Toolpath praise

Leeds-based Vacform Group says VISI's 5-axis machining played a key role in turning it into one of the industry's most innovative and market-leading manufacturers in the UK. Just three years ago, the company was using the 'teach' method of driving a stylus around a vacuum-formed part to program Geiss ECO trimming machines. "Where we had big complex jobs, this could take up to two days, meaning we were losing all that production time, while the machine was down and out of action," says managing director Kevin Quinn. And with vacuum formed products becoming increasingly more complex, technical director Mustafa El-Etriby says CNC trimming is the most important part of their operation. "Without the 5-axis capability that VISI Machining from Vero Software gives us, we just wouldn't be able to compete in the market," he acknowledges. Image: Vacform Group is programming 5-axis routers with Vero's VISI 5-axis machining software VISI Machining 5-axis software, introduced three years ago, is now used to create the trimming toolpaths, with the first job being a cosmetics point of sale display that won a top design award. The unusual shaped display comprised eight different vac-formed parts that were CNC machined, then bonded together with inserts on the inside. The completed unit looked like it had a continuous machine finished edge. Says Mr Quinn: "That job could not have been manually taught; it wouldn't have achieved the high level of finish required and just wouldn't have looked right. We took it on, knowing that VISI would do exactly what we wanted. As it was our first job on the software, we received excellent support and assistance from the Vero team, and we've gone on to complete many more successful jobs using a range of thermoplastics, including ABS, high impact polystyrene, polycarbonate, polypropylene and high density polyethylene (HDPE)." Mr El-Etriby currently undertakes all programming for Vacform Group 5-axis Geiss ECO trimming machines himself and is impressed with the complete control the software provides over the 5-axis toolpath, the tilting of the tool axis, the lead-in/lead-out methods and toolpath editing capabilities needed for vacuum formed components. "It is by far the most efficient way of getting the job done. We can even program quite complex parts in just 15 minutes," he states. And Mr Quinn highlights another vital aspect of the software. "We use the powerful kinematic simulator to make sure the toolpath is collision free. If you bang the head on the machine, it can cost £2,000 to recalibrate it, so every program is verified on the kinematic simulation, which has been an absolute godsend for our programming. It walks us through the complete program and shows where any problem will occur. We then go to each tilt line and tweak the toolpath to get it right, based on how we need to manufacture the part. "We take the vac-formed part, put it on a CNC jig and VISI finishes the component. It takes all the labour and human error out of it. Also, it's just one process for trimming. If we did it manually, not on 5-axes, we would need up to six separate processes to trim certain parts." The company has also reduced machine downtime by 40%, it is reported. Summing up, Mr Quinn says of VISI Machining: "We wouldn't be as big as we are. Bringing in VISI three years ago was a key decision. This technology is tremendous for us as a company." PLAIN SAILING FOR 5-AXIS From vacuum forming to yacht building , according to Jason Taylor, 5-axis CNC programmer at Viking Yachts: "When it comes to CAM for 5-axis programming, Delcam's PowerMILL is hands down the easiest and best I have ever used," he confirms. Image: Viking Yachts is benefiting from Delcam PowerMILL's 5-axis machining capability His company first adopted Delcam software after it acquired an MR125 gantry milling system able to handle parts 50 ft long by 20 ft wide and 10 ft high. This machine can mill patterns as large as a vessel's bridge and helm, as well as Viking's smaller hulls, in one piece. "I have been programming with PowerMILL for over five years now," explains Mr Taylor. "Here, at Viking Yachts, we use cutting-edge software for all our engineering needs. PowerMILL helps us stay on top of the competition. "When I first started using PowerMILL, we were on version 5. Now, after at least eight major updates, we are running the 2011 version. With each update, Delcam and the team at our reseller, DM Solutions, make my job easier, while saving our company time and money. "We machine all our parts with two 5-axis routers," he explains. "Those parts range in size from a few inches, all the way up to fifty feet in length. We also use some very unique tooling and materials. PowerMILL handles the big files without a hitch, and creating the custom tools is really easy. Even with parts that contain thousands of surfaces, creating boundaries, patterns, work-planes and toolpaths is fast and very simple. Most of our machined parts have very tight corners and difficult areas that the tools need to get into, so we rely heavily on PowerMILL's collision avoidance and simulation tools prior to running the NC programs." And he concludes: "The best part of using Delcam software is the support. Getting help is quick and easy, unlike other suppliers I've used for programming software. DM Solutions provides everything from basic support to new programming strategies. Jeff Fischer and the rest of the support staff are always there to assist us in our time of need. DM Solutions and Delcam never leave us waiting for an answer, and that is very important to us, because downtime can be very costly in our business." Box item 1 Wizard idea for programming Miyano machines Citizen Machinery's CNC Wizard, a low-cost programming aid, can now be used to program Miyano fixed-head machines, as well as Citizen CNC sliding-head turn-mill lathes (01923 691500). The software, developed in the UK and to be launched at MACH 2012 (16-20 April, Birmingham, NEC) for global distribution, provides the advantage of off-line programming support for new and less experienced staff, and minimises machine resetting and changeover time. Investment for multiple seats is under £1,000, while training required is under one hour. With CNC Wizard, the operator does not need to learn M and G codes or have to consult a manual that can be daunting and lead to longer non-production periods. The operator simply follows a step-by-step routine through the process. Each operation is explained in a clear description with simple diagrams to which the relevant data is added. The program template is automatically generated, including start, finish and wait commands. The package covers all the popular Miyano models and all main operations. Full explanatory text and graphics are included in the package. Program input/export for multiple head applications is saved in separate files, which enables import to the Citizen Cincom style of side-by-side display that is a major advantage to the user when individually editing each head application. Support for viewing and printing Miyano programs in a synchronised view helps visualisation of any possible lost time for waiting commands. An engraving capability has also been added to CNC Wizard for the first time. (see video here) Box item 2 Links to more [] Delcam was presented with the Best Supplier Partnership award for its efforts with Coventry Engineering Group at the MTA Manufacturing Industry Awards [] ZW3D 2012, formerly VX CAD CAM, promises significant improvements in many areas – includes video [] PSL DataTrack has introduced its new DataTrack 2012 production management and business administration software [] SolidCAM UK has become a Tier 2 member of the Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) [] SpaceClaim Engineer can now be directly integrated with SigmaNEST [] SigmaNEST Version 9 sees interface enhancements, requiring fewer steps to generate code - includes video First published in Machinery, March 2012