VisualMill 4.0, a PC-based CAM package for programming three-and four-axis operations on machining centers, features fourth-axis continuous machining, plunge roughing/re-roughing, high speed machining and optimized horizontal finishing.

This version introduces several new options for tool-path creation. For example, the between-two-curves method can be applied to complex flow areas, such as grooves with contoured sidewalls and fillets. Optimized horizontal/vertical finishing allows contoured surfaces to be machined with uniform scallops left on the part. A fourth-axis continuous machining feature facilitates programming of machines with rotary tables.

Improvements include high speed roughing with smooth cut connections to eliminate jerky movements that reduce tool life and cause excessive wear on machine axes. Smoothing of corners and arc fitting are said to promote more efficient machining at high feed rates. Horizontal re-roughing capability is now based on operations so that the cut model from previous operations is used to calculate new tool paths. Parallel finishing has been revised with a Z-containment option to stop machining at a preset Z level. An upgrade to flat area finishing allows pocketing tool paths to be applied in addition to parallel machining tool paths for improved efficiency.

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