cadcam supplement -...
TRANSCRIPT
www.newelectronics.co.ukwww.machinery.co.uk
October 2011
CADCAM S U P P LE M E NTCGTECH, DELCAM, SIGMATEK EUROPE, TECH CADCAM AND VERO
The Magazine for Production Engineers
Cadcam oct11 cover.qxp:Layout 1 29/9/11 17:25 Page 1
Visit us at Stand 622
P002_MCSP_OCT11 29/9/11 14:24 Page 1
GibbsCAM VoluMill has made it
possible for Quelch Engineering to
achieve startling reductions in its
machining times. The Uxbridge-based
company specialises in aerospace, motor
sport, petrochemical and electronic
components, and has made parts for the
Ariane space rocket. As a subcontractor,
a high proportion of parts are new and
unique, leading to a heavy demand for
CNC programming.
Quelch Engineering first invested in
GibbsCAM in 1999, choosing it for its
simplicity of operation. Now the
company has two seats of the software,
using it to program all of its 11 CNC
machines, including milling, turning and
multi-task mill-turns.
As part of its investment programme,
Quelch Engineering has continually
upgraded its GibbsCAM software,
adding modules for 4-axis positional
and rotary machining, full 3D
machining, multi-task machining and
solid modelling, giving it the ability
to read native CAD models,
including CATIA V5TM, Pro-
EngineerTM, NX-CADTM and
SolidworksTM. The VoluMill
module was the next logical
investment and, in 2009, Quelch
Engineering became the first company in
the UK to install this technology.
“Roughing operations form a very
significant part of our machining
activities, so any reductions in time are
highly advantageous,” explains Alan
Baldwin, technical director at Quelch
Engineering. “VoluMill allows us to keep
the chip thickness constant and enables
us to push feeds and
speeds up dramatically.
Through a process of
machining trials, we have
found the ‘sweet spot’ for
our combination of tools,
holders, fixtures and
machining centres, giving
us a reduction in roughing
cycle times of 75%, in some
cases.
“Our machines are fully loaded most
of the time, so not only does VoluMill
increase our available production
capacity, but it helps us to reduce lead
times and gives us considerably longer
tool life.”
For more information: call 01284
754781; email: [email protected];
visit www.techcadcam.net ■■
Quelch roughs four times faster
iiiwww.machinery.co.uk • October 2011
CADCAM SUPPLEMENT – GibbsCAM VoluMillAdvertisement Feature
CADCAM_Gibbs.qxp:Machinery 29/9/11 13:15 Page iii
Cloud computing provides software,
data access, and storage services that
do not require end-user knowledge of the
location and configuration of the system
that delivers the services. The latest
version of CGTech’s VERICUT CNC
machine simulation and optimisation
software, VERICUT 7.1, features significant
parallels to this, allowing disparate users
and work groups to efficiently develop,
analyse, inspect and document the CNC
programming and machining process.
Cloud computing describes a new
model for the delivery and consumption of
IT services, based on internet protocols,
typically involving dynamically scalable and
often virtual resources. Cloud computing
fills an IT need: a way to increase capacity
or add capabilities in real time, without
investing in new infrastructure, training
new personnel or licensing new software.
Unlike cloud computing, however,
VERICUT software resides with the user.
However, the latest version of the
software features significant
enhancements to reduce the time
required for manufacturers to work
collaboratively on any CNC programming
and machining process. These include the
new standalone Reviewer, which makes
every project easily scalable – from
reviewing a single machining operation to
the simulation of the manufacture of a full
kit or assembly of component parts.
Developed to detect and remove
potential toolpath errors and inefficient
motion, as well as negate the physical
prove-out process, VERICUT software fully
simulates all NC machining. This includes
multi axis milling, turning and mill-turning,
and electro discharge machining. The
software eliminates errors that could ruin
the part, damage the fixture, break the
cutting tool, or crash the machine.
“A very powerful project collaboration
tool, the Reviewer allows 3D simulations
to be shared with anyone in the design,
manufacturing and management
departments, without the need for
additional VERICUT licences,” explains
CGTech managing director John Reed.
The Reviewer provides full simulation
play forward and backward, while
removing and replacing material. Error
messages and NC program text is
highlighted when a collision on the stock
or fixture is selected. A toolpath line
display is optional. The user can rotate,
pan and zoom, just like normal VERICUT,
and the cut stock can be measured using
all the standard X-Caliper tools. The
Reviewer file can be saved at any point in
a VERICUT session.
Cutting conditions are shown in the
status display and are available when
stepping through the program using NC
Program Review. The feature shows
detailed information about the cutter’s
engagement with material, including: axial
depth, radial width, volume removal rate,
chip thickness, maximum surface speed
and contact area.
Mr Reed adds: “The report
enhancements in VERICUT V7.1 allow
users to preview and customise report
templates to include features such as
pictures and videos, and links to files and
websites. They become increasingly
valuable as VERICUT users share CNC
machining process information across
work groups within organisation, and
across whole supply chains.”
As well as the collaborative tools,
VERICUT Version 7.1 further improves
VERICUT’s user interaction, simulation
capabilities, cutting tool creation and
CADCAM integration. These include a
new feature added for VERICUT collision
checking: which allows the user to stop
the simulation at an ‘exact’ collision point
between the machine components. The
iv
VERICUT Reviewer provides ‘Blue Sky’ thinkingThe latest version of VERICUT CNC software offers major enhancements to speed up collaborative working
on any CNC programming and machining process
VERICUT is...
SIMULATION: A powerful inspection tool… 3D solid simulation of the workpiece and NC
machine tool that enables the user to visualise the machining exactly as it occurs on the
shopfloor.
VERIFICATION: Correct tool path errors before machining… VERICUT detects fast feed
errors, potential crashes/collisions, gouges, over/undercutting, and much more.
ANALYSIS: Verify dimensional accuracy… VERICUT includes comprehensive analysis tools
for measuring; cross-sectioning the part to make sure that the part machined will exactly
match the design intent.
OPTIMISATION: Run NC machine tools at the maximum efficiency level possible… VERICUT
automatically determines the best feed rates for every portion of the toolpath and adjusts
them, based on the cutting conditions.
CGTech Ltd, Curtis House, 34 Third Avenue, Hove, East Sussex BN3 2PD
T: 01273 773538 F: 01273 721688 W: www.cgtech.co.uk
October 2011 • www.machinery.co.uk
CADCAM_CGTech.qxp:Machinery 29/9/11 10:14 Page iv
v
CADCAM SUPPLEMENT – CG TECH
www.machinery.co.uk • October 2011
new feature is turned on/off using the new
‘Stop At Collision’ check box on the
‘Start/Stop’ panel. The new logic is applied
only to the Machine Simulation collision
checking, and only to machine
components other than the ‘stock’
component. It is not applied to the
holder/stock and tool/fixture collision
checks. While simulating an NC block with
the ‘Stop At Collision’ box checked,
VERICUT will stop in mid-motion at each
collision point. Clicking the ‘Step’ button
continues simulation to the next collision
point or to the end of the motion, if no
other collisions exist.
The software now also supports
material removal for gear hobbing and has
a powerful algorithm that synchronises
the tool spindle with the part spindle.
Material removal for general broaching
operations is also supported.
VERICUT’s Project Tree continues to be
refined to make sessions simpler to set
up. A shortcut Toolbar has been added
that enables users to quickly go to a
particular Project Tree branch. Users can
hold the cursor over the icons to see what
branch the icon goes to. Model file names
are shown in parentheses for all models
that have model files associated with
them. Double clicking on NC Programs or
NC Subroutines displays the appropriate
file selection window. Also, NC Programs
and NC Subroutine files can be added by
simply right-clicking in the Project Tree.
Any mistakes made while configuring a
project can be addressed with a general
purpose ‘Undo/Redo’ button available, at
the top of the Project Tree.
STEP COMPONENTS EXTRACTED
CAD Model Assembly is another new
feature. Assembly, in the Open model file
selection window, enables users to extract
all the individual components of a STEP
assembly file and store them as individual
model definitions. If Assembly is toggled
‘on’, a separate model will be created for
each component in the STEP file. When
toggled ‘off’, all components are used to
create a single model. This feature
supports STEP, Catia v5 and NX models.
To further simplify creating a VERICUT
tool library, solid CAD models of inserts
and holders can be imported into
VERICUT. The new feature added to the
Tool Manager displays the CAD Geometry
window that allows users to identify
which parts of the CAD model file
correspond with holders, cutters or
inserts. Only CatiaV5 and STEP models
are currently supported.
The ability to create and display co-
ordinate systems in the Tool Manager has
been added and these can be used to
align tool components.
Additional improvements include the
enhancement of the Pro/E interface to
improve the creation of parametric, sketch
and solid tools. Helical milling material
removal is enhanced by creating a ‘true
helix’ motion simulation. Simulation of
back spot-facing tools is also supported.
With the latest version, VERICUT now
supports a full range of 6-axis robots to
simulate machining, waterjet trimming,
fibre-placement, and drilling and fastener
insertion.
The ability to output an NC program, of
a different format than the input program,
is added to base VERICUT functionality.
The method for re-formatting the program
is user-configurable. All popular controls
continue to be enhanced with new
advanced features, including Siemens
840D, Fanuc 30 range, Heidenhain,
Okuma OSP and Mazak Matrix.
Mr Reed concludes: “CGTech always
welcomes input. Regardless of where the
feedback is received from – the VERICUT
user forum, CGTech technical support, or
at one of the many VERICUT User Group
Meetings held around the world. Our
users’ input is what drives the vast
majority of enhancements included in
each VERICUT software release.” ■■
Above: the new VERICUT Reviewer promotes
manufacturing collaboration across
departments within enterprises and the whole
supply chain
Advertisement Feature
Below: VERICUT collision checking allows the user to stop the
simulation at an ‘exact’ collision point between the machine
components
CADCAM_CGTech.qxp:Machinery 29/9/11 10:14 Page v
P006_MCSP_OCT11 29/9/11 14:26 Page 1
vii
CADCAM SUPPLEMENT – Delcam
Delcam’s FeatureCAM key toexpansion at Lion Engineering
www.machinery.co.uk • October 2011
Lion Engineering has invested heavily in machine tools of late – but
the real productivity booster has been Delcam’s FeatureCAM
Changing to Delcam’s FeatureCAM
feature-based CAM software has
helped Lion Engineering make a success
of a major expansion in its machining
capacity. The company has invested over
£1 million in Mazak machine tools during
the past 18 months, but only achieved
the increased productivity that the new
equipment was expected to deliver when
it replaced its previous CAM system with
FeatureCAM.
Lion Engineering primarily
manufactures components for the
onshore/offshore drilling industry; it
produces many types of products for
down-hole drilling and production
equipment. Lion also specialises in
applying hard-facing treatments and
welding services to help reduce wear in
abrasive conditions.
Director Martin Brown, who joined the
company in 1972 and took part in a
management buy-out from the previous
owners in 1985, explains that working for
the petrochemical industry could be very
demanding, with the standards and
expectations being extremely high. “We
are as busy now as I have ever known it
since joining the company,” he highlights.
Lion Engineering first moved into
CAM four years ago when it increased its
milling capacity and acquired a CME
4-axis milling centre. The company tried
various CAM systems, but was never
completely satisfied with the software or
the support staff. “They never seemed to
have the knowledge and experience we
needed,” says Mr Brown.
“Problems with the software were
affecting our ability to deliver parts as
quickly as our customers demanded,” he
remembers. “Quite rightly, they weren’t
interested in the shortcomings of our
programming system. They wanted to be
using the equipment, not listening to
excuses over our delivery times.”
The need for a change became even
more critical after Lion Engineering
invested over £1 million in new Mazak
machine tools, including an Integrex e-
500 mill-turn, a VTC-800 5-axis mill, a
VTC-300 4-axis mill and Nexus 3-axis
lathe with live tooling. The existing CAM
system didn’t have post-processors for
the new equipment. In addition, it
couldn’t program the helical milling
operations needed to produce critical
features that keep the components
stable in use.
“Once the decision to change had
been made, we immediately began to
look at other CAM providers, including
seeking references from some of our
subcontractors who had experience with
Delcam,” says Mr Brown. “We bought
FeatureCAM two years ago, and have
found both the software and the support
to be really good.”
Machinist and programmer Neil Boags
had struggled with the previous CAM
system for his first year at Lion
Engineering, and couldn’t believe how
much easier and more reliable
FeatureCAM was. “It just worked!” he
states. “I was new to CAM when I came
to Lion, as I had only used programming
on the control at my previous company.
The support I received from the Delcam
staff was excellent. They helped me work
around any problems I had and were able
to undertake some minor changes to the
post-processors to get the machines
running exactly as we wanted.”
“FeatureCAM gives us the high
quality surface finish we need for our
specialist surface treatments,” adds Mr
Brown. “Our integrated machining and
surface finishing service is one of the
most important reasons why our
customers prefer to use us. We need to
deliver the highest quality at every stage
to satisfy some very demanding clients.”
The original reason for the major
investment was to enable a
diversification away from the oil industry.
However, high demand from old and new
customers in the sector has meant that
most of the new capacity was quickly
taken up. And Mr Brown still feels that a
broader client base will be needed in the
long term. In the meantime, he is already
looking into a further expansion in
capacity and has applied for planning
permission to add another new building
to suport the company’s next stage of
development. ■■
For more information, visit
www.delcam.co.uk
Investment has been leveraged with FeatureCAM
Helical milling is easy with FeatureCAM
Advertisement Feature
CADCAM_Delcam.qxp:Machinery 29/9/11 10:20 Page vii
S O F T W A R E
®
Advanced nesting softwarethat speaks any machine’s language.
Nest with the Best®
www.sigmanest.com
SigmaNEST�LV�VLPSO\�WKH�PRVW�DGYDQFHG�DQG�HIÀFLHQW�QHVWLQJ�VRIWZDUH�IRU�
VKHHW�PHWDO�IDEULFDWLRQ�DQG�SURÀOH�FXWWLQJ��6LJPD1(67�LV�DV�ÁH[LEOH�DV�\RXU�
PDFKLQH�VKRS��,W�DOORZV�\RX�WR�UXQ�DOO�\RXU�PDFKLQHV�IURP�RQH�VLQJOH�V\VWHP�
Please call +44 2476 323 065 to
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VROXWLRQV�IRU�\RXU�FXWWLQJ�V\VWHP��
Fabtech 2011 Booth # 708
P008_MCSP_OCT11 29/9/11 14:27 Page 1
ix
CADCAM SUPPLEMENT – Sigma
SigmaNEST and Autodesk: Certified Integration
www.machinery.co.uk • October 2011
SigmaNEST is helping Autodesk Inventor users gain maximum
value from their CAD investments
SigmaNEST is the leading CADCAM
nesting system for CNC profile
cutting and punching machines.
Optimised for plasma, laser, punch,
oxyfuel, waterjet, router, knife, tube/pipe
and combination cutting machines, it
ensures the best results, in terms of
material utilisation, machine motion
optimisation, part quality, workflow
integration, material handling, accurate
costing estimates and information
management. Users can go from design
to parts in minutes, instead of hours.
SigmaNEST is making automated
design innovations possible in the vertical
sectors of manufacturing, while helping
Autodesk Inventor users gain even
greater value from their CAD investment.
Through rigorous functional and
performance testing, SigmaNEST has
once again passed the criteria outlined by
Autodesk to become a Certified Product
with Autodesk Inventor 2012.
With the use of the Autodesk Inventor
Integration module, SigmaNEST can
directly import both Inventor parts and
full assemblies to streamline the
transition from CAD to CAM. In using
SigmaNEST’s 3D importing module,
detailed information can be gathered
from the part or assembly file
automatically, thus entirely eliminating
the need to re-enter part information,
such as material, thickness, quantity, etc.
This process also helps eliminate user
errors that may occur during exporting
from Inventor and importing into
SigmaNEST. Rather than taking extra
time to export and then import the
respective part files, SigmaNEST
automates the process.
Receiving the Autodesk Inventor
Certification affirms the high
performance standards SigmaNEST
seeks. The new SigmaNEST Version 9 is
an advanced automatic nesting and NC
programming package, offering an easy-
to-use, streamlined work method for
programmers, estimators and material
management personnel.
SigmaNEST not only brings an
improved way for transitioning from CAD
to CNC code, but it also offers powerful
flexibility in programming CNC hardware:
❏ Support for all major profile cutting
and punching machine brands
❏ Support for all major machine
controllers
❏ Support for advanced machine
features.
SigmaNEST also integrates with
business systems to aid in effective and
efficient workflow between the business
side and the manufacturing side of a
fabricating facility:
❏ Complete integration with ERP
systems
❏ Customised support for business
management software
❏ Two-way interaction with remote or
networked locations anywhere in the
world
Furthermore, with SigmaNEST you
can also:
❏ Dramatically improve your
productivity without changing your
shopfloor setup
❏ Reduce scrap and manage sheet
remnants painlessly
❏ Eliminate rework or unnecessary
processes.
SigmaTEK’s technological leadership is
maintained by a commitment to
excellence, and continued investment in
research and development. Designed to
maximise production productivity and fit
seamlessly into a workflow system,
SigmaNEST offers a comprehensive suite
of production management and database
integration tools. Our open architecture
allows users to customise post-
processors and management reports.■■
SigmaTEK Europe
Unit 17, Barclays Venture Centre,
University of Warwick Science Park,
Sir William Lyons Road, Coventry,
West Midlands,CV4 7EZ
T: 024 7632 3065 F: 024 7632 3060
W: www.sigmanest.com
Advertisement Feature
Waterjet cutting machines are just one of thetechnologies SigmaNEST supports
Oxyfuel cutters benefit from SigmaNEST
CADCAM_Sigma.qxp:Machinery 29/9/11 11:13 Page ix
The Lamiflex Group, based in
Bergamo, Italy has been an
industry leader in the use of
composite materials for over 30
years, supporting industries such as
the aerospace, medical,
telecommunications and the sports
sector.
In 2009, the company was
involved in the development of an
innovative piece of fitness
equipment designed by Italian
product designer Luca Schieppati –
the Ciclotte. It is a unique exercise
bike with an ultra-modern carbon
fibre frame, touch-screen display
and reduced pedal distance to
ensure the correct bio-mechanics
throughout the complete leg
rotation movement.
The large central wheel forms
the cornerstone of the design and is
reminiscent of the classic unicycles
dating back to the end of the 1800s.
However, thanks to cutting-edge
engineering and modern sports science,
the Ciclotte is destined to become a
must in the world of interior design and
luxury fitness. The unique outline makes
the Ciclotte instantly recognisable and
much admired, in terms of design
aesthetics and state-of-the-art
technology.
The Ciclotte has been designed to
accurately reproduce the dynamics and
performance of on-road pedalling and is
ideal for high intensity aerobic training,
such as ‘spinning’, which is all made
possible via the innovative epicycloid
crank system.
At the beginning of 2009, a first
aesthetic prototype was produced to test
the market feedback, before moving onto
a fully functional prototype. All
components were designed in 3D and
simulated as a virtual assembly to
highlight any potential issues prior to the
assembling procedure.
To coincide with the Ciclotte project,
Lamiflex evaluated the software market
and invested in a new integrated
CADCAM system. “Previously at
Lamiflex, we used a parametric CAD
system that we found difficult to use and
quite restrictive when working with
complex organic surface forms. After
extensive benchmark testing, we decided
to implement VISI from Vero Software, as
we believed it offered the best balance
between performance and price. We are
currently running multiple licences of VISI
Modelling and VISI Analysis for Design,
and VISI Machining with Compass
Technology for 2D through to 5-axis
milling”, explains CAD designer Marco
Perani.
Says Federico Carrara Castelli, R&D
director at Lamiflex and Ciclotte project
leader: “We have used VISI for the
design and manufacture of all composite
mould parts that were used to build the
Ciclotte. With regards to the moulds for
the carbon fibre wheel and the handlebar,
all of this was achieved in less than
100 hours of CAD work.“
Once the moulds were complete
(and polished), the fabric and epoxy
resin are applied, and then inserted
into a vacuum bag and placed inside
the autoclave for the curing
process. Once hardened, the parts
are then passed through to the
CAM department for finish
machining.
“At Lamiflex, we run several
milling machines including two
simultaneous 5-axis CNCs running
VISI Machining. For the finish
machining of the composite
products, the ‘trimming’
method is often used, where
the side of the tool is driven
along the surface edge. For
additional control,
synchronisation curves can be
used to control the tool movement in
local areas where the potential direction
changes are at their most extreme. For
the machining of planar holes, the tool is
tilted perpendicular to the surface, but,
when product holes are difficult to reach,
further tilting of the tool is required, in
order to avoid collision with the tool
holder. When the toolpath is complete,
the machine operator is able to virtually
walk through the complete program,
using the kinematic simulator, and prove
the toolpath is collision-free,” explains
Mr Carrara.
Concluding, he says: “Introducing the
software has streamlined our
manufacturing processes, reduced the
potential for error and ultimately
increased our productivity. We are a
company always looking for innovative,
often revolutionary solutions and
consider Vero to be an important partner
in this philosophy.”■■
For more information, visit
www.vero-software.com
Reinventing the exercise bike
CADCAM SUPPLEMENT – Vero
October 2011 • www.machinery.co.uk
Leading Italian composite specialist Lamiflex used Vero’s VISI suite of design and manufacturing tools to put
a modern spin on the traditional exercise bike, making both technological and design statements
x
Ciclotte – leading technology and design
Advertisement Feature
CADCAM_Vero.qxp:Machinery 29/9/11 14:30 Page x
The UK meeting
point for the
developing
organic and
printed electronics
industries
The UK meeting
point for power
generation plant
operational teams
and their supply
chains
The UK meeting
point for the
aerospace
engineering
industries
The UK meeting
point for the
composites
design and
manufacturing
industries
Co-located within one open Hall at the NEC, Birmingham, these 4 events form ‘UK Advanced Engineering
2011’, dedicated to facilitating business and networking between these high-value markets, and making
the most of the shared applications and opportunities for the UK’s advanced technology capabilities.
gearstick image courtesy of epm:technology
Organised by
4 of the UK’s most important advanced engineering markets converge under one roofJoin us at the NEC, Birmingham, 9-10 November 2011
www.compositesexhibition.com www.aeroengineeringshow.com www.energyengineeringshow.com www.plasticelectronicshow.com
For exhibiting or sponsorship enquiries contact us at [email protected], or call +44 (0)208 783 2399
STILL TIME TO EXHIBIT
ALREADY 230+ EXHIBITORS!
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