Pioneers prosper with integrated software  

One of the earliest adopters to introduce simultaneous 5-axis machining into its region of Italy, Modulo Tre, chose the Visi integrated CAD/CAM system from Vero Software, to drive its CNC machine tools. PES reports.

Modulo Tre was founded in 1995 by partners Alessandro Corà, Marco Dal Bianco and Gilberto Dal Pozzo. The company now has a large fleet of latest generation CNC machines capable of producing workpieces up to 12,000mm (X), 1,500mm (Y) and 3,200mm (Z).

Adopting 5-axis technology means the Schio, Northern Vicenza, Italy-based company, can machine a wide range of components such as hollow and grooved profiles with deep and sloping holes without material constraints. It typically works with stainless steel, light and super alloys.

The decision to move to continuous 5-axis machining came around seven years ago when the company invested in a Soraluce FP 12000, a floor type multi-purpose milling and boring centre. Alessandro Corà describes it as a pioneering choice which opened up new horizons, giving the company inroads into the energy industry, producing hydroelectric, oil, gas and wind components, along with parts for automotive companies and, more recently, the aerospace sector.

The complexity of orders has also increased, and today the company can carry out any customer-designed milling work.

It also manufactures turbochargers for the hydroelectric industry and work in the moulding sector on both sheetmetal deformation and thermoforming – in particular producing interior panels for the automotive sector. And it has now started to operate in the aeronautics field, creating flanges which are then assembled by a nearby company.

Logical modelling

The 5-axis method created the need for reliable and simple CAD/CAM integration, which led Modulo Tre to introduce the Visi portfolio of 3D CAD modelling, and 2D 5-axis machining, interfaced with the Eureka kinematics simulator.

“Our primary requirement was having an integrated CAD and CAM system,” explains Alessandro Corà. “In the past, we had to leave the CAM environment to make any modifications or corrections and then reset it all. But with 5-axis machining this becomes very complex, so we decided to replace the previous software and introduce Visi which is fast and intuitive, even on corrections and modifications that often have to be applied to the customer’s original CAD model for manufacturing purposes.”

With Visi modelling, small errors found in imported model surfaces can be automatically fixed during stitching, avoiding the time-consuming process of constructing very small surfaces to close tolerance gaps. Where surfaces are corrupt or missing, Visi automatically produces edge curves that make it easy to create new surface data.

To check tolerances, the old and new surface can be compared, and the maximum and minimum distances checked, as well as the curvature difference. The solid closure of a surface model eliminates any design problems that may arise, making it easier to remove or add holes, fittings and other modelling features. The ability to move from solid to superficial model and vice versa also gives maximum freedom in managing CAD modifications.

Another key requirement for Modulo Tre was having a reliable kinematic G-code simulator, to virtually walk through the machining process before sending to the machine, especially during unattended shifts.

To satisfy this need, an application for interfacing Visi with Eureka has been developed, transferring all part and CNC machine models, tool parameters and toolpath data from Visi to the simulator.

“For complex 5-axis machining, it's crucial to be able to drive almost with your eyes closed, avoiding collisions and tool issues that could compromise the entire machining of the workpiece. Machines often work round the clock, so a simulator is indispensable for operations in unattended areas,” says Mr Corà.

Familiar features

Among the most popular Visi functionality, according to Marco Dal Bianco, is the ability to automatically recognise manufacturing features such as holes and pockets, and to generate the appropriate toolpaths. He says that as Visi is an integrated system, machining individual plates can be accomplished automatically through feature recognition.

“All holes are recognised automatically and the correct machining cycle applied,” he explains. “For complex machining, Visi allows us to handle high speed and 5-axis operations, as well as traditional milling.

“And thanks to the feature recognition (Compass module), it’s also possible to associate hole recognition with custom drilling sequences such as centre, threading, boring, and pocketing. Once the tool set has been established with the correct feed, rotation and parameters, the system automatically shows the tool that best suits the drilling type and the corresponding optimised tool path.

“Apart from greatly accelerating the machining process, this automation is particularly useful in deep drilling – even up to 600mm – and with intersecting holes, for example in automotive moulds with complex cooling.”

He adds: “When an intersection is detected, the system automatically reduces the speed, eliminating the risks of possible puncture breaks which, at certain critical points, would be really disastrous. Vero Solutions engineers have provided us with all the support we need to pre-set the system and create proven custom cycles.”

Visi also delivers a wide range of multi-axis machining strategies particularly suited for the development of turbine impellers, one of Modulo Tre’s main business areas.

Turbines are typically rough machined using traditional roughing or rough milling along a curve/guide. Milling with a guide curve allows a high chip rate to be maintained, optimum tool contact, and constant material removal.

“This means a constant load for the spindle and all five moving axes. Particular care is also required in defining the finishing strategy due to remaining stock. The rest machining command will detect areas left by previous tools, so that they can be re-machined. For very fine details, this process can be repeated as many times as required to make it possible to successfully machine all part geometry,” says Mr Dal Bianco.

Visi also provides solutions for 5-axis blade machining. High surface quality, limited space and angular movement of the rotating axis make this a highly complex process. Visi creates each toolpath with a regular distribution of movement coordinates. By sending CNC code with optimised point distribution to the machine tool, superfluous vibrations are drastically reduced, eliminating the need for alternative manufacturing processes due to the presence of thin walls.

MODULO TRE www.modulotre.com

VISI www.visicadcam.com

 

 

Company

Vero Software

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