"Injection Mould Calculations Xls"
: plastic tooling solutions Dedicated tools for the design and manufacture of plastic injection moulds : one vision shaping your world 01 : tooling solutions Everything we do is driven by a desire to make your work more productive through the development of intuitive and specific software. 02 : the complete process... moulding the future Survival and competing in a global market may depend on a single competitive advantage or highly skilled knowledge built over many years. Vero provide both, combining unique and dedicated applications for tool design and manufacture with a knowledgeable development team striving to keep Vero at the leading edge of technology. The VISI suite of software is unique in that it covers all aspects of the plastic injection process - from model analysis and flow simulation through to 3D tool design and manufacture. 03 : tooling solutions Based on the industry standard Mould makers and moulders alike 3D tool design is made simple using Parasolid kernel, flexible solid and will benefit from using Vero’s hybrid a parametric tool structure that allows surface technology tools combine with meshing technology for plastic injection the designer to quickly construct intelligent geometry healing tools to simulation to achieve cost effective a mould layout using libraries from provide the ideal platform for managing and reliable mould designs and the leading suppliers. The repetitive tasks the most complex data. The extensive optimum moulding conditions. of the designer are greatly reduced range of data translators ensures by the use of intelligent standard that users can work with data from Understanding how moulding components from over 35 different almost any supplier. Very large files conditions will affect the final suppliers. can be handled with ease and users component provides invaluable working with complex designs will information to the tool designer. 2D & 3D toolpaths can be created benefit from the simplicity with which Before any tool design is started, directly from the 3D model with their customer’s CAD data can be preventative analysis can detect automatic recognition of complex hole manipulated. potential manufacturing issues; such and pocket features. All toolpaths are as welding lines, air traps and best tailored towards high speed machining Dedicated tools for the analysis and gate location etc, providing the and designed to minimise retracts, evaluation of model data prior to core maximum possible time frame for a maintain a constant tool load, minimise and cavity creation ensure that any corrective solution. any sudden direction change and potential design issues are spotted automatically smooth the CNC code. early within the design process. EDM electrode creation can be one of the most complex and time consuming Many complex moulds contain cavity projects for any mould maker. VISI areas with small radii that can only be Electrode is an automated module machined using small diameter tooling. for the creation and management of 5 Axis toolpaths allow the programmer electrodes and their holders, providing to approach from a different angle a step change in productivity. allowing the usage of shorter tools to increase rigidity and ultimately maintaining a more consistent and higher quality surface finish. The underlying technology makes it easy to successfully program high speed machine tools using VISI. 04 : knowledge driven automating the design process using applications based on extensive experience 05 : tooling solutions Ever shortening lead times and the increase in global competition have had a dramatic impact on the tool making industry. VISI Modelling is the foundation for all ensure that users can work with data Model Analysis of the design tools. Using the industry from almost any supplier. The ability to VISI Analysis provides a suite of standard Parasolid kernel, true hybrid skip corrupt records during the import dedicated tools for the validation and solid and surface modelling provides process provides a platform from preparation of model geometry. Finding a dynamic structure from where it where even the most inconsistent data potential problems at an early stage is possible to work with either solid, can be managed. Very large files can within the project will greatly simplify surface, wireframe (or a combination of be handled with ease and companies the task of the designer and generate all three) without restrictions. working with complex designs will huge time savings further into the benefit from the simplicity with which design process. Solid modelling has become the their customer’s CAD data can be fundamental cornerstone of design but manipulated. VISI Analysis is an automated module is often limited to prismatic or basic for the preparation and validation of geometry. Solid modelling commands Small gaps between surfaces on model data before starting the tool include boolean technology such imported models can be automatically design. Dedicated options for the as unite, subtract, extrude, revolve, healed, preventing the time consuming mould designer include the ability sweep, cavity, intersect and hollow. process of rebuilding very small surface to check a new model revision for patches. Where surfaces are corrupt design changes. Any design change Surfacing technology provides a or missing VISI will automatically create is highlighted using a colour graph different set of tools and techniques the edge curve geometry making it to clearly represent the geometry for more organic, free-form geometry easy to rebuild new faces using the deviation from the original model. creation. Surface modelling functions comprehensive surfacing suite. To include ruled, lofted, drive, sweep, ensure the new surfaces are within Automatic split line creation and parting n-sided patch, drape, tangent, draft, tolerance, the new and the old surfaces face tools ensure that the designer revolved and piped surfaces. can be compared to check for min/ can quickly analyse the model for These modelling commands combined max distance and curvature deviation. mouldability before starting the core with advanced surface editing Closing a surface model to produce and cavity design. tools make it easy to heal imported a solid body eliminates construction geometry or construct the most problems later in the design process Dynamic part splitting allows the user complex 3D data. and immediately brings the benefits of to represent the moulding process solid modelling to the user. The ability and animate any moving components An extensive range of data translators to seamlessly switch between solid and within the moulding cycle. including Parasolid, Catia, UG, Pro- surface technology provides unlimited Engineer, Step, Acis, Iges, Solid Works, freedom. Solid Edge, Vda, Stl and DXF/DWG 06 : intelligent automation plastic flow analysis > 3D tool design Mathematical analysis and simulation of the flow of plastic material through the injection moulding process. A high level application which saves an enormous amount of time in the estimation of the mouldability of any component. The creation of the parting and shut VISI Flow is a unique prediction tool, Post-production analysis off faces are often one of the most ideal for pre and post-production When a component is already in time consuming and difficult tasks analysis and concurrent engineering of production and not performing as that any designer can face. Providing injection moulded plastic components. expected, moulding simulations can help by removing the laborious tasks help the operator better understand will release the designer and fully Initially introduced to the injection the conditions inside the mould utilise their experience and maximize simulation market over 25 years ago, cavity during the moulding cycle. their productivity. Using the traditional VISI Flow presents a user friendly This can help the operator judge the benefits of solid modelling and the interface; combining short model effectiveness of any corrective actions unlimited flexibility provided by a preparation and calculation times with and help them produce the most surface modeller, core and cavity the powerful versatility of VISI Modelling effective improvements to the moulding construction is made easy. and the undisputed result accuracy results. of Finite Element Analysis. VISI Flow Keeping the model within the same provides the complete solution for part- Concurrent engineering product environment throughout the mould designers and plastic injection Pre-production and post-production complete design cycle from design moulding technicians; from filling analyses can certainly be very helpful to manufacture guarantees data analysis, to warpage calculations and but they do not guarantee the consistency and greatly smoothes the thermal optimisation analysis. complete optimisation of the part/ design process. mould/moulding process. This is only Pre-production analysis made possible through an integrated Plastic Flow Analysis Before any tool design is started, CAD/CAM/CAE analysis. All areas of moulded component preventive analysis can detect creation can benefit from the potential manufacturing issues – such An uninterrupted data exchange optimisation of the mould tool design as welding lines, air traps, best gate between the design and the analysis and moulding process parameters. location, etc, providing the maximum environment provides the ability to Part designers, mould makers and possible time frame for a corrective identify possible critical situations, moulders will all benefit from using solution set the most effective moulding Vero’s patented technology for injection parameters, optimise the runners and simulation to achieve cost effective, cooling layout and predict problems reliable mould designs and the concerning any part of the plastic optimum moulding conditions. component creation process. 07 : tooling solutions 3D Tool Design Libraries of mould bases and rendered and 2D drawings. Importantly, VISI Mould provides the complete intelligent components accelerate standard catalogue components mould tool design solution based the manufacture and documentation will also have the correct detail on industry specific automation that of a tool design with automatic representation within a section view. guides the user through the mould view creation and accurate B.O.M. development process. generation. A change in the solid model will result in a modification to the 2D view along VISI Mould optimizes the mould design Cooling channels can be inserted with any fully associative dimensions. process by guiding the user through in 3D with automatic alignment and Parts list table items and their the design sequence following a graphical positioning. As the cooling respective balloon references can be simple question and answer wizard. channel is inserted it is possible to added to the drawing using dedicated Dynamic operation previews provide check for interference with the model, assembly management tools. the designer with a ‘real time’ view of standard library components and other how component changes will affect the cooling channels. Any cooling circuit Automatic milling and drilling cycles tool design. can be exported as a design template can be produced directly from the 3D and re-used on a different tool design. model using VISI MFR. Total control over the tool definition is If the bolster sizes are different, the retained with the ability to update and cooling circuit can be automatically Streamlining the design process by modify any component at any time with adapted to coincide with the new plate removing the laborious tasks and the complete tool assembly adjusting sizes. Water fittings are attached to helping the designer with intelligent to take into account the design the cooling channels to represent an decisions will generate huge cost changes. accurate and complete solid model of savings. the water cooling system. Comprehensive libraries of standard Like all modules within VISI, VISI Mould components from leading suppliers A complete set of 2D detailed drawings is a completely integrated solution; all and the ability to create user defined can be generated directly from the the functions of VISI Modelling and VISI assemblies and tooling templates allow solid tool assembly. This includes fully Analysis are available at any stage of the user to produce a complete mould editable 2D and isometric section the design process. assembly in minutes as opposed to views, automatic plate dimensioning hours. Repetitive tasks are greatly and hole-type position tables. reduced by the use of intelligent standard components from over 35 Individual details can be created from different catalogue suppliers. any component within the assembly and displayed as a mixture of 3D 08 : electrode design dedicated electrode design Even the most experienced electrode designer will benefit from the combination of knowledge based automation and user interaction provided by VISI Electrode. The combination of solid and surface technology will provide a step change in productivity. EDM electrode creation can be one of An intuitive interface guides the user piece, electrode, multiple electrode the most complex and time consuming through the creation of the electrode positions, vertical, horizontal and projects for any mould or die maker. nose. An option is available for angled simulation, collision checking, adding an extension height with either HTML and EPX output. To ensure VISI Electrode is an automated module a vertical or tangential extension. compatibility with other CAD/CAM for the creation and management For open-sided electrodes, multiple systems, each electrode can be of electrodes and their holders. extrusion directions are available for automatically exported relative to the Comprehensive holder design, side extension. correct workplane using a neutral data simulation and collision checking format such as IGES, STEP or STL. ensures that the electrode will operate The electrode base and stock are right first time. interactively added to the electrode. Once the electrode has been designed, Electrode name, material, burning it can be machined directly (without After identifying the areas which need operation type, identification marks, any unnecessary data transfer) to be manufactured with an electrode, edge chamfers, position and rotation using VISI Machining. A datum enclosing the area with a 2D or 3D can all be applied. for machining and positioning the boundary provides a quick and simple electrode is automatically created to way to arrive at the required electrode Holders can be constructed manually ensure continuity throughout the entire geometry. Graphical face selection is by applying width, depth or height, or manufacturing process. also available to permit easy extraction by simply selecting from an extensive of the more complex areas. library. Where access for the electrode Machining templates containing is limited by neighbouring surfaces, the tooling, tool path operations, feeds, Understanding that VISI Electrode is holder can be offset from the centre speeds, depth of cut, etc, can all be a tool to compliment the experience of the electrode to provide enough stored for re-use on similar electrode of electrode designers, VISI combines clearance for the EDM machine to families. Applying them to a new automation with the ability to manually operate. Dynamic animation and electrode will automatically create a construct geometry and apply it to the collision checking ensure that the new set of toolpaths using the same electrode. This technology combination complete electrode does not violate settings, greatly reducing programming provides the user with the freedom to the part geometry. time and using company standards edit the design and ensures that it will which have already been proven on a always be possible to complete the VISI Electrode provides the operator previous job. electrode design. with a tool to manage the work 09 : tooling solutions : design > manufacture intelligent toolpath creation VISI creates intelligent toolpaths on the most complex 3D parts. Dedicated high speed milling techniques and built-in smoothing algorithms create highly efficient NC code. Intelligent toolpaths will reduce cycle times on your machine, improve productivity and continuously produce high quality components. 10 : 2D, 3D & 5 Axis toolpath generation directly from the 3D model Vero have been providing world class recognition. If any inclined features are minimise the number of retracts, CAD/CAM solutions since 1988 and detected, a new datum is created for maintain a constant tool load, minimise VISI Machining offers all you need to each setup and automatically filtered any sudden direction change and increase productivity, maximise cutting against the physical machine limits. automatically smooth the CNC code. capacity and reduce delivery times. If a non standard feature is found, it The underlying technology makes it Mould machining is not necessarily is possible to force the system to use easy to successfully program high about cycle time. It is how to achieve a particular machining process or speed machine tools using VISI. the highest possible surface quality and existing cycle, providing an open and reduce EDM and manual finishing time. configurable system for automatic plate Adaptive clearance toolpaths allow machining. the tool to rough the part in a unique Using VISI Machining it is possible to way - by roughing out from bottom to machine directly from the 3D model Cutter radius compensation capability top. The principle behind this method or from 2D construction data. A provides practical CNC code for use is to machine large steps utilizing combination of intelligent toolpath on the shop floor. When the cutter the full flute length of the tool with automation, user-defined cycle cannot machine tight internal radii, a small stepover and then machine templates and powerful editing tools the system will automatically create the intermediate levels back up the ensure the operator is always in residual stock geometry (defined by the part. The tool remains on the part as control. previous tool) and enable re-machining much as possible and the toolpath with a smaller diameter tool. automatically switches to a trochoidal A highly graphical interface guides the type motion when necessary. This user through machining parameters, The system will automatically avoid ensures there are never any full width cutting conditions and holders for user defined clamps and fixtures cuts guaranteeing a constant tool selected tooling providing a practical during machining operations. Obstacle load. Tool wear is spread evenly and intuitive CAM solution. management ensures collision across the cutting surfaces and the avoidance, and helps to reduce centre of force is half-way up the tool, Automatic feature recognition detects the cycle time on the machine by reducing deflection and the potential complex holes and pocket features eliminating unnecessary Z retract for vibration. directly from the solid model. Extraction moves. Optimisation of the toolpath of diameters and depths from the ensures the shortest distance for tool Using adaptive toolpaths, the cycle model makes it easy to enter drilling travel and reduces cycle times offering automatically adjusts for efficient and parameters and eliminate the possibility maximum productivity. safe machining; improving cutting of MDI errors. conditions and allowing higher Intelligent 3D toolpaths can be machining speeds to be maintained. For every standard component added created for the most complex parts to the tool design, CAM feature data with toolpaths tailored towards high The result is savings of up to 40% in is applied to the model for feature speed machining and designed to actual cutting time. 11 : tooling solutions High-speed finishing requires the same this process can be repeated as many Many complex moulds contain deep fundamentals as high-speed roughing - times as required to make it possible cavity areas and small radii which consistent tool loading, lighter cuts, to successfully machine with very need to be machined with small minimising any sudden direction small cutters. The toolpath can work diameter tools. Generally this would changes, optimising NC code and from the outside to the centre or from involve the use of tool extensions or reducing stress on the machine tool. the centre to the outside providing longer tools, which would increase the Many of the strategies can improve a smooth and flowing toolpath and risk of deflection and provide a poor the productivity of older CNC’s with minimising the number of retract surface finish. By approaching this dramatically reduced air cutting time movements, helping to eliminate shock from a different angle, the head can be and both roughing and finishing loading on the tool and keep feedrates lowered and the collision detection will toolpaths with smoothing arcs to help as high as possible. automatically tilt the tool and holder maintain a continuous machine tool away from the work piece. The major motion. All toolpaths are gouge checked advantage of this strategy is the use against neighbouring surfaces to of shorter tools which will increase Finish machining strategies are largely eliminate the possibility of a tool tool rigidity, reducing vibration and defined by the part shape. Traditional collision. In addition, small smoothing deflection. As a result, a constant toolpaths such as ISO-machining, radii are automatically added to chip load and higher cutting speed Raster, Waterline, Radial, Spiral, Offset internal corners, stopping the tool from can be achieved which will ultimately and Curve machining are supported dwelling in the internal corners, which increase tool life and produce a higher by intelligent combination routines that can cause the tool to pull into the job quality surface finish. In more shallow automatically adapt the toolpath to creating an unexpected gouge, which areas, larger bull nose cutters can be suit the geometrical form. This strategy would not be detected by toolpath used with a small lag angle. The major allows steep areas to be machined verification. advantage of this approach is a lower using a Z waterline method and number of toolpath passes which also shallow areas to be machined using To maximise the deployment of the reduces machining time and improves 3D constant stepover. This strategy software, VISI uses multi-threading surface finish. operates as a one stop finishing routine technology to allow multiple operations including a helical option which creates to be calculated at the same time and An extensive library of postprocessors a single continuous toolpath for steep batch processing to allow jobs to be is available to suit most machine areas with no lift off - eliminating queued for unattended calculation, tools and all postprocessors are witness lines and greatly improving out of normal working hours. To fully configurable to suit individual surface finish. further speed up the preparation of requirements. programs, individual operations can Small features on a part will usually be post processed separately, so Configurable set-up sheets are require rest machining with a smaller that machining can start on roughing automatically generated as either tool to completely finish the detail. Rest operations while finishing operations HTML or XLS files; including machining will reliably detect areas are still being calculated. information regarding datum position, left by previous tools, so that they can tooling, cycle times and the entire be re-machined. For very fine details, cutting envelope limits. 12 : wire edm a cut above the rest Wire EDM technology is an integral part Support for unmanned or overnight Toolpath verification tests whether of the mould design process as more machining is possible by leaving the completed part is removable from moulds are being designed to have the slugs attached while all of the the component and also provides fewer, but more complicated inserts preliminary cuts are taken. Numerous the capability of part comparison. that are wire-cut. strategies are available to cut the By comparing the target model and part; for instance, taking all of the cut part, any potential rest material Vero provide an intuitive environment rough cuts before finishing, in which or gouge issues are automatically for the comprehensive programming case all rough cuts are taken while highlighted. of all wire EDM machine tools - leaving the tags attached, then the supporting an extensive list of wire tags are removed, and finally the trim By using the complete solution from EDM machines from leading machine cuts are taken. Alternatively, take the Vero, not only will programming time tool manufacturers; including JOB rough and finish cuts while leaving be minimised, but also the cut-path and Script for Agie, CMD and CT the tag in place and then removing will be far more efficient, saving further Expert for Charmilles, Brother, Fanuc, the tag and skimming this area. time on the machine tool. Add in Hitachi, Makino, Ona, Sodick, Seibu the comprehensive simulation and and Mitsubishi. The advanced With apertures that decrease in proofing tools and you have a system postprocessors aren’t just limited to size, slug management is more that not only streamlines day-to-day the use of generic G and M codes; complex. Complete ‘no-core’ production, but also reduces costly special posts are easily configured pocket destruction cycles and errors and eradicates the need for to suit different machine models and full 3D simulation guarantee valid dry-runs, giving you a competitive configurations. slug removal. Additional support for advantage. cam and gear profile generation is Wire EDM is extremely accurate and delivered to DIN/ISO and AGMA enables the machine to cut internal standards. corners with very small corner radii based on the wire diameter and spark The completed wire path can be gap. It becomes easy to cut square simulated using rendered solid model apertures without the need of splitting graphics, including fixtures and target the mould or producing accurate pin parts. Any collisions that are detected holes in a plate after heat treatment. are highlighted both on the model and via on-screen messages. As Strategies for all types of EDM slugs become detached by cuts, the machining are supported including simulation advises the programmer 2-axis, 2-axis with taper and full that this is the case and graphically 4 axis machining with geometry removes the part, emulating the exact synchronisation. cutting process on the machine tool. 13 : tooling solutions : global presence a network of over 70 partners in 40 countries The VISI suite of CAD/CAM software is written and developed by Vero Software; part of Vero Software Plc, a UK based public company launched on the London AIM Stock Exchange in 1998 Vero Software Plc comprises of ten leading aerospace, automotive, Service & Support companies in England, Italy, the United packaging and medical companies to Vero has a support network of States, Japan, China, Canada and give a clear competitive advantage in engineers who understand your France. today’s tough business environment. business through experience. Continual software development is core The company creates, owns and to the philosophy at Vero; we have an VISI is a comprehensive suite of distributes software for aiding the extensive development team striving software in one environment with one design and manufacturing process in constantly to keep VISI at the leading interface. Invite our engineers to look specific sectors of the industry. The edge of software capability. at your business to see how VISI can specific sectors include the design improve your productivity, quality and and manufacture of plastic injection Vero works in partnership with its performance. moulds, sheet metal stamping dies, customers – for the long term. progressive dies and others. Understanding the demands of their The company now has more than business and providing practical and 6,000 users registered for its annual The company firmly believes that step innovative solutions. We listen to our maintenance services and supplies gains in productivity can be made by customers’ requirements and build products to more than 40 countries building as much knowledge of specific answers into the software to meet their through its wholly owned subsidiaries design and machining processes expectations now and for the future. and competence centres. within it’s software as possible. This philosophy of productivity through With thousands of licenses of VISI We will guide you through the modules specialisation has led to new in use world wide, and double digit and recommend the most appropriate applications in the design of mould growth year on year, Vero Software is combination of software, training and tools and progressive dies. one of the world’s leading CAD/CAM services that suits your needs. developers. Since 1988 Vero have been providing innovative and specialised solutions VISI has modules for specific for the engineering industry through applications. Choose the ones to suit a network of over seventy partners in your individual business, yet have the more than forty countries. room for growth. Better still, all the modules are totally integrated and work VISI is used by the world’s most in just one environment with one easy advanced toolmakers, as well as to learn interface. 14 Vero Software Plc tel. +44 (0) 1242 542090 Hadley House fax. +44 (0) 1242 542099 Bayshill Road email. email@example.com Cheltenham web. www.vero-software.com Gloucestershire GL50 3AW United Kingdom