

a path for designers and engineers to get into the manufactur-

ing world,” Graves recalled. “They won’t have to learn a new

interface, the tools won’t be intimidating, and we will make it

easy for them to be successful in CAM.”

Autodesk began beta-testing CAM 360 last December,

Graves said, and a commercial version of the cloud-based

CAM is scheduled to be available later in 2014. CAM 360 in-

cludes the company’s basic Fusion 3D modeling capabilities,

and the system also is available with up to five-axis machining

functionality in a tiered pricing model.

Improved Machine Simulation

With the proliferation of multitasking

machines and more five-axis machining,

manufacturing operations need better

machine simulation capabilities to deal

with programming complexities. The

latest CAMWorks 2014 release added a

new module that offers users seamlessly

integrated true G-code machine simula-

tion, noted Vivek Govekar, R&D head,

Geometric Technologies Ltd. (Mumbai

and Scottsdale, AZ).

Using true G-code simulation and

verification dramatically speeds up

machine setup times, Govekar said, and

helps users machine their parts right

the first time. “Time-to-market is the key

competitive edge that customers are

seeking today,” Govekar said, “and the

ability to verify their work, literally with

the click of a button, is definitely a big

advantage for them.”

The CAMWorks simulation and verifi-

cation adds a lot of value for multitasking

systems that have multiple turrets, he

added. “The important thing is it’s based


CAD/CAM Software

The new CAMWorks 2014 from Geometric Technologies

includes true G-code simulation and verification.

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on G-code,” Govekar said. “You see a lot of systems around with

simulation, but they’re all based on CL [cutter location] data.

For simpler scenarios, with no sub-programs, canned cycles

or advanced tooling, that may not be a big deal but for today's

sophisticated machine tools, it is an

absolute necessity.”

Machine simulation is increasingly

important, noted Steve Sevitter, regional

director—Americas, Vero Software

(Cheltenham, UK), developer of CAM

software including the EdgeCAM, Ma-

chining Strategist, Sescoi, Surfcam, and

WorkNC packages. “The latest five-axis

or multitask machines are a ‘collision-

rich environment’ with a high risk of a

clash between part and machine, or

even machine head to table,” Sevitter

said. “Advanced machine simulation

can both avoid these collisions, plus

reduce machine time by allowing the

user to optimize the toolpath.”

“A seamlessly integrated solution offers users

transparent workflow where they can’t tell where the CAD tools end and the

CAM tools begin.”

In aerospace machining, highly accu-

rate machine simulations are mandatory.

With the Dassault Systèmes V6R2014

suite of CAD/CAM applications, aero-

space users can now take advantage of

full machine simulations before taking

product designs to the shop floor, noted

Jean-Marc Cauzac, Delmia Manufactur-

ing Consultant, senior machining expert,

Dassault Systèmes (Paris), and it’s impor-

tant for software developers to work with

customers in tight process integration on

designs both upstream and downstream

before going to the factory floor.

“The main development today is on the specific applica-

tion,” Cauzac said. “In the aerospace domain, one of the big-

gest requests is from customers machining structural parts with

a lot of pockets. People are machining pocket by pocket, and

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machining that manually. But today we are delivering an operation that is able to do

that automatically.” With Delmia’s V6 Machine Builder and related applications, users

can accurately visualize aerospace bulkheads, wings or other structural components

as well as all the machine tool elements prior to cutting components.

Multitasking and Swiss-style machines continue to be very popular and are

available with increasingly dynamic configurations, said Dave Bartholomew, product

manager, DP Technology Corp. (Camarillo, CA), developer of Esprit CAM software.

“More than ever

before, we’re see-

ing an increase in

the complexity of

machined parts,

more advanced

and complex

machine tools,

and heightened

complexity in NC

programming,”

Bartholomew said.

“As a means of

contending with

the increasing complexity, CNC programmers are looking for a complete program-

ming solution—one that is easy and intuitive to use, takes full advantage of the

capabilities of their machine tools, and produces accurate NC code.”

Ensuring a complete solution means providing a realistic representation of the ma-

chine tool for simulation and verification, including the ability to see all axes’ movements

and, in cases of potential violations, the opportunity to easily make corrections, he

added. “It also means providing a user interface that easily and reliably allows the user

to take full advantage of all the machine tool’s capabilities. And while the former two

points are important, the most vital attribute of any CAM system is its postprocessor,”

Bartholomew said. “The simulation on the screen must match what happens at the

machine tool, he added, and accurate G-code is directly dependent upon a complete

postprocessor. The goal is to push a button and see G-code, with no edits required.”

Leveraging Machine Kinematics

For the ultimate in machine simulation, some CAM software uses machine tool

kinematics to more accurately describe machining movements in very rich simula-

tions. “The biggest project that’s coming to fruition for us is the UKM, Universal

Kinematic Machines,” said Bill Gibbs, president, Gibbs and Associates (Moorpark,

CA), developer of GibbsCAM. Gibbs’ UKM, which will be out sometime in 2014 for

the next GibbsCAM update, allows the software to give users a true representation of

any machine configuration, Gibbs said, with very accurate simulation of kinematics

of highly complex multitask machining (MTM) systems.

The GibbsCAM UKM system is not lathe or mill-focused, he said, and it pro-

grams multiple-flow toolpaths, simulates and creates postprocessors for any

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CAD/CAM Software

Machining of a leading-edge rib component for an

aerospace customer is simulated in Dassault Systèmes’

V6R2014 Machine Simulation software.

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machine configuration. “One of the problems we have is we’re

addressing a problem that the market is not particularly edu-

cated on,” Gibbs said. “A lot of our customers do basic milling

and turning. Every release we put out is divided between do-

ing basic improvements and future technology updates.”

Other CAM software developers have worked on similar

machine kinematics projects. “One of the most fascinating

technologies we’ve developed is the incorporation of the kine-

matics of exact machine tools, creating virtual machine tools

on which the knowledge of the machine is used for not only

simulation, but for toolpath calculation,” said DP Technology’s

Bartholomew. “The knowledge of the machine’s kinematics

and dynamics can be used in programming by incorporating

program coordinates and feed rates to optimize acceleration

and velocity while eliminating jerk.”

Today’s CAM software relies upon a CNC programming

model that dates back to the 1960s, Bartholomew noted.

“This methodology is a geometric approach that uses little

more than the definition of the part and stock to calculate

the resulting toolpath. An evaluation of the CAM systems on

the market today reveal that this model has not evolved since

the inception of CNC controls,” he said. “Esprit offers a more

complete knowledge of the entire machining process, as well

as a data-driven, highly optimized and more efficient toolpath-

generation engine.” This new technology will overcome many

limitations innate to all CAM systems, he added, particularly in

the field of five-axis machining.

Tooling Simulation

Simulating 3D cutting-tool models also has become increas-

ingly important in recent years, according to Bill Hasenjaeger,

product marketing manager, CGTech (Irvine, CA), developer

of the popular Vericut NC simulation/verification/optimization

package. Cutting-tool developers Kennametal, Iscar and Sand-

vik all have projects in various states of completion, projects

intended to supply 3D tool models to end-user customers.

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CAD/CAM Software

“It’s interesting for us to see this evolve and become

available since CGTech has advocated tool manufacturers

supply 3D cutting tool models for many years,” Hasenjaeger

said. “Machining simulation requires 3D models of cutting

tools and is a critical link of the automated CNC machin-

ing process chain. Machining path generators only use

parametric descriptions of the cutter, not the 3D model.

Some toolpath generators have provided visualization of 3D

models along a path for years, but this has little practical

utility. Broad industry acceptance of CNC process simula-

tion [and customer pressure] has finally provided enough

incentive for cutting tool manufacturers to do the work to

provide these models.”

Embedding CNC machining process simulation in the

manufacturing engineering process chain also has been a

recent recurring theme, he added. “Vericut is used by a lot

of large and mid-sized manufacturing companies with re-

sources to automate its use in their processes,” Hasenjaeger

said. “Fortunately Vericut has a broad suite of automation

features and we’re sensitive to how valuable this is to our

end users. In fact, we use Vericut’s automation features in

our own internal product testing methods. When used in this

way Vericut becomes a kind of ‘go’ and ‘no-go’ gage to test

NC programs.”

Programming for Maximum Efficiency

To optimize productivity, CAM software gives manufactur-

ers many ways to try to cut costs when automating machine

tools. “We think the first thing that a business should look at is

money, and when you look at money, the first cost is machine

time,” said Gibbs, who believes shops must be aggressive in

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Blisks and other bladed aerospace components can be

easily machined in new machining options available with

GibbsCAM 2014.

analyzing overall machine time. “If you want to utilize your

machines more, another thing you have to look at is your

human labor component. It costs money to have somebody

standing by every machine.”

Automation improvements with optimized cells, automatic

probes, and pallet changers can help reduce machine down-

time, Gibbs noted. “CAM software has the potential to make

sure that you don’t take problems to the machine,” Gibbs

said. “With simulation, you can check to ensure you have all

your tooling presets, make sure the programming concepts

are validated, and spend much less time checking programs

for errors.”

The latest GibbsCAM 2014 offers improved five-axis

machining with two 5-Axis MultiBlade options for machining

of turbomachinery components such as impellers, blisks, and

blings. The software also incorporates the latest versions of

the VoluMill toolpath optimization for roughing toolpaths to

speed up machining.

High-speed roughing from Delcam is now available

in PowerMill 2014 with the company’s new Vortex high-

efficiency area clearance strategy. Delcam’s patent-pending

Vortex “takes a different approach to other apparently similar

developments as it is based on maintaining a controlled angle

of engagement and so allows a near constant feed rate for

cutting moves, rather than focusing on aiming for a consistent

metal-removal rate with varying feed rates,” said Peter Dickin,

Delcam marketing manager.

“The goal is to push a button and see G-code, with no edits required.”

A key trend is more widespread acceptance and adoption

of “dynamic” style toolpaths, said Steve Bertrand, sales man-

ager, CNC Software Inc. (Tolland, CT), developer of Master-

cam. “It’s a technique we’ve been developing and expanding

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for the last five years. These toolpaths use more of the tool

and allow deeper cuts, delivering faster machining and less

tool and machine wear.”

Programmers also need a full understanding of a part’s

changing stock model, Bertrand noted.

“Using the changing stock model to

automate and streamline subsequent

operations helps create the most effi-

cient motion possible. This is especially

useful with mill-turn machines and re-

positioning for multiaxis manufacturing.

“NC programmers are a unique

mix. They tend to be smart and

forward-looking, while still being strongly practical,” Bertrand

said. “This results in users looking for both new technology

they can exploit as well as a constant improvement of estab-

lished techniques.” ME

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Autodesk Inc.Ph: 415-507-5000

Web site: www.autodesk.com

CGTechPh: 949-753-1050

Web site: www.cgtech.com

CNC Software Inc.Ph: 860-875-5006

Web site: www.mastercam.com

Dassault Systèmes/DelmiaPh: 248-267-9696

Web site: www.3ds.com

Delcam plcPh: 877-335-2261

Web site: www.delcam.com

DP Technology Corp.Ph: 805-388-6000

Web site: www.dptechnology.com

Geometric Technologies Inc.Ph: 480-222-2255

Web site: www.geometricglobal.com

Gibbs and AssociatesPh: 805-523-0004

Web site: www.gibbscam.com

Vero SoftwarePh: +44 (0) 1242 542040

Web site: www.verosoftware.comE-mail: [email protected]

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