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TEBIS is a High-End Cad/Cam Software serving the Die, Mold and
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 • • • • • • • • • • • 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 Top 10 reasons why our customers buy TEBIS How can you find out if the claims I’m making are true ? Top 10 reasons why our 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 Data Collection Methods •die and mold manufacturing Collecting surface data with a White Light Scanner Processing Scan Data Data Collection Methods •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 •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: [email protected]
