Photo courtesy CNC Software Inc.

cad/cam software

The Dynamic Motion technology in Mastercam takes an advanced approach to speeding up toolpath creation that extends tool life
and easily cuts harder materials.

The CAD/CAM Challenge:

Keeping the Complex Simple

T
New solutions offer more support o stay ahead in the game, manufacturers constantly
seek an edge over the competition. With todays CAD/
for complex multitasking machines,
CAM software, the builders of aircraft, automobiles and
optimized high-speed roughing, other complicated systems get the innovative program-
and better simulations ming tools needed to coax the most performance from complex,
expensive machine tools. The latest CAD/CAM software features
more support than ever for the complicated multitasking ma-
Patrick Waurzyniak
chines that can cut costs and boost production through done-
Senior Editor
in-one single setups. Highly realistic simulation capabilities help
machinists visualize everything from the NC metalcutting process
to full machine simulation.
The highly fragmented CAD/CAM market has continued on
its long trend of consolidation, with many bigger players buying
up technology by acquiring smaller CAM-centric companies. In
November 2014, additive manufacturing developer 3D Systems
Corp. (Rock Hill, SC) signed an agreement to buy Cimatron Ltd.

March 2015 | AdvancedManufacturing.org 67

 Cad/cam software
(Givat Shmuel, Israel) for approximately $97 million in cash.
Last year, CAD giant Autodesk Inc. (San Rafael, CA) finalized
its $286-million purchase of CAM-centric developer Delcam
Ltd. (Birmingham, UK).
Rethinking Multitasking
With the complexity of todays multitasking machines
(MTM) rising, programmers of these systems need the best
solutions available for handling multiple spindles and multiple
turrets machining simultaneously. MTM operations neces-
sitate precise timing of machining operations, and optimal
simulation of machining operations to prove out processes
Image courtesy Gibbs and Associates
The Universal Kinematic Machines (UKM) in GibbsCAM 2015 is a next-generation
architecture for supporting programming and simulation of highly complex
multitasking machines.
before ever cutting metal. CAM developer Gibbs and Associ-
ates (Moorpark, CA) has taken a new approach to supporting
these machines with its new Universal Kinematic Machines
(UKM) shown last fall at IMTS.
Some of the most important trends in CAM software
today are the necessity of supporting the evolution of ad-
vanced CNC machines, and creating a single programming
environment for end users that encompasses programming
of all types, including integration with 3D printing, said Bill
Gibbs, president, Gibbs and Associates. No longer are CNC
68 AdvancedManufacturing.org | March 2015
machines simply a mill or a lathe. Instead, the variation of
configuration of MTM machines continues to expand and
blossom in pursuit of ever-greater manufacturing efficiency.
The challenges include unlimited axes in unlimited con-
figurations, Gibbs said, combining five-axis milling, multiaxis
turning, multiple tools cutting at the same time, multiple part
stationsall in pursuit of material in and finished parts out.
GibbsCAM 2015 UKM is a next-generation architecture
that aims to dramatically increase support of program gen-
eration and simulation of such machines. UKM offers sup-
port of the simplest to the most complex CNC machines
in the same integrated CAM environment, with advanced
postprocessing capabilities, and machine
simulation, providing a rich environment
with the highest level of user interface
consistency, Gibbs said. Its easy for
a programmer to support a variety of
machines, as he only has to learn a single
CAM software to do it all.
Virtual Machining
More realism in simulations is key for
any shops tackling advanced manufactur-
ing processes, particularly with multitasking
machines and simultaneous five-axis ma-
chining operations. Many choices prolifer-
ate in CAD/CAM, with improved simulation
components in nearly every CAM system,
ranging up to high-end, very detailed simu-
lations offered by NC simulation, verification
and optimization software like Vericut from
CGTech (Irvine, CA).
Simulation is being used more and
more as a process validation tool, not just
a tool to check for catastrophic errors such
as machine collisions and gouges in the
workpiece, said Bill Hasenjaeger, CGTech product mar-
keting manager. The latest Vericut 7.3 version features an
updated desktop layout for improving customer experiences,
and the software adds an enhanced status display for users
to monitor machining processes. With accurate representa-
tion of material removal in Vericut, its becoming practical to
predict the effects cutting has on the tool and the workpiece
at a very detailed level, said Hasenjaeger. This information
can be used to validate a new cutting process, or adjust an
existing one for better efficiency.
 Cad/cam software

The latest Geometric CAMWorks 2015,

introduced at IMTS, has further refined the
machine simulation capabilities of its G-code
simulation, noted Nishant Saini, director,
corporate marketing and communications,
Geometric Technologies Ltd. (Scottsdale, AZ,
and Mumbai). Weve added many machines
and 25 different controllers, he said. It has
full machine simulation that includes the
fixtures, the machine envelope, and any of

Photo courtesy CGTech

the moving parts. This way a machinist can
say, This is what I need to model, and that is
what I dont need to spend time on. These
are ready-made, out-of-the-box solutions.
Katrin Vogl views a Vericut simulation at test and measurement manufacturer
This CAMWorks Virtual Machine func-
tionality offers users true G-code simulations
using the machine tools G-code, rather than using cutter
location (CL) data as do other CAM systems. Virtual Machine
offers full support for complex multitasking and mill-turn ma-
Rohde & Swarz.
chines, and it includes synchronized simultaneous machining
with multiple channels using timing codes, which are easily
controlled using CAMWorks Sync Manager.
The software also allows automating specific routines with
color-coded definitions that enable easy viewing of simulation
components, which can be useful especially in the medical in-
dustry. These are based on scans of actual body parts, taking
the cloud information and converting it into surfaces, added
Vivek Govekar, head of R&D for Geometric. There are a lot
of facets, so that takes a lot of time. Color coding those gives
you the advantage of seeing which ones need machining.
In Siemens PLM Softwares (Plano, TX) portfolio, many
simulation options are available, from simulations in its
recently updated NX 10 CAD/CAM/CAE software to the
companys Tecnomatix digital manufacturing solutions and
also newer testing simulation functionality in its LMS simula-
tions. We certainly see simulation having gone mainstream,

ROLLERS said Aaron Frankel, Siemens PLM Softwares director of

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product marketing. More simulation is now available within
the NX 10 line, including CAE applications for multiphysics
and new production line design capabilities for automotive
assembly that allow engineers to visualize layouts of produc-
tion lines within NX, and use Siemens Teamcenter product
data management and Tecnomatix to manage, validate, and
optimize manufacturing processes.
Speeding Roughing Operations
Faster metalcutting methods are in high demand, and
users get a lot more high-speed roughing material removal
choices among the latest CAD/CAM releases. By speeding

70
FXW-068C 3.25x4.625.indd 1
AdvancedManufacturing.org | March 2015 1/27/15 1:47 PM
up roughing operations, the most time-consuming part of any CAD/CAM customers want software that is more power-
metalcutting, many manufacturers are seeing cost payback ful, flexible, easier to learn and faster to use, said Peter
that helps make economic sense for reshoring mold-and-die Dickin, Delcam marketing manager. Software companies
work from the Far East (see Advanced Programming Makes are working hard to meet those needs. On the CAM side,
the Case for Reshoring Moldmaking
Operations in the December 2014 issue
of Manufacturing Engineering).
Roughing options abound in CAD/
CAM today, with many CAM providers
licensing the VoluMill high-performance
toolpath technology from Celeritive
Technologies Inc. (Cave Creek, AZ), while
others employ their own home-grown
strategies. Those solutions include
Delcams Vortex controlled-engagement
toolpaths and also the Dynamic Motion
toolpath technology developed by CNC
Software Inc. (Tolland, CT), developer of
Mastercam software.
The key trends in CAM software
are still simple but powerful: constantly
increase the speed and efficiency of
the software, automate where possible,
deliver programming methods that

The New Grinding Edge

make the best possible use of machine
tools, tooling, and material, and make
the software capable of handling the in-
creasing variety of jobs a shop encoun-
See the SMART-III technology at Eastec. The series is now
available in a multi-functional two- or three-axes CNC surface grinder. The
ters, said Ben Mund, CNC Software
SMARTs PC-based control, combined with a user-friendly conversational
marketing manager.
TaskLink function, makes it easy to learn and operate. CNC experience
A great example is the wider
is not necessary. The SMART control features a highly efficient, constant-
adoption of dynamic-style toolpaths, a
contact auto dressing function and variable spindle speeds with constant
technique weve been developing and
surface speed control that reduces initial dress time from hours to minutes.
expanding across our products, Mund
All data transfer is simplified by using a USB data port or an Ethernet
said. This technique is a different philos-
connection. The simulation mode is great for job shops, to prove-out a
ophy on creating cutter motion that uses
program prior to putting it in production, reducing or eliminating scrapped
more of the tool and deeper cuts, while
parts and simplifying part set-up. The table size is up to 24"W x 80"L with
reducing machine time and tool wear.
table loads up to 1,473 lbs.
Another example, he said, is better
understanding of a parts changing stock Call your local dealer to see our comprehensive product line for all
modelusing the changing stock model your machining needs and see you at Eastec.
to automate and streamline subsequent
SEE US AT EASTEC BOOTH 1058
operations helps create the most efficient
motion possible. This is especially useful 800-243-8253 / 562-903-1929
We shape your ideas. www.ChevalierUSA.com
with mill-turn machines and repositioning
for multiaxis manufacturing.

March 2015 | AdvancedManufacturing.org 71

CMI_mfg_eng_SMARTB818III_half pg island_4clr.indd 1 1/28/15 4:51
 Cad/cam software

coming more complex, especially multitasking

equipment with multiple turrets and spindles,
so CAM software needs to be able to program
these more advanced machines.
At the same time, cutting tools are able
to achieve metal-removal rates that would
have been unthinkable even a few years
ago, he added. New strategies are needed
Photo courtesy Siemens PLM Software

to take full advantage of these capabilities.

The new Siemens NX 10 software offers an Advanced Studio Display rendering
mode supporting global illumination, soft and ambient shadows, and reflections
based on high-dynamic range images.
much of the development is being driven by developments in
machinery and cutting tools, Dickin said. Machines are be-
The Delcam Vortex high-speed roughing
functionality, which can achieve up to 60%
faster machining cycle times, is now available
across its entire CAM line including in
PowerMill, FeatureCAM and Partmaker.
Another option for high-speed roughing is
ProfitMilling in the Esprit 2014 CAM software
from DP Technology Corp. (Camarillo, CA). In
smoothing the toolpath and combining engagement angle,
chip load, lateral acceleration with feed rate optimization,
Esprit ProfitMilling technology drastically
reduces machining time, said Ced-
ric Simard, DP Technologys director,
global marketing and communication,
noting that ProfitMilling supports two,
three, four and five-axis machining.
CAM users will benefit from bottom-up
roughing cycles, he said. Rather than
traditional top-down strategy, bottom-
up roughing allows users to tremen-
dously reduce cycle time by taking the
full depth of a cut in the first pass.

More Automation, Smart Machining

The Original Toggle Clamp
Company
DE-STA-CO has expanded since 1915 to provide
complete automated solutions
destaco.com/mfgeng
Another key area in CAD/CAM
development is automating best prac-
tices and leveraging knowledge-based
systems to help speed up machining
processes. A significant advancement
has been the introduction of software
intelligence, which reduces reliance on
CAD/CAM experts, said Steve Sivitter,
CEO of Vero Software (Tuscaloosa,
AL, and Cheltenham, UK), developer
of several CAM packages including
Edgecam, Radan, Machining Strategist,
888.DESTACO Surfcam, WorkNC and the VISI Mould

72 AdvancedManufacturing.org | March 2015

and Progress moldmaking packages. This can be achieved
with a knowledge-based database, which adapts over time
and can be used by anyone to achieve the same results, fol-
lowing proven and tested rules and conventions.
Manufacturers that establish plant-wide database de-
faults that represent company standards will ensure that,
from user to user and job to job, the company produces
consistent results and high-quality tooling, Sivitter noted.
Intelligence can be added to the software so that the sys-
tem can automatically select the best strategy or machin-
ing parameters based on remaining stock or geometrical
attributes, he said. One example of this is the ability to
take a standard three-axis toolpath and convert it for use as
a five-axis toolpath, rather than having to rework it from the
beginning. This is particularly useful for dealing with both
short-reach cutters and deep pockets.
The integration of a CAD/CAM system ensures that data
can be successfully passed from CAD to CAM, he said. Those
same features, diameters, hole depths, etc., can be automati-
cally read by the CAM system, instilling confidence in the user
regarding programming and automation, Sivitter said.
Notable developments in cloud-based CAM include
Autodesks CAM 360 announced last year. In contrast,
DP Technology is using a cloud-enabled CAM connec-
tion with Esprit, keeping the software as a stand-alone
CAM system while offering links with the Machining Cloud
(Stans, Switzerland), a provider of cloud-based machining
system and tooling database information. At DP Technol-
ogy, we understand and value the cloud trend. Still we are
also aware of its limits and risks with respect to the CAM
industry, said DP Technologys Simard. We have decided
to keep Esprit as a stand-alone CAM application for it to be
as close to the machine tool as possible, or in other words,
completely integrated in shop floor and the machinists
physical environment.
With the Machining Cloud, Esprit programmers have
access to complete and up-to-date tooling product data,
cutting hours of programming time by eliminating manual
tool creation, Simard added. Cloud-enabled Esprit simpli-
fies the selection of cutting tools. It offers a list of recom-

We certainly see simulation

having gone mainstream.

Automating the know-how of frequently performed opera-

tions is key for many manufacturing processes, particularly
for machining operations such as pocketing on large aircraft
structural components, noted Jean-Marc Cauzac, Delmia
Manufacturing Consultant, senior machining expert, Dassault
Systmes (Paris).
Reusing this captured knowledge is important. Especially
for manufacturers working on one domain, like aerospace,
this is key because youre working on the same kind of parts.
CATIA V6 includes a lot of knowledgeware inside, Cauzac
added. You want to reuse the same parameters because
you know its working.

CAM in the Cloud

New cloud-based systems also are another positive
development in CAM, Cauzac said. The cloud solution is
very good. With the cloud, I think were at the beginning.
When you take a look to your daily activity, everything is done
through the Internet. This allows you to manage the supply
chain through the cloud.

March 2015 | AdvancedManufacturing.org 73

 Cad/cam software

mended cutting tools based on machining fea-

tures and machining sequences, and simulates
with accurate 3D models of tool components
and assemblies.

Adding Additive
With the growing interest in additive manu-
facturing, CAD/CAM developers are also looking

Photo courtesy Vero Software

into programming alternatives for innovative new
hybrid additive-subtractive machining systems
coming onto the market. But most see this as a
complementary technology to traditional subtractive
manufacturing techniques and software, given the
New Workflow process shown in Edgecam 2015 R1 leads programmers
current limitations of AM on part precision and for
through milling toolpath creation.
manufacturing in large volumes.
An additive toolpath is not a CAM toolpath in reverse, Manufacturing processes have evolved in many ways over
said Frankel of Siemens PLM Software. We are working with many years, said Veros Sivitter, noting that the advancement
DMG Mori to develop research and development on this. Its of polymers made many previously machined components
research at this point in time. unnecessary. So its certain that additive manufacturing will
negate the need for some machining operations andin the
cases of some prototypes and patternsit already has, Sivit-
Precision ter said. Its also worth noting that production speed and build
hydraulic window will always be a restriction for 3D printing. However,
workholding new machines such as the DMG Mori Lasertec 65which can
devices that deploy metal powder, weld with a laser, and mill in five axes
produce better can improve production and costly reworking procedures.
parts in less Developments on GibbsCAM include the integration of 3D
time with printing as another machine and process that manufacturing
companies will need to consider and support in the future for
repeatable
integration into their processes, Gibbs said. In my opinion,
results.
the future of manufacturing is Digital Fabrication. This is not
my term, I first heard it used by Avi Reichental, CEO of 3D
Systems, Gibbs said. He uses it to describe the growing
integration of functionality from part design through multiple
integrated manufacturing steps all the way to a finished part.
The separate component pieces exist today, but not in a
single, coordinated solution.

An additive toolpath is not

a CAM toolpath in reverse.

The dream is smart, integrated software that allows engi-

Learn more, CALL: 800-992-0236 neers to design with full consideration of optimal, integrated
sales@vektek.com www.vektek.com manufacturing, Gibbs said, including seamless transitions
from 3D printing to whatever CNC processes are required.

74 AdvancedManufacturing.org | March 2015

 Some aspects of what that software would look like together software, Gibbs stated. Working towards this goal
include managing with the entire process from a single soft- has to be the most important trend in CAD/CAM today. It
ware package and the inclusion of manufacturing knowl- is a mighty undertaking. But you can see major companies
edge-based assistance for designers and manufacturing en- acquiring the technologies they need to pursue it.
gineers, Gibbs added. It would make
standard full associativity to automati-
cally reprocess changes in the design,
all the way through the manufacturing
processes. It would support the most

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March 2015 | AdvancedManufacturing.org 75