A 64-bit version of PowerMILL 2010 is now available. Users benefit from being able to calculate much larger parts, as well as more complex and micro parts that require high tolerances for precision machining. Delcam recommends that users invest in 64-bit Windows Vista and Windows 7 operating systems with 12GB of RAM. Recent benchmark tests have shown that PowerMILL 2010 64-bit is on average 2.5 times faster than PowerMILL 10.

A range of toolpath strategies and functionality benefit from additional multi-threading in PowerMILL 2010, including:

PowerMILL 2010 eliminates thin upstands of material around a block edge by ensuring that the profile pass around the block is always equal to the programmed stepover in Area Clearance strategies. This prevents tool damage when removing material, resulting in extended tool life and reduced tooling costs. Additionally, users also benefit from reduced machining time.

Rest Roughing toolpaths are even more efficient in PowerMILL 2010. For the vast majority of parts the overall length of non-cutting moves has been reduced significantly, resulting in ordering improvements of up to 68%. This has been achieved by firstly improving the general ordering of the toolpath segments and secondly by better alignment of the start points of roughing segments. Benefits include:

• Reduced cutter wear.
• Lower tooling costs.
• Faster machining times

A brand new Toolpath strategy called Corner Clearance has been added in PowerMILL 2010 to optimise the roughing of internal corners. The rest material is removed in a series of user definable stepovers and stepdowns as the tool follows the direction of the corner. This new approach eliminates the time consuming and manual process of creating several corner finishing toolpaths with sequentially smaller cutters to pick out the material in the corner. Benefits include reduced cutter wear, lower tooling costs and faster machining times.

PowerMILL 2010 enables users to machine undercut regions of a part directly with a Constant Z toolpath as long as the current tool geometry or tool axis permits. This is particularly beneficial for users utilising a 'lollipop' type cutter on a 3-axis machine to machine undercuts.

3D Offset Finishing has been enhanced with the addition of a new Smoothing option. Activating 3D Offset Smoothing removes all sharp changes in direction, resulting in a better surface finish and reduced machining times. Technology similar to the patented Raceline Smoothing in Area Clearance is employed to smooth out the whole toolpath, including the corners.

New tool holder profile functionality in PowerMILL 2010 makes it very easy to automatically calculate the maximum tool profile for multiple toolpaths. The tool holder profile is calculated for each individual toolpath and then combined to give the maximum profile for all selected toolpaths. Users can quickly and easily experiment with different overhang and holder combinations that fit within the profile to find the optimum machining setup. Benefits include:

• Reduced vibration.
• Faster feedrate, resulting in minimal machining time.
• Extended tool life.
• Better quality surface finish and less hand finishing.
• No time consuming tool holder collision checks.
  

Two new tool axis tilting methods have been added to the Collision Avoidance functionality in PowerMILL 2010. The Lead then Lean and Lean then Lead methods allow the tool to tilt in a secondary direction if a collision free position cannot be found using the first method. These options are particularly useful in areas of sudden direction change where a single tilting direction will fail.

PowerMILL 2010 offers many improvements to the tool axis smoothing functionality. One such improvement is the addition of a new 'look ahead' smoothing parameter for collision avoidance. This new parameter will remove any sudden tool axis change and ensure a smooth transition when collision avoidance takes place.

PowerMILL 2010 has the ability to smooth the Azimuth and Elevation axis independently of each other using one of several smoothing options. The new stepped stabilisation smoothing option stabilises the rotary axis movement by maintaining a fixed tool axis as much as possible within an angular range. The toolpath will appear as series of 3+2 axis segments with 5-axis transitions between them. The transitions can either be completed on a surface or with a lift.

The new Orientation Vector functionality gives users the ability to control the orientation of the head and/or table of the machine tool relative to the part at any point during machining. This functionality helps to prevent collisions between the component and the head of the machine tool.

Previously known as Interleaved Constant Z Finishing, not only has this strategy been renamed in PowerMILL 2010 to more accurately reflect the machining operation, but more importantly it has undergone a major improvement with the addition of several new options, including:

• The choice of Raster or 3D offset machining for shallow regions.
• The addition of a wall clearance parameter to prevent the tool from rubbing against steep walls.
• This strategy has now matured in PowerMILL 2010 into an effective 'all-in-one' solution for the semi-finishing or finishing of a wide variety of parts in soft or hard materials.
  

Constant Z finishing has benefited from a significant upgrade in PowerMILL 2010 with the addition of two new important functions:-

• An Area Filter that removes small enclosed pockets of toolpaths, preventing tool damage.
• Machine down to flats that inserts a final profile pass exactly at the base of a flat pocket
  

Working with expressions is much easier in PowerMILL 2010 thanks to a new expression editor that automatically lists appropriate parameters as soon as you start typing the expression.  Alternatively, parameter names can be pasted into the Expression Editor simply by clicking in a parameter field on a form. Forms that already contain expressions will be easier to identify with the introduction of a blue highlight around the parameter field.  Benefits include:-

• Ability for users to fully customise their PowerMILL operations.
• Automated programming procedures.
• Reduced manual programming inputs.

The majority of toolpath strategies have now been updated to the new improved form design that first appeared in PowerMILL 10. The new form takes up far less space on the screen due to the innovative explorer style design that allows quick and easy access to all the parameters associated with the toolpath from within a single compact form.

PowerMILL 2010 includes improvements to the way toolpaths are limited to the block profile. Finishing and roughing strategies now have the option to allow the tool centre to go outside the block. This makes the limiting behaviour consistent across the complete range of toolpath strategies.

The Setup Sheet functionality has been improved in PowerMILL 2010, enabling users to:

• Add annotations for the both the tool and the holder within the tool drawing.
• Add custom text and lines when creating snapshot images.

Creating and editing workplanes is even easier in PowerMILL 2010. A new dedicated workplane toolbar contains a range of additional functionality, including:

• Double mouse click to instrument and edit a workplane at any time.
• Advanced PowerSHAPE-style positioning form.
• Interactive and accurate alignment of workplane axis using intelligent cursor.
• Undo and redo any workplane edits.

The latest workplane improvements in PowerMILL 2010, along with the original enhancements implemented in PowerMILL 10, means that even the most complex of machining setups are quick and easy to define.

The new Z Heights Viewer allows users to select and view a single Z height of an Area Clearance or Constant Z toolpath. Users can step through the list of Z heights one-by-one or view a specific Z height by entering a Z coordinate. The list can also be filtered to only show Z heights that machine flats.