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Code-generating Software


WELsoft have looked at, but do not have in-depth experience of, all of the software mentioned below. We make no claims for performance or suitability for your purposes. Only you can decide. The software mentioned covers a range of types, prices and purposes. In most cases demonstration versions are available for you to evaluate. The critical question is "Can the software be configured to create NC code in the WELmill format?"

Introduction
It takes a long time to prepare NC code by hand particularly if the part to be machined is complex. Inexpensive CAD software, such as AutoDesk's QuickCAD, can ease the task: a drawing of the part is made and the CAD software is used to report co-ordinates and other data. This saves the labour of manual calculation. Preparation of code by hand is really only feasible for 2.5D machining: even assuming it can be calculated by hand, 3D code files can be vast. WELmill can handle code files with up to 2,147,483,647 lines (2 to the power of 31) which may take over 2.85 years to machine at a fast feed rate let alone the time for the PC to pre-process: WELmill should satisfy all but the most unusual needs!

AlphaCAM from Licom Systems Ltd, is expensive but there is special pricing for educational establishments. AlphaCAM is powerful and easy to use. It can generate CNC code for turning as well as milling. It can also create 3D tool paths as well as 2.5D. WELsoft are very familiar with AlphaCAM and a post processor is supplied with WELmill in the folder \WELmill\Allsorts. See www.licom.co.uk

EdgeCAM from PathTrace, generates CNC code for turning and milling. It can create solid models and import, without data translation, solid models from major solid modelling software . Post processors will be available for both WELmill and WELturn in the near future. See www.edgecam.com

Galaad please see Galaad

Other software
includes MasterCAM and CAPSmill. Details of these programs can be found on the internet.

Cpost is from Softcover International Ltd. It imports DXF files created in CAD software, allows you to set tool paths and creates all the NC code for you. As WELsoft have looked at but not used Cpost, you will need to get the supplier to prepare a post processor which generates code in the ISO G code format required by WELmill:CNC File Specification for WELmill. See www.softcover.co.uk

All the above and similar high quality programs can be expensive but usually there is special pricing for educational establishments. Provided they allow the user to configure a post processor, they should be able to create code in the form required by WELmill.

DeskProto
This program can import files in STL and other formats so that toolpaths for 3D machining can be set and NC code for WELmill generated. The program is available in full and Lite versions both with a 50% educational discount. It can be used in Wizard ot Expert mode. It is easy to see when an imported model is in the desired machining position. Toolpath and code generation is extremely fast. Post processors for the F1 and WoodWorker mills, with installation instructions, are supplied with WELmill. DeskProto can be purchased from WELsoft. A fully working 30 day demonstration version is available from www.deskproto.com

To be able to use code files generated by DeskProto, the WELmill PC software must be version 2.0.10 or higher. An upgrade to the latest version is available on www.welsoft.co.uk

MiniCAM / MillWizard
These are utilities which can import 3D drawing files in STL and other formats. They enable tool paths to be set and NC code created and saved. Supplied with WELmill, in the \WELmill\Allsorts folder are various files which must be copied to various places in the MiniCAM/MillWizard folder so that code is generated in the WELmill format. Full instructions are provided with these files.

In both these programs, the method of orientating the imported model into the desired position for machining is confusing and the creation of toolpaths is painfully slow.

MiniCAM is normally only supplied with ArtCAM. However it is available by itself only to UK secondary schools for around £150. It is available from the following machine tool suppliers: Boxford Ltd, Denford Ltd and Emco Education Ltd. Non-education users will need to purchase MillWizard. MiniCAM needs to be configured with files supplied with WELmill, to create code for WELmill.

MillWizard is virtually identical to MiniCAM (see above) and is available to the world at large. It needs to be configured with files supplied with WELmill, to create code for WELmill. See www.millwizard.com for details and price.

Note on Depth of Cut in MiniCAM/MillWizard
In MiniCAM/MillWizard, for some reason the Depth of Cut is called "Step Down". Some of the default values for Step Down are very large. Take care to check and alter them as necessary.

3D-GeoCAM
This program has been developed by Boxford Ltd to create code for 3D machining. At first sight it looks like MiniCAM, and has a similar step-by-step user interface, but it creates toolpaths much faster and includes a range of advanced machining strategies which give a better finish to products than raster machining alone. It has two post processors for WELmill: one for the F1 mill and the other for the higher spindle speed WoodWorker mill. Boxford Ltd say that they will only sell the program to educational establishments. For further details see the Products - 3D CAM section of  www.boxford.co.uk/boxford/

Image Relief
This is a program which can import a bit map photographic image and create toolpaths the depth of which are proportional to the grey scale of each part of the picture. The NC code which is produced can be used to machine a relief image in thin, translucent plastic. The program is available from Boxford Ltd at educational and commercial prices. Post processors are available for WELmill. Post processors are not user-configurable but Boxford will write them for any machine. For further details see the Products - 3D Photo Engraving section of  www.boxford.co.uk/boxford/

VisualMill
This is available in two versions: VisualMill and VisualMill Basic, the latter being a reduced version of the software. The full version of VisualMill has very powerful machining features. Both versions of the software offer 2.5D and 3D machining capability, something not found in MiniCAM or DeskProto. The software has a user-configurable post processor so it should be possible to create code in the WELmill format. Ask the distributor if there is a discount for educational establishments. Further details are available on the web site of the UK distributor, CNC Technologies UK Ltd, at  UNCONVERTED WINHELP MACRO:! ExecFile("www.cnclabs.co.uk/Templates/software_vm.htm")www.cnclabs.co.uk/Templates/software_vm.htm

Millit
This program weighs in at nearly 5000 Euro to industrial users (there may be a discount for educational establishments) but it is worth downloading the demo version and working through the tutorial just to see what the Emco F1 mill with WELmill could do given this software. Millit generates code for 3D and rapid prototype machining. It can import a complex 3D object with inner voids and undercuts and slice it into sections which can be machined by a 3-axis mill. Further information is available on its publisher's web site UNCONVERTED WINHELP MACRO:! ExecFile("www.millit.com")www.millit.com and the UK distributor is CNC Technologies UK Ltd UNCONVERTED WINHELP MACRO:! ExecFile("www.cnclabs.co.uk")www.cnclabs.co.uk

Note on STL Files
These stereo lithography files are mentioned several times in these notes. They store 3D image data. The image is described as a mesh of triangles: see www.uclan.ac.uk/clt/calm/stl.htm  The smaller the triangles, the better the description of the image and the smoother the surface of the machined product. However, the smaller the triangles, the more triangles needed to describe an image. The more triangles used, the bigger the data files. A very small image, say 60 x 60, can use many megabytes of computer disk space.

If an image is created at coarse resolution, the describing triangles will be large and the image will appear to be made of many flat facets and not smoothly curved. However, the file size will be small. If an image is created at fine resolution, the describing polygons will be small and the image will look smoother, but, the file size will be large.

There needs to be a balance between image/machined product quality and image file size. There is a real risk of a hard drive rapidly becoming filled with STL files.

By contrast, while the NC code files generated by 3D machining software may run to tens of thousands of lines, they are text files and need fairly small amounts of disk space.

Web List
There is a lot of software out there, some good, some flakey, some relatively inexpensive, some very costly, some very irritating to use. The critical question is "Can the software be configured to create NC code in the WELmill format?" You might like to view the very long list of CAD and CNC programs, with links to suppliers, at www.woodbin.com

Also take a look at CNC Technologies UK Ltd and also, in the USA, MCAD

2.5D and 3D Machining
AlphaCAM
CAD/CAM Initiative for Schools
CAD Software as an Aid to NC Code Preparation
CNC File Specification
Code File Header Information
Design Resources
Example of Manually Created NC Code
WELmill NC code file extension