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Vero VISI 18: Design

Al Dean looks over the latest release of Vero Softwares VISI CADCAM system with a specific focus on its design and mould filling simulation tools

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ith its roots at Italian manufacturer Olivetti in the 1980s, Vero Software and its flagship product range, VISI, has a background steeped in the business end of manufacturing. Having grown from a mould and die focussed modelling and machining solution, the range now offers a wealth of CAD tools for simulation, design and manufacturing, even delving into the more esoteric realms of wire EDM.

The last few releases have seen a huge amount of work done on both the integration and extension of the new tools the company has acquired such as the mould filling simulation tools from Plastic & Computers and wire EDM tools from Camtek. So, with this amount of product to look at, wed better crack on and start with the basics. Vero has been working hard on the systems user interface. It looks fresh and modern with a crisp graphics display and a

Product: VISI 18 Supplier: Vero Software Price on application vero-software.com

neatly task oriented user experience that helps to instil a certain level of confidence in the working environment. Specifically, this release features a consolidation of the file/open and file import commands, which were previously separate. Now the user has drag & drop access to all of the following formats - Acis, Catia V4 & V5, DXF/DWG, Iges, Parasolid, Pro Engineer, Solid Edge, Solid Works, Step, STL, Unigraphics and VDA. While this may seem an extensive list, work has been done on the output of data. So, as well

WORKFLOW: DESIgnIng SPRIngbACK InTO STAMPIng DIE

1 A complex automotive panel requires over-bending to allow for material elasticity

2 Preserving geometry is used to hold conditions and Matching geometry is used to drive the deformation

3 An intermediate mesh preview is provided to allow multiple parameter combinations

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as supporting interaction with mesh data, VISI will also read PLY polygon files and will output directly to Z Corporations own ZPR format for 3D printing. VISI 18 also brings on board tools for working with mesh data, which may for instance come from a reverse engineering process or a simulation. All of the tools needed to clean up that data are provided, such as hole filling, rationalising normals, deleting areas of data and sharpening up edges (something that reverse engineering capturing devices suck at). Although its not a specialised tool like those developed by Geomagic and CopyCAD, it will let you work with the data once its been processed. In terms of interaction with geometry, the reliance on the dialog has been removed and instead the drag handle approach, now common in all 3D design tools, is used. Its been nicely implemented here, particularly when dealing with fillets that have multiple radii and other complex areas. The drag/ drop and push/pull concept is pervasive throughout the user interface making geometry wrangling much more efficient.
1 Interactive bending of a solid model using the deformation tools 2 Plastic filling simulation with complete tool design and hot runner circuit 3 VISI 18 introduces new tools for the management and manipulation of mesh bodies

Geometry mAnIpulAtIon
Whilst many may think that the 3D geometry issue has been solved, its clear that theres still more work to do and VISI 18 shows this perfectly. This is evident in the new Advanced Modelling set of tools, which have been implemented in two forms. The first is the ability to deform a surface model with much more freedom compared to most surface modelling tools. The user can Stretch, Bend, Twist and apply a Radial Bend (Bend + Twist) to the geometry. Whats interesting is that these tools arent restricted to surface geometry, but can be applied to any mix of surface, solid, mesh or indeed, wireframe. In practice, theyre pretty easy to use. Take the Bend operation for instance and point to two points. The first is where the geometry is held, the second is where you apply the bend. In terms of control, you have a great deal, not only over the amount of movement, but exactly where its applied. Whats interesting is how the system applies the changes. Its capable of maintaining surface quality and you can specify whether the holding condition is positional, tangential or curvature constrained, up to G4 standards (3D acceleration). Similarly, if you Stretch and Twist, all three will maintain the surface

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quality needed while allowing you to achieve the deformation required. text, our 6 step workflow below should show 1 you how it works more clearly. In order to understand the level of control at hand you need to consider why Vero has provided this tool. VISI is commonly used in the stamping die industry where, as anyone experienced in the field will know, springback is a constant problem. The nature of the process together with the materials used mean that if the die is designed based on the nominal CAD data, the resulting part wont match. The reason being that while huge force has been applied, the sheet material still retains its elastic nature and springs back out of the die to a different shape. This is a true black art and requires some serious knowledge on a part by part, machine by machine basis. The way its accounted for

tArGet DrIVen DeformAtIon

The second and more advanced of these tools is Target Driven Deformation (TDD). While the first four operations discussed above allow you to define global deformations, these give a further level of control. Not only in terms of how the geometry is deformed, but also what faces and features are affected and which are retained. In short, they allow you to deform a model based on multiple start and end conditions. So, think of taking an edge set from a starting model, creating the edge set that you want the model to conform to and having the system carry out the modification. While this probably sounds mildly baffling in

4 A new deformed set of geometry is returned maintaining face continuity

5 Face tangency and continuity (up to G4) can be constrained

6 Dynamic sectioning and part detailing shows the model

deviation

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is by making changes to the die that over compensate for the spring-back so that when removed from the die, the part will represent the required form. The specialist (using digital simulation tools such as Autoform or Dynaform) will be able to look at the part, the production process and predict where the spring back is likely to occur and be able to account for it. The problem traditionally has been that its quite difficult to model that design change in order for a die to be machined. Vero is looking to solve this with Target Driven Deformation by allowing the user to sketch in edge conditions, or take point data from a CMM machine, which defines where the compensation is required, and have the surface matched to those new geometry conditions. Basically, you start with an edge chain, sketch out where you want it and have the system deform the surfaces to effect that change. Of course, applying this might cause unwanted deformations to specific features like holes and bosses that need to be a specific shape for assembly. For this reason you can use the Preserving Group option to specify areas that are not allowed to change. Chances are, you will use multiple applications of this command to achieve the result you want for complex parts and the system will give feedback about the variance of tolerance (for position, tangency, curvature) and support its use in an iterative manner. It also supports symmetry, if thats applicable to your parts. While the example used here is stamping die specific, the good thing is that this type of geometry manipulation can be applied to many other problems that regularly occur, whether thats fixing small gaps in surfaces, adding draft to a part without affecting key features or to manipulate mesh data. In combination with Veros mould filling tools, its even possible to discover where a plastic part will warp and define the changes required to overcome that warpage. So the TDD tools will account for it and rerun the mesh file to compensate the warpage.

In combination with Veros mould filling tools, its even possible to discover where a plastic part will warp and define the changes required to overcome that warpage

products that actually does offer complete design to manufacture capability. Many of the more mainstream vendors, particularly Autodesk at the moment, are making huge noises about how they support a complete process, but the fact is that, until youve got the CAM tools in there, youre nowhere near a fully integrated solution. While only the major design and mould filling simulation tools have been discussed here it should be clear that Vero are achieving a very happy medium by adding new tools and improving existing ones. The complete integration of VISI Flow is excellent and offers an interesting alternative to Moldflow as you have the flow simulation tools integrated with
5 A number of

gemetry deformation tools have been introduced for VISI 18. Here is an example of a deformation being applied to a surface

concluSIon
VISI is one of those very rare suites of

a system that actually lets you fully account for problems that may arise. Much of that is driven by the new geometry manipulation tools, which are first class. VISI has allowed you to work directly with dumb geometry for decades now but the difference now is that its been what its users have needed to do for decades as well. And this release shows that this work is still important and the new mesh-based modelling tools, combined with the new deformation capabilities, enable you to make the edits you need, where you need to, without worrying about much else. Well conclude things with a look at the manufacturing update next month and a bigger conclusion, so stay tuned.

VISI FLOW: InTEgRATED MOuLD FILLIng AnALySIS

Vero acquired the TMconcept product from Italian software house, Plastic & Computers back in 2007. When I looked at it for the first time, I saw a tool with huge potential, particularly considering the lack of diversity in mould filling simulation tools on the market (which has traditionally been dominated by Moldflow, now owned by Autodesk). But that potential was tempered by a pretty clunky user interface, a lack of integration with the tools required to make changes and a general lack of involvement in the process. The last three years have seen a great deal of work done by the Vero team on bringing this system into the VISI Fold and that work reaches a level of maturity with the VISI 18 release. VISI Flow is now fully integrated into the VISI Suite. In terms of functionality updates,

the set-up process remains much the same, but theres been more intelligence added to the meshing process. The system supports complete tooling simulation, not only the part form, but runners, cooling and such. Whats changed is that the meshing process will only remesh parts that have changed. This is much more efficient and enables you to play with parameters and positional variants (such as the position of cooling channels, dimension of runners, gating positions etc) more effectively. Ultimately that means you can get closer to an ideal solution more quickly. The other big change is in the quality of visualisation. Although the manufacturing engineer may think that pretty pictures, shaded models and animations will not help make design decisions and

changes to tooling, the fact is that you often have to present these decisions to non-technical colleagues or management. VISI Flow now has the high-quality visualisation tools that Vero has built into VISI, along with some more specialised tools. For example, if you know a pressure limit in a mould, then you can show a colour-coded display of the model with the quality spread of the part along with labels (such as temperature). It gives you all that is needed to make a judgement call on what to change and where. An example is being able to visualise the tooling as well as the filling simulation at the same time, which allows you to validate the impact around the parting line and recognise if additional venting is required. In general, the new results-

related tools allow you to work out where problems are and whats causing them without too much complexity in the way of getting to that information. In terms of documenting that process, 3D notes can be added onto the model and can incorporate any mould design data you already have, whether thats specific plates, cooling systems and runner or the full mould stack. While it may sound unnecessary, being able to add more context to a presentation or report means you can remove ambiguity for the non-techie and get your point across more efficiently. Finally, to assist with reporting, you can generate a report as before, but you can also now set-up specific views of your simulation run and click the add to report icon to automate things a little more.

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Vero VISI 18: Manufacturing

n the November 2010 issue we took a look at the design oriented tools within Veros flagship VISI product discovering a system that has improved and expanded its capability. In this issue we turn our attention to the world of manufacturing - an area in which Vero and VISI earn their collective bread and butter. So, lets begin with something thats often overlooked by many CAD/CAM software developers: progressive die design.

Following the design focussed review in the last issue, Al Dean now completes his review of Vero Softwares VISI CADCAM system with a look over whats coming up for manufacturing, covering Progressive Die Design, Machining and Wire EDM

VISI ProgreSS
Progressive die design involves a fascinating process in terms of workflow. It essentially starts with a part, typically sheet metal in nature, and works it backwards to arrive at a blank form. The user then creates the punches and formers at each stage taking the developed blank to final form. The actual tool is then designed around those entities. When complete, the die is built, the sheet metal is fed in and out pops a typically complex component. This may seem counter intuitive for those not experienced in the industry, but it works beautifully. The first part of the die design process is perhaps the most complex. While the folded form of a component can typically be defined in a single operation for each fold, unfolding that same form for each die stage is often much more involved. Firstly, some bends need to be applied in multiple stages, either to purely achieve an extreme change in angle or to allow the die to create other features. Additional complexity arises as the progressive die design needs to account for not only the bending and punching of materials, but also for the distortion and stretching of the sheet metal as it progresses through the process. In essence, its not just a case of flattening out a sheet metal model of a part and using it. The flanges also have to be unfolded.

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In VISI Progress 17 flange unfolding was substantially improved. This release sees that work mature with disparate commands and options consolidated into a handful of operations. These are context and selection sensitive so that the geometry the user selects will predefine the method used to fold specific geometry. Theres also greater feedback and reporting on the more complex operations, such as using a binder surface to unfold complex faces. This allows the user to predefine a sheet form onto which flanges will be developed. The system then calculates the deformation in order to provide an accurate geometric form. For this latest release the forming process is now animated and coloured feedback shows where thickening or thinning of the sheet metal will occur. There are also tools to show how edges are shifting between each stage. For instance,
Product: VISI 18 Supplier: Vero Software Price on application www.vero-software.com

1 Combination finishing routine based on angle ranges 2 Interactive drilling allows the user to override feature recognition for live editing 3 Interactive milling allows dynamic creation of simple 2D machining tasks

constraints can be added to hold specific edges in order to maintain particular features. Finally, after completing the blank development, it is possible to generate a HTML report that provides all the relevant information for the production of the part. This includes weight, theoretical thickness, area, perimeter, plus additional details for all internal forms. Information like this is vital when preparing a quote. Next up for VISI Progress 18 is greater support for the smaller details such as Ribs and Bosses (or, to use the more common parlance, Bird Beaks), which add strength to parts. As these have a dedicated feature, the user defines the geometry on which to base them (essentially a line), and then picks the geometry to which theyre applied. Also key is a new ability to integrate assembled components into the parts at individual stages. This ensures that the stages defined

WORKFLOW: DISCOVeRINg AND PROgRAMMINg FeAtuReS FOR WIRe eDM

1 Setting up the EDM environment including clamps and obstacles

2 Feature recognition will find 2D and 4-axis features

3 If necessary, features such as taper can be dynamically edited

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replaceable components that would typically experience the most wear and tear during the dies life cycle and are usually made of hardened steel. The system will ensure that multiple inserts in a single plate dont come too close together as this can cause weakness in the assembly. It will then spit out a report with images and dimensions for production as well as positioning details if required. The last update is a new Blanking Batch file into which files can be added, development parameters set up, and then the system can chunk through the list, generating the blanks where needed.

VISI PePS-WIre
Vero acquired UK-based Camtek Limited some time ago and its tools, including the PEPs suite of specialist CAM technologies, are now beginning to merge into the flagship VISI product. PEPSs mastery always lay in the field of Wire Electrode Discharge Machining (EDM). This is linked heavily to the more mainstream world of 2.5-axis machining, but has a very different requirement in terms of capability and control as well as integration with a range of specialist machines. It starts with feature recognition that finds not only parallel-sided pockets but also those with land and taper, variable land and more complex 4-axis tapers (which are most commonly used for extrusion dies and large scale mouldings). Next, the user works through the features, adding in the necessary start holes and approach points. The system then presents a machining operation best suited to the geometry at hand. For example, if its a parallel or tapered aperture, itll present 2-axis operations whereas a 4-axis operation will be offered for more complex ruled surface features. Of course, for more simple wire-EDM type jobs, a 3D model isnt always necessary or available and in these cases operations can often be driven from 2D geometry just as efficiently. In practice, the user switches to the Wire environment, selects the features to work with, and uses the appropriate technology for a specific machine tool (VISI PEPS-Wire has a wealth of predefined technology for a lot of different machines) and filtering operations to define the toolpaths required. These can be either automatically created, or in more complex scenarios, perhaps due to machine head movement or intricate geometry, taper, approach and exit angles

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in production will allow these intermediary steps to be performed and that the folding or production process doesnt foul with the die during fabrication. A typical die stack consists of a number of plates, each with different apertures for punches and for slug removal. VISI 18 sees the introduction of some automated features to aid the assembly and manufacture of the common features. First off, VISI Progress is able to apply relief holes to vertical edges of internal pockets and automatically assign feature attributes that can be used to generate drilling tool-paths. Second is the ability to create automatic die housing inserts, which include minimum distance checking and key corner radius adjustments to avoid incorrect assembly. These are

4 Machine setup will load specific EDM technology data

5 Toolpath parameters including tagging, No. of cuts, power settings are all available

6 Dynamic simulation can also be used to validate slug removal

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select them individually to create a toolpath. In essence, overriding the automated tools, the user can make changes that might not be inferred from the geometry recognition alone. For example, rather than re-modelling a couple of holes as a result of a design change, the user can simply edit the diameter of both holes interactively from the tool-path execution. This type of control is then extended to the Interactive Milling tools, which allow users to manually create and edit simple 2D machining tasks. Essentially, this means defining the cutter, sketching out the tool-path using simple mouse clicks, and creating offsets to the depth and number of steps required. The last two major updates for machining are as follows. Firstly, a new feed-rate reduction option allows users to define a maximum/minimum angle and reduce the feed-rate in those ranges. This allows for greater control over cutting speeds as the tool climbs up and down walls. Secondly, there is a brand new tool-path/operation type called Aggregate Machining. This is most useful for highly complex geometry where users can mix and match machining strategies for steep and shallow areas in the same part. The model is broken down into individual zones based on angle ranges into which a separate toolpath strategy can be applied. In previous releases, this was created as a single tool-path. However, from VISI 18 onwards, it can be split it into separate operations over which the user has finite control of the toolpath type including raster, spiral, radial, morph, waterline and constant step-over - after all, these are typically the final machining operations and for those wishing to achieve the highest surface quality possible, a high degree of control is needed.

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can be manually edited. Tagging is also critical for Wire-EDM processes, as users may want to retain the slug for removal at the end of all the machining operations or have the slugs removed as early as possible. Finally, as the system is integrated into VISIs existing machining-related products, advantage can be taken of the systems full suite of machine and part-based simulation and verification tools. This ensures that the part runs well, with additional tools used to help remove the slugs resultant from tapered or 4-axis pockets. focus is on building greater support for mesh geometry. We covered this in general in the November 2010 edition, but with specific reference to machining Vero has now added tools that allow the user to manipulate the mesh that underlies all CAM operations (N.B. the majority of machining systems use a tessellated mesh rather than the surfaces on which to build tool-paths). In practice this allows users to take that mesh and quickly create an offset. An example is adding machining or grinding stock to a casting, something that might be very difficult to achieve using surface geometry. Another addition is the ability to edit mesh parameters for local areas on the model. This allows the user to tighten up the machining tolerances in critical areas without penalising the calculation time by applying smaller tolerances across the entire model.
4 Automated die housing insert construction 5 Corner relief for

internal apertures

VISI MAchInIng
VISI is best known for CAM and Vero has been in the game for quite some time. In fact, many of the other CAM vendors license the same code on which to build their applications. At present the toolset is incredibly well developed and runs a wide range of machining operations and types. From basic 2.5-axis production machining jobs into the more complex world of surface machining for tool and die applications. In terms of updates for this release, a major

InterActIVe DrIllIng
The new release has also seen work done on interactive drilling cycles. This provides complete flexibility regardless of model topology and allows users to find holes and

concluSIon
Over the last two issues, weve discussed all of the major updates to the VISI product range for the 18th major release and I have to say I continue to be impressed with what Vero is accomplishing with its flagship product. The design tools continue to evolve and expand, not only in terms of process coverage, but also the types of geometry one can work with, and how one works with them. What I like the most is how the introduction of new capabilities in one area feeds into others. For example, the support for mesh geometry enables new meshbased capabilities for the CAM user. The new advanced modelling tools will be useful to any user looking to make complex geometry modifications, but they also enable the accurate compensation for spring back in stamping dies. However, alongside a focus on solving complex problems, it also enables low-tech workflows. So, its about using the best approach, however high or low tech it might be, to the greatest effect both in terms of common sense and time. To me, thats a perfect combination and one which makes VISI one of the most impressive toolkits for manufacturing focussed designers and engineers on the market.

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