TEBIS is a High-End Cad/Cam Software serving the Die, Mold and

Transcription

TEBIS is a High-End Cad/Cam
Software serving the Die, Mold and
Pattern
making Industries
Tebis America, Inc.
Presented By: Scott McLeland
Outline
A. Brief Corporate Overview
B. 10 points on why our Customers buy Tebis
software
C. Overview of Tebis Product Line with
references and examples of functions that are
specific to Tebis
D. Questions are Welcomed !
Corporate Profile
• 1985 - Tebis is established in Munich Germany
• 1991 - Becomes a Stock Corporation (Tebis AG)
• Today Tebis has over 3,000 seats installed worldwide.
• To over 1000 customers
• Tebis has approximately 150 employees worldwide
• In 1996 Tebis America is established and is
located in Troy, Michigan - serves the U.S. and
Canadian markets.
Tebis in Munich
A New Corporate headquarter is
currently under construction
Completion is
expected the 4th
Quarter of 2002
Capacity is to
exceed 300
Employees
Tebis Around the World
Tebis AG
Tebis Italia
Tebis Scandinavia
Tebis France
Tebis America
Tebis UK
Delta CAD
Delta Tools
Turbo Engineering
Nimbus Tech.
Cimco
Arizen
Germany
Italy
Sweden
France
USA
England
Spain
Portugal
South Korea
India
Mexico
China
Munich/ Hamburg
Torino
Göteborg
Lyon
Troy Michigan
Coventry
Madrid/Barcelona
Marinha Grande
Seoul
Pune
Mexico City
Shanghai
North American
Corporate Customers
• The Boeing Company
(Reverse Engineering-R&D dept.)
• Ford Motor Company
(Design Models & Production Dies)
• DaimlerChrysler
(Production Dies)
• Honda of North America
• Toyota
(Design Models)
• Goodyear
(5-axis tire molds)
(Design Models & Production Dies)
Large North American
Tooling Suppliers
• Venture Industries (Design Models & Injection Molds)
• Louca Mold & Aircraft (Injection Molds & Aircraft Work)
• Vehma International (Hydro-Form Dies)
• Massive Die Form (Automotive Stamping Dies)
• Ogihara (Automotive Stamping Dies)
• Tower Automotive (5-axis Laser Cutting)
European Corporate Customers
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BMW
Volkswagen
DaimlerChrysler
Audi
Opel
Fiat
Saab
Volvo
Ford Europe
Land Rover
Jaguar
Top 10 reasons why our
customers buy TEBIS
1.
Tool-path Calculation Speed
2.
Ease of use
3.
Efficient cutting strategies
4.
Excellent Machine Run Times
5.
Excellent Graphics
6.
Versatility
7.
Superior Accuracy and Surface Finishes
8.
Integrated Surface Modeling
9.
Integrated Scan Data Processing
10. Reduced Wear and Tear on Machines
Number ONE
CALCULATION SPEED

Tebis gets programs to the machine faster

Allows changes when changes are necessary

BOTTOM LINE – When a block is sitting on a
machine waiting for a program, there is no substitute
for SPEED !
Number TWO
Ease of use

Cam functions are very straightforward

Tebis is not a corporate graphics system

It is a system for the manufacturing community

Tebis provides an optimized “sub-set” of CAD functions that
they feel are most necessary in manufacturing

The learning curve is much shorter than the popular
corporate graphics systems on the market today

It is designed to be simple
Number THREE
Excellent Machine Run Times

Not only do you get toolpath that is calculated more
quickly and more accurately,

You also get toolpath that take less time to run at the
machine.

Once again, there is no substitute for getting a block
on and off the machine in a hurry !
Number FOUR
Excellent Graphics (don’t underestimate the value of a good shaded model)
Number FIVE
Versatility –

Both Windows P.C.’s and Unix platforms
are supported

A Floating License option is available soon

Tebis works in both office and shop floor
environments
Shop Floor Programming
We recommend that no
data translations are done
on the floor
We do recommend that
surface models are quality
checked in Tebis before
delivery to the shop-floor
2ax – 5ax programs can be
created right on the
shopfloor
Wide array of ergonomic
custom shop-floor cabinets
Number SIX
Efficient cutting strategies

Versatile Roughing strategies

slope angle machining

Interactive “Mode” programming

Constant “Z” cutting

Best in class re-machines

Tebis has special options for HSC
Successful HSC
Requires the proper combination of:
Machine Tool
CNC Controller
Cutting tools, and
CAD/CAM system
Tebis and HSC
HSC requires high quality
CAD-Data because.......
Fine finishing amplifies flaws
in surface data
Tebis provides software that:
9 Analyzes each surface and it‘s
neighbor surfaces
9 Quickly identifys holes, gaps and
overlaps in the surface model
9 Also verifys tangency conditions
Tebis and HSC
•
The Tebis Roughing
modual creates
rounded tool-paths,
smooth stepover
transitions and
analyses the residual
model for a constant
stock condition
•
Climb cutting
•
Tebis Finish programs
provide smooth
machine motion
through slope angle
technology
•
Rounded stepovers
toolpath provide
Tebis and HSC
Synchronized point
distribution for lowcurvature surface milling
Advantage:
Better surface finish due to
synchronized chordal
deviations
allows high speed machines to
run with uniform acceleration
and deceleration due to
uniform point spacing
NC-points
Number SEVEN
Superior Accuracy and Surface Finishes

Better surface finish reduces bench and
polishing time

Better accuracy reduces fitting time

Better accuracy also leads to better
inspection reports at a CMM
Benchmark Test
Superior Finish
Superior Accuracy
Superior Accuracy
Number EIGHT
Integrated CAD functionality
In many Tooling environments, the
same person does the
necessary surface modeling
and CNC programming.
In shop-floor programming
environments, native CAD
Data is passed to the floor
instead of an IGES file that
needs to be re-translated
Curve and surface CAD
elements also aid in the
programming process
Number NINE
Integrated Scan Data Processing
When cutting Digitized Data,
It is convenient to split the
model up into regions that
will be cut from different
directions. This eliminates
the need for wire-frame
boundaries, and the unnecessary extra motion
produced by over-lapping
areas. This caters to shops
with 5-axis machine tools,
so the entire part can be
cut in one setup.
Number TEN
Tebis Reduces Wear and Tear on your
Machines Tools

Smoother machine motions enhance machine longevity

Excellent 3+2 and 5-axis capabilities, allows the use of shorter
tooling, which produces less chatter and machine vibration

Less retracts puts less mileage on your machines

We receive many recommendations from Machine Tool
Vendors because they know our software is going to benefit
their machines in performance and reliability
customers buy TEBIS
How can you find out if the
claims I’m making are true ?
customers buy TEBIS
1. By asking a Tebis Customer
2. Or by testing it for yourself
Tebis has a try before you buy policy
Tebis Product Line
CAD Modules
3D Design
Base Module
Advanced Surfaces
CAM Modules
2.5D machining
3 axis and 3+2 milling
5-axis milling
5-axis offline laser programming
Scan Data
Modules
Processing Digitized Data
Reverse Engineering
STL Translator
Translators
IGES
VDA
DXF
Catia Direct
U.G. Direct
CMM output
Surface Point Measuring module
Tebis Modules
Base Module
Basic interface
Basic CAD functions, mirror, rotate, move, ect.
Shading
3D Design Module
CAD
Modules
Basic 3D wire frame
surfaces
Trimmed surface functionality

Advanced Surfaces Module
Open shell solids or “skins” technology
Allows multiple surface trimming
Each surface knows neighbor surface
Tolerant sewing ability
Surfaces are
linked into one
Topology or
“skin“
Boundari
es
Profile of electrode
area
Once a trim
curve is
projected onto
the “skin“,
•The Advanced
Surfaces module
allows complex
multiple surface
trimming
operations
•Resulting Electrode
Tebis Modules
2.5D machining
3 axis milling
CAM
Modules
3+2 axis milling
5-axis Simultaneous milling
5-axis Laser programming
Tebis 2.5D Module
FEATURES
Automatic Hole and
Pocket Processing
Full 5-sided support
3 Levels of Operation
9 Manual
9 NC-Sets
9 Features
2.5D-Machining
Tebis
NC-Set
Are user definable
Canned Cycles for:
Chamfering
Boring
Drilling
Tapping
Thread milling
Spiral milling
Pocketing
Profiling
Etc…
2.5D-Machining
Tebis Features
Features
Are graphical entities
that coorespond to a
canned cycle in the NCset library
The Features can be
placed in any
orientation
2.5D-Machining
Available 3rd
Party Software
to Integrate
Features from
•Catia®
•Vamos ®
•Pro/engineer®
•Unigraphics®
2.5D-Machining
Machine Features
•Tebis provides
structure in
hole and
pocket
Programming
•Leads to
possible
standardization
company wide
2.5D-Machining
3ax Roughing Module
Easy stock creation
Based on user defined
CAD Model
Define any shape through
CAD to represent roughing
stock
Roughing in Planes
3ax Roughing Module
Easy blank
creation
user defined profile
curve and model
Profile
Curve
User adjustable
min/max height values
Roughing in Planes
3ax Roughing Module
Easy blank
creation
User Defined 3D Casting
Offset
Roughing in Planes
3ax Roughing Module
Use multiple
stock models in
one file
Roughing in Planes
3ax Roughing Module
Residual
Model
Remaining
stock is tracked
Color coded
model identifies
the amount of
stock that is left
Utilized for Reroughing
Roughing in Planes
3-Axis Milling
Calculation
Automatic
Interactive mode
Batch mode
3ax milling
3-Axis Milling
Z-constant
finishing cuts for
steep wall areas
Definable by
slope
3ax milling
3-Axis Milling
Axis parallel
machining of
flatter surfaces
Definable by
slope
3ax milling
3-Axis Milling
High-speed
contouring
programs with
smooth lead-in
and lead-out
movements
3ax milling
Machining Surfaces
Combine
contour
parallel
machining
with curve
normal
machining
3ax milling
Machining Surfaces
3D stepover
using Tebis isoparametric
machining for a
constant scallop
height
3ax milling
3-Axis Milling
Slope defined
re-machining of
uncut stock
User inputs the
previous tool that
was used
Use different
strategies depending
on surface
steepness
3ax milling
3-Axis Milling
Flow cut remachining using
current tool –
previous tool
selection
Fast calculating
Smooth cutting
3ax milling
3+2 Axis Milling
Easy 3+2
programming
provides
Better finish
Shorter tools
Longer tool life
Tilted Axis System
Selection Box
3ax milling
Simultaneous
5-Axis Milling
Considered
easy to
use compared to
other 5-axis systems
Simultaneous
5-Axis Milling
Applications
Machining of curves
Machining of undercut
or tapered walls and
pockets
Machining of undercut
grooves and slots
Machining of surfaces
Simultaneous
5-Axis Milling
5-axis Multiple
Surface Machining
•Tebis CAD checks for
surface tangency
•2 degrees or better is
desirable
Simultaneous
5-Axis Milling
5-axis Surface
Cutting
•Utilizes advantages of
Surface Machining with
Bull Nose cutters
•Gains a 5 to 1 stepover
ratio compared to a ball
cutter and delivers a
superior finish
•Automatic dynamic lead
angle
Simultaneous
5-Axis Milling
5-Axis
Laser Cutting
Off-line programming
of multi-axis laser
cutting machines
Use of low cost P.C.‘s
Tebis stand-alone
solution
5-Axis Laser
Cutting
Practical
Applications
•trimming short to
medium run prototype
parts
•Automotive sheet
metal
•And plastics
•Aerospace parts
5-Axis Laser
Cutting
Tebis provides High-End
Simulation
•CAD generated
Laser head
geometries
•Graphical
simulation of laser
head motion
•Full collision
checking on the
entire Head
5-Axis Laser
Cutting
5-axis Laser Cutting
Tebis can
Simulate the
part setup
•Add clamps
•Add the Part Fixtures
5-Axis Laser
Cutting
Collision Free
automatic collision
avoidance
Manual intervention to
program alternative path
5-Axis Laser
Cutting
Support:
beam-on and beam-off
velocity changes
Circular interpolated
movement in any plane
compensation for beam
diameter
Sheet metal thickness
compensation
5-Axis Laser
Cutting
Tebis Modules
Tebis Processing Digitized Data
Manipulate triangle data
Filter, smooth, stretch, fill holes,
Offset, section, combine,
Scan Data
Modules
Supported Native Formats
9Hymarc Laser Scanner
9Atos White Light Scanner
9Steinbichler White Light Scanner
Tebis Reverse Engineering Module
Construct surfaces over scanned data
Tebis Bi-directional STL Translator
Data Collection Methods
1. Touch or Tracing
probe data
2. Laser scans
3. White light scanners
using
photogrammetry
Processing
Scan Data
•die and mold manufacturing
Collecting
surface data
with a White
Light Scanner
Processing
Scan Data
•model making
Collecting
profile data
with a Romer
arm
Processing
Scan Data
•Triangle meshes
are generated by a
White Light
Scanner
•imported via Tebis
STL-interface
Processing
Scan Data
400 MB STL-data
2 million triangles
Tebis can process
very large files
The same data can
chokes other systems
Processing
Scan Data
Imperfect
scanning
processes leave
holes in the
triangle model
Processing
Scan Data
Tebis
automatically
finds holes in the
mesh
holes in
mesh
Processing
Scan Data
Processing
Scan Data
Close-up
And closes
multiple holes
quickly and
easily
*close holes with tangent
transition
Processing
Scan Data
•Splitting the
mesh lends to
the NC
processing
from multiple
angles
Processing
Scan Data
exact locations
for split
Further splitting
Processing
Scan Data
•optimize
meshes
Processing
Scan Data
•Optimizing the
mesh decreases the
number of triangles
from 2 million to
600,000
Processing
Scan Data
sharp edge lost
in digitizing
process
Sharp
Corners
are difficult
to capture
with a
White Light
scanner
Processing
Scan Data
sharp edge lost
in digitizing
process
Close-up
Processing
Scan Data
Modified sharp
edge
Solution:
Generate curve
In Tebis CAD
Modify meshes to
the curve
Processing
Scan Data
automatically
generate
sections cuts
along guide
curve
•insert surface
Processing
Scan Data
exact surfaces along
wind shield
build surfaces
utilizing
intersections and
curves
Processing
Scan Data
exact surfaces along
wind shield
hybrid model is a
combination of
meshes and
surfaces
Processing
Scan Data
Example Reverse Engineering Process
with
Tebis
Example provided by Venture Industries
White light Scanner
Processing
Scan Data
•model making
Collecting profile
data with a Romer
arm
Processing
Scan Data
Example : Vacuum mold with a carbon fiber part
Step 1:
A sheet metal part is scanned with an optical scanner.
The resulting “point cloud” is used to create a triangle
mesh representation of the part.
This example has nearly 4 million points
Step 2:
A secondary line scan is produced to define the part
periphery and interior holes
Profile scan produced with a portable Romer arm
Step 3:
After merging the line scans and the triangle mesh, the
mesh is then trimmed to create precise part edges.
Trimmed part shown below
Step 4:
After trimming the mesh, “runoff” surfaces are created.
The hybrid model is now ready to machine
(Hybrid model with triangle mesh and CAD generated surfaces)
Close-up
Step 6:
Machining the mold. All of Tebis’ cutting strategies are available
to cut a hybrid model (Slope angle technology shown)
Corner picking routine
Step 7:
Carbon fiber “laid-up” and then vacuum bag formed.
Finished mold and Carbon Fiber part.
Facts and Figures
•
•
•
•
Scanning process:
Data preparation:
Machining the mold:
Vacuum forming process:
• Total time:
1 day
1 day
1 day
1 day
4 days (32 hours)
Example Finish in Hard
Tooling
•machined from scan data
•machined from
•scan data
machined from scan data
•from the machine tool library
Virtual
Machine
Selection of
a Machine
Tool
NC-Simulation
•virtual
production
environment
NC-Simulation
Tool and Machine
Head
•visual checking prior
to nc-programming
•position on the table
•Consideration of
clamping devices
NC-Simulation
Tracks
Machine
Envelope and
Machine
Kinematics
NC-Simulation
In Closing….
High Level Automation is a double edged sword
It usually means less programming time but can also leads
to less efficiency at the machine tool
It is advantageous to be able to do both
High End usually means high price but also high value
Flexibility in a programming system leads to more efficient
programming
Thank You and
Have a Good Day !!!
Tebis America, Inc.
I-75 Tech Park
1389 Wheaton Rd., Suite 500
Troy, Mi 48083
Call Toll Free 1-877-74-TEBIS
www.tebis.com
mailto: info@tebisusa.com