Sometimes you don’t know how much better something can be until the right combination of circumstance, opportunity, and ingenuity click – and the light bulb goes on. Such was the case recently with the Nickel Tooling Technology division of Weber Manufacturing Limited.
Nickel shell used to create an automotive instrument panel. VERICUT’s Model Export was used to help create the casting blank faster and with fewer resources.
The company recently "discovered" how to create castings faster, easier, and more profitably. "As CAM technology improves, new approaches are possible that you could never have previously considered," says Jurgen Kreisel, systems manager.
Weber designers create large castings for mandrels (master re-usable models) to produce nickel shell molds for automotive parts such as instrument panels. Typically, to generate the CAD surfaces for these large castings is a time-consuming, labor-intensive process. They use surfacing software on the CAD model to create the casting pattern. These parts can have thousands of complex surfaces, which routinely disappear, or collapse while creating the offset CAD surface model. It is necessary for the designer to spend several days (or longer) trimming, deleting, offsetting, and repairing the surface data. Until now…
VERICUT’s new Model Export feature gave the designers at Weber an idea. Since VERICUT’s Model Export module can export a CAD surface model, they realized if they force the tool path to undercut in VERICUT, they could export the VERICUT model as a casting model in less time, using minimal resources. From there, they could easily create a tool path to cut the casting blank.
"The first part we tried was an instrument panel casting," said Kreisel. "We created NC programs that cut the finished dashboard using a 1" ball. We then put VERICUT on autopilot letting it run overnight, using a 2" ball. This created a ½" undercut in the VERICUT model that we quickly exported as an IGES surface file of the casting. We then used PowerMill™ to create the NC programs for the casting pattern. The entire process took less than two hours and no manpower was required, whereas, creating the same pattern manually (the old way), would have taken one of our designers several days."
Weber Manufacturing Limited has been in business for more than 35 years and is quite possibly the only mold manufacturer building highly complex tools in nickel, steel and aluminum. The company designs and builds a full range of injection, compression, RIM (Reaction Injection Molds) and RTM (Resin Transfer Molds) molds for customers in Europe and North America. From prototype molds, production molds, styling models or secondary bonding tools, Weber’s goal is to accommodate virtually all customer requirements, including surface creation from wire frame.
Airbus is selling so well that the demand to increase build rate has never been higher. BAE Systems (Filton, UK) needed a simple way to improve throughput - it found the answer in VERICUT.
With VERICUT, engineers at Stellex Monitor modeled the Sidewinder and Spar Mill machines.
Tell Tool of Westfield, Mass., has integrated VERICUT CNC simulation software into its numerical control program prove-out process.
VERICUT enabled us to start ordinary production after a minimum of time. Since this product is new for Volvo Aero Norge and our company had never before had parts with similar machining complexity, it is difficult to estimate the amount of cost saving.
Before implementing VERICUT, the company experienced the usual time-consuming and expensive manufacturing problems related to NC program prove-outs such as scrap loss, broken tooling, and a danger of occasional machine crash.
Over the last two years, AH has used Machine Simulation to speed the implementation of several new 5-axis machine tools.
VERICUT showed the NC programmers leftover or heavy stock." And the software detected a couple of places where the depth of cut was too large and tools were shanking out," said Collings. They then went back and corrected the errors in the tool path before
Dassault, Seclin initially purchased VERICUT in order to reduce the number of manual prove-outs using polystyrene material, which represented a significant expense in terms of time and money.
VERICUT enabled the designers and programmers see exactly what they were building as and in-process model in different stages of the machining cycle.
We utilized VERICUT to verify the CNC programs for cutting the tooling before they were sent to the machine control,
To protect their investment, they have been using VERICUT since 1996. They have two people to verify the accuracy of their G-code files.
"When we first started using OptiPath we concentrated on the feed rate option; now we use the constant chip thickness capability. With jobs up to 200 hours long, 50% saving is significant like having another machine tool."
The entire process took less than two hours and no manpower was required, whereas, creating the same pattern manually (the old way), would have taken one of our designers several days.
The verification process stays ahead of the actual machine position in the NC code being verified. Opera-tors can see errors before they occur.
The bottom line? Using VERICUT has made Supreme's existing machine tools more productive. Enthusiasm is up, delivery times have been reduced, and pricing is more competitive.delivery times have been reduced, and pricing is more competitive.
Using VERICUT to compare the electrode burn with the mold cavity ensures that we have all the correct clearances in the electrodes and that we have 100% clean-up." says Allen.
If I was using VERICUT at the time I would've caught the problem, and had a chance to fix it before it damaged the part.
Now I rarely see the potential crashes because the students find and correct them before I review the work. Catching those costly problems is a non-event now!
VERICUT can change speeds and feeds according to cutting conditions including difference in material and tooling. It is done automatically; the programmer does not have to make even one manual insert into the code."
Flying shrapnel from shattered cutting tools and components is avoided by using VERICUT to test student programs before they are run on NC machines.
The NC programmers at Ingersoll also rely on the simulation software to prevent mistakes when programming complex, five-axis parts.
After creating the NC programs in Mastercam, they began simulating the machining process in VERICUT by simulating the G-code data. There often can be a difference between the motion as programmed and the code after it's run through the post processor
After selecting VERICUT for third-party verification, each NC programmer attended two days of basic training where they experienced first-hand the type of results they could expect to achieve.
The program simulates milling, drilling, turning, wire EDM, and mill/turn machining operations using both G-codes and CAM output.
VERICUT provides simulation capabilities for the all the 3-5 axis and wire EDM parts, with focused control over the orientation of our 5-axis machine tool including the cutters used on that machine.
The inspection probe is created as a tool in VERICUT so the complete in- cycle gauging sequence is checked for collisions.
The bottom was machined first. This effort took about 24 hours from start to finish. By using VERICUT software from CGTech, Elliot was able to test the NC program for any problems before it was ever cut on the machine.
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Sometimes you don’t know how much better something can be until the right combination of circumstance, opportunity, and ingenuity click – and the light bulb goes on. Such was the case recently with the Nickel Tooling Technology division of Weber Manufacturing Limited. 
"The first part we tried was an instrument panel casting," said Kreisel. "We created NC programs that cut the finished dashboard using a 1" ball. We then put VERICUT on autopilot letting it run overnight, using a 2" ball. This created a ½" undercut in the VERICUT model that we quickly exported as an IGES surface file of the casting. We then used PowerMill™ to create the NC programs for the casting pattern. The entire process took less than two hours and no manpower was required, whereas, creating the same pattern manually (the old way), would have taken one of our designers several days."