: visi helps double production - Vero Software

case study: visi helps double productionPlastica Thermoforming, a specialist in the development of syntheticproducts, doubled its production capacity by adopting VISI to work inconjunction with its 5-axis CNC machineswww.verosoftware.comPlastica Thermoforming located in Bergen op Zoom (NL), has 65 yearsexperience as a supplier in the design, development and production ofsynthetic products. The main activity of Plastica Thermoforming is thethermoforming of client specific products based on customer defined productspecifications and functional requirements.Plastica have been using VISI Modelling for the design of customer definedCAD models since early 2000. “Everything is now constructed in 3D,” statesAndre Ekeren. “The advantages of using VISI Modelling for us are the flexibilityto make our own 3D designs and the continual use of the data for our ownengineering needs. VISI offers several standard CAD translators and thisallows us to work with data from almost any supplier. Using VISI Analysis, wecan easily detect minimum radii, product draft and wall thickness for example.When the product design is complete, the model for the thermoforming mouldand clamping fixtures are constructed in 3D prior to 5-Axis milling. Sometimeswe only have a master mould of which we measure the points to reconstructthe complete product using VISI” concludes Ekeren.5-axis successPlastica has 25 years of experience with 5-axis simultaneous milling for thetrimming of the thermoformed products. Before using VISI, the previous ‘teach’procedure was very labour-intensive as one engineer had to manually drivethe CNC around the component – This would often take half a day, even fora simple job. The diversity of the products has increased and they are alsogetting larger in size. The decision was taken to purchase a new 5-axis GeissECO in 2005. Together with the machine, Plastica also decided to invest in the5-axis simultaneous milling module from Vero Software.For the Geiss ECO, all 5-axis programs are currently generated off-line usingVISI Machining, based on the CAD model. The programmer has completecontrol over the 5-axis toolpath, the tilting of the tool axis and the lead in/lead out methods. For the trimming of the thermoforming products, the “Swarfcutting” method is often used, where the side of the tool is driven along thesurface edge. Often, product holes are difficult to reach, and an extra tiltingof the tool is required in order to avoid collision with the tool holder. For themachining of planar holes, the tool is tilted perpendicular to the surface. All ofthe possibilities are clearly defined within the graphical interface which greatlyhelps the operator when defining the NC program.When the toolpath is complete, the operator programmer is able to virtuallywalk through the complete program using the integrated kinematic simulatorand prove the toolpath is collision-free.“The programming is now faster and of higher quality. When the program onthe PC is complete, the CNC machine is started immediately, without furtherdelay. The Geiss machine is now used to maximum capacity and we havebeen able to double the production”, says Timo Osse.Vero Software LimitedHadley House, Bayshill Road, Cheltenham, Gloucestershire, GL50 3AW, UKtel. +44 (0) 1242 542040 fax. +44 (0) 1242 542099email. info@vero.co.uk web. www.verosoftware.comAbout The Company:Name: Plastica ThermoformingBusiness: Plastic ThermoformingWeb: www.plasticabv.nlMachines Used:Geiss ECOMaka KPF 334RTGeiss G98 (Siemens 840D)Norma Profil (Num 1060)Maka KPF2500 (CNC783)Benefits Achieved:• Production capacity doubled• Single software source for all 5-axisCNC machines• Excellent CAD tools to managecomplex customer data• Total control over the 5-axistoolpath including tool axis tiltingand lead in/out methods• Support commitment from a keysupplierComments:“The programming is now faster andof higher quality. The Geiss machineis now used to maximum capacityand we have been able to double theproduction.”Timo Osse

case studyExpansionAfter the success with the Geiss ECO, Somatech, the Benelux softwaredistributor of VISI generated post processors for all the other 5-axisCNC machines: the Maka KPF 334RT, the Geiss G98 (Siemens 840D),the Norma Profil (Num1060) and the Maka KPF2500 (CNC783) have allbeen constructed to run with VISI. The last two machines are locatedat Plastica Thermoformage, a division in Lille (Northern France).Importantly, all machines are programmed off-line, from Bergen opZoom, using VISI Machining 5-Axis.Improvement of productivity“It is easy to notice the progress we have made on the shop floor afterswitching to VISI. Everything runs more smoothly, there are no moreinterruptions as a result of the program and the machine-operators donot have to stand around waiting for a solution to be able to continue.The continuity and reliability ensures we are now able to keep to ourplanning schedule more accurately than before. Close relationshipswith the software distributor, Somatech, and the VISI products havenow established themselves as an integral part of our operations. Itis important for us to know that we have a commitment from a keysupplier to support us in a positive manner.” concludes Ton Proost,R&D Director.www.verosoftware.comVero Software LimitedHadley House, Bayshill Road, Cheltenham, Gloucestershire, GL50 3AW, UKtel. +44 (0) 1242 542040 fax. +44 (0) 1242 542099email. info@vero.co.uk web. www.verosoftware.com