The CAD/CAM Challenge: Keeping the Complex Simple T€¦ · The CAD/CAM Challenge: Keeping the Complex Simple Patrick Waurzyniak Senior Editor New solutions offer more support

March 2015 | AdvancedManufacturing.org 67

cad/cam software

The CAD/CAM Challenge: Keeping the Complex Simple

Patrick WaurzyniakSenior Editor

New solutions offer more support

for complex multitasking machines,

optimized high-speed roughing,

and better simulations T

o stay ahead in the game, manufacturers constantly

seek an edge over the competition. With today’s CAD/

CAM software, the builders of aircraft, automobiles and

other complicated systems get the innovative program-

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-

chines that can cut costs and boost production through “done-

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.

Photo courtesy CNC Software Inc.

The Dynamic Motion technology in Mastercam takes an advanced approach to speeding up toolpath creation that extends tool life

and easily cuts harder materials.

68 AdvancedManufacturing.org | March 2015

(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 today’s 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

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

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

stations—all 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. “It’s 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, it’s 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 Universal Kinematic Machines (UKM) in GibbsCAM 2015 is a next-generation

architecture for supporting programming and simulation of highly complex

multitasking machines.

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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). “We’ve added many machines

and 25 different controllers,” he said. “It has

full machine simulation that includes the

fixtures, the machine envelope, and any of

the moving parts. This way a machinist can

say, ‘This is what I need to model, and that is

what I don’t need to spend time on.’ These

are ready-made, out-of-the-box solutions.”

This CAMWorks Virtual Machine func-

tionality offers users true G-code simulations

using the machine tool’s 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-

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 Software’s (Plano, TX) portfolio, many

simulation options are available, from simulations in its

recently updated NX 10 CAD/CAM/CAE software to the

company’s Tecnomatix digital manufacturing solutions and

also newer testing simulation functionality in its LMS simula-

tions. “We certainly see simulation having gone mainstream,”

said Aaron Frankel, Siemens PLM Software’s director of

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

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cad/cam software

Katrin Vogl views a Vericut simulation at test and measurement manufacturer

Rohde & Swarz.

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up roughing operations, the most time-consuming part of any

metalcutting, many manufacturers are seeing cost payback

that helps make economic sense for reshoring mold-and-die

work from the Far East (see “Advanced Programming Makes

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

Delcam’s 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

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-

ters,” said Ben Mund, CNC Software

marketing manager.

“A great example is the wider

adoption of dynamic-style toolpaths, a

technique we’ve been developing and

expanding across our products,” Mund

said. “This technique is a different philos-

ophy on creating cutter motion that uses

more of the tool and deeper cuts, while

reducing machine time and tool wear.”

Another example, he said, is better

understanding of a part’s changing stock

model—using the changing stock model

to automate and streamline subsequent

operations helps create the most efficient

motion possible. “This is especially useful

with mill-turn machines and repositioning

for multiaxis manufacturing.”

CAD/CAM customers want software that is more power-

ful, flexible, easier to learn and faster to use, said Peter

Dickin, Delcam marketing manager. “Software companies

are working hard to meet those needs. On the CAM side,

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much of the development is being driven by developments in

machinery and cutting tools,” Dickin said. “Machines are be-

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

to take full advantage of these capabilities.”

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 Technology’s 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

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,

Surfcam, WorkNC and the VISI Mould

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cad/cam software

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.

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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.

“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

Systèmes (Paris).

Reusing this captured knowledge is important. “Especially

for manufacturers working on one domain, like aerospace,

this is key because you’re 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 it’s 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 we’re 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.”

Notable developments in cloud-based CAM include

Autodesk’s 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 Technology’s 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 machinist’s

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-


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

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

current limitations of AM on part precision and for

manufacturing in large volumes.

“An additive toolpath is not a CAM toolpath in reverse,”

said Frankel of Siemens PLM Software. “We are working with

DMG Mori to develop research and development on this. It’s

research at this point in time.”

Manufacturing processes have evolved in many ways over

many years, said Vero’s Sivitter, noting that the advancement

of polymers made many previously machined components

unnecessary. “So it’s certain that additive manufacturing will

negate the need for some machining operations and—in the

cases of some prototypes and patterns—it already has,” Sivit-

ter said. “It’s also worth noting that production speed and build

window will always be a restriction for 3D printing. However,

new machines such as the DMG Mori Lasertec 65—which can

deploy metal powder, weld with a laser, and mill in five axes—

can improve production and costly reworking procedures.”

Developments on GibbsCAM include the integration of 3D

printing as another machine and process that manufacturing

companies will need to consider and support in the future for

integration into their processes, Gibbs said. “In my opinion,

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-

neers to design with full consideration of optimal, integrated

manufacturing,” Gibbs said, “including seamless transitions

from 3D printing to whatever CNC processes are required.”

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cad/cam software

New Workflow process shown in Edgecam 2015 R1 leads programmers

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Some aspects of what that software would look like

include managing with the entire process from a single soft-

ware package and the inclusion of manufacturing knowl-

edge-based assistance for designers and manufacturing en-

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

advanced multiaxis CNC machines,

while providing simulation and digital

prove-out to perfect programs before

they get to the machine, eliminating

human error from endless edits.

“Many CAD/CAM software sys-

tems can do some pieces of this. But

the fully integrated Digital Fabrica-

tion environment promises so much

more than a hodgepodge of patched

together software,” Gibbs stated. “Working towards this goal

has to be the most important trend in CAD/CAM today. It

is a mighty undertaking. But you can see major companies

acquiring the technologies they need to pursue it.”

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CGTech949-753-1050 / cgtech.com

CNC Software Inc.860-875-5006 / mastercam.com

Dassault Systèmes/Delmia248-267-9696 / 3ds.com

Delcam Ltd. 877-335-2261 / delcam.com

DP Technology Corp.805-388-6000 / dptechnology.com

Geometric Technologies Inc.480-222-2255 / geometricglobal.com

Gibbs and Associates805-523-0004 / gibbscam.com

Siemens PLM Software800-498-5351 / siemens.com/plm

Vero Software+44 (0) 1189 226699 / verosoftware.com

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The CAD/CAM Challenge: Keeping the Complex Simple T€¦ · The CAD/CAM Challenge: Keeping the Complex Simple Patrick Waurzyniak Senior Editor New solutions offer more support