Proven Concepts

Proven Concepts BV, based in Valkenswaard, Netherlands are model making, prototype and production specialists with a strong emphasis on the automotive sector. The recent installation of an Omnia-63 high speed machining centre from Italian producer Parpas and virtual machining from Vero has led to a step change in productivity. For the design and machining of all products running on the machine, Proven Concepts make maximum use of the integrated VISI Modelling and VISI Machining CADCAM software from Vero Software.

Ron Cornelissen, model and prototyping manager is particularly positive about the speed and simple usage of the software. "We have been using VISI for 2D & 3D machining on our Mikron and DMG machining centres for seven years. Having used other CADCAM solutions in the past, we knew how important local support is. In this respect, Somatech, our local representative have been great and offer all the support we need including the development of our Heidenhain TNCi 530 post processor." It is therefore no surprise that Proven Concepts selected VISI Machining 5 Axis to run the new machining centre.

The installation of the Omnia-63 machining centre has greatly expanded the machining possibilities with a 6000mm (X) by 3000mm (Y) by 1500mm (Z) machining envelope. Besides this large machining area and with the help of a switch design, a HSK 63 spindle or HSK 100 spindle can be installed to add two extra rotation axes to the machining possibilities. The machine is also fitted with a laser measuring system for checking vital measurements. After the machining operations, the products can be checked on the same machine by an integrated system for measuring and scanning, in a similar way as on a 3D-coordinates measurement machine. The measurements are compared with the 3D-model and relevant feedback is automatically presented to the operator. Importantly, this allows the product to be corrected during the same set-up.

The 3D model geometry is generally supplied by the customer and the CAD models are loaded without any problems with the help of standard Iges and Step data readers. Additional Catia V4 and V5 native readers are used for product development. "When dealing with the automotive industry, working with Catia data is vitally important and the data readers in VISI are very robust and close to seamless," explains Cornelissen.

Understanding tooling interactions
With use of the 'kinematic simulation', the complete toolpath program is calculated and validated 'virtually' on the PC before the program is sent to the machine. Toolpath simulation is particularly important with 5-Axis machining as the operator is able to fully understand the interaction between cutting tools, tool holders, clamping aids, work piece and the physical machine.

"The ease of use is very important", explains Cornelissen. "The G.U.I. graphically displays the different machining possibilities during the data input and this is especially important for the 5 axis toolpath, the tool axis tilting method and the lead in/out options."

Explaining the benefits of tool tilting, Cornelissen states; “The tool can be fixed to a tilting axis (X, Y or Z), or a side tilting or lead angle can be applied in an opposite direction to the cutting angle. This tilting method can be very useful in cases where there are higher cutting forces applied to the tool than in normal circumstances. In general it is better to use a shorter presetting length for stability but this is often impossible when the tool axis is fixed in the Z direction. For example, when you machine difficult to access areas in a deep cavities mould, the tilting of the tool allows the use of shorter tools."

Machining Templates
Cornelissen is keen to highlight the use of machining templates as one of the great advantages of the package. "You are able to generate advanced CAM 'templates' in a simple way, which makes it possible to perform several machining operations in a row with minimal adjustments: 'roughing', 'semi-roughing', semi-finishing' and 'finishing'. When making a new program you can use previously tried and tested template. In this way, new programs can be generated easily, regardless of the new work piece measurements. This approach ensures we maintain a high company milling standard, regardless of the machine operator. As the operators are closest to the operation, it is also possible to adjust the default settings or machining strategies for future use."

Proven Concepts
Web: www.provenconcepts.nl

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