GibbsNews Spring 2007 Issue

GibbsNews
A Publication for Manufacturing Professionals
What’s Inside
Greetings from Bill
Development Update . . . . . . 2
GibbsCAM Support for
Windows Vista . . . . . . . . . . . 3
2007 is rolling along nicely. Everybody at Gibbs is staying
very busy.
Reverse Engineering
Paves the Way . . . . . . . . . . . . 4
We had our Worldwide Reseller Meeting in February. It’s
always fun to spend time with the people who represent our
product around the world. This meeting was an especially
busy and long meeting as it provided training on new products
including our new 5-Axis and MTM Simulation modules.
Macros are not a new capability, but they have been upgraded
and we provided training on the enhanced functionality as
well. The highlight of this event is our awards banquet where
we recognize our top Resellers in a variety of categories. Our top Resellers by sales volume
receive our President’s Club award. This year the winners were Matsuura Machinery
Corporation of Japan, Texas Offline of Texas, Midwest CAM Solutions of Minnesota,
Braden Engineering of Illinois and California, Productec of Switzerland, Fructus Data AB
of Sweden, and Virtual Manufacturing Services of Ohio. They all do a great job for their
customers, too.
GeoEdit . . . . . . . . . . . . . . . . . . 5
GibbsCAM 5-Axis Option . . . 6
Customer Showcase . . . . . . 7
March 2007 was a bright spot for Gibbs as we set a new all-time sales record for one
month. One great month is not enough to ensure a good year, but it’s not a bad sign either.
I’ll take it gladly and smile.
GibbsCAM 2007 has gone “Gold” and is back from CD duplication. It is being shipped to
all maintenance customers and is the current shipping version. Also called v8.5, it is the
international languages release of v8. It has numerous improvements as well. 5-Axis and
MTM Simulation will be incremental releases over the next month or so. Both are undergoing final testing now. Today, as I write this, we are holding a 5-Axis training class for
beta testers, the first customers to be using our new 5-Axis module. We’ve got a crowded
classroom with about 25 people in it. They seem to be having fun with the new software.
CGTech is the maker of VERICUT, a high-end simulation software popular with large
manufacturing sites. They have formed a partnership with us to provide integration
between GibbsCAM and VERICUT, to better support the customers we share. At first
glance their product is similar to our own Machine Simulation. VERICUT is a more sophisticated and expensive product, which includes program analysis and optimization. CGTech
will develop machine models for a fee. We were honored they picked us for this opportunity.
Development is hard at work on GibbsCAM 2008 (v9) which is scheduled for release later
this year. Stay tuned as future issues of GibbsNews will be providing some insights into this
upcoming release.
That’s all the news from Gibbs. I hope your businesses are doing well.
Best regards,
The newsletter is also available as
a downloadable PDF file at
www.GibbsCAM.com.
Spring 2007 • Volume XVIII • Issue II
Published by Gibbs and Associates
Development Update, by Bill Gibbs
Not a lot has changed since the 1Q Dev Update. I
described the current release schedules in my Q2
President’s column. Finishing up the general release,
MTM Machine Simulation, and 5-Axis are the short
term projects. GibbsCAM 2008 (v9) is the long term
project. All is going well.
There have been some product shifts with the new
GibbsCAM releases. Productec ProAXYZ 4as is
now the GibbsCAM 4-Axis option. We have taken
over development and will continue to
improve the 4-Axis option
for rotary milling. This
is a free upgrade for
maintenance customers.
The new GibbsCAM 5Axis module is not
Productec ProAXYZ 5as,
but is rather an entirely
different way to program 5axis mills and 5-axis parts.
All Productec ProAXYZ 5as
customers will be offered a
free copy of the new 5-Axis
module, provided they pick up
the maintenance fees in the
future. Post processors and
ProAXYZ Drivers are compatible. Customers may
continue to use Productec 5as as well. The two 5-axis
products have different strengths. Customers may
decide if one or both are the best solutions for their
type of work. GibbsCAM 5-Axis can program 4-axis
parts as well, adding additional value in this space.
GibbsCAM 5-Axis does not include the functionality
of GibbsCAM 4-Axis, in the same way that
Productec’s ProAXYZ 5as includes all of ProAXYZ
4as functionality. They are now different modules.
If you want both, you will need to buy both. And you
will need to understand which 4-axis programming
option is best for you:
GibbsCAM Rotary Mill–adds geometry wrapping
to GibbsCAM CAD (flat geometry / cylindrically
wrapped), and machining of wrapped geometry as
simultaneous rotary machining. G-code output is all
at Y0 (no wall angle control options), and supports
multiple rotation single G1 moves. Cylindrical (mill
or lathe) and Polar (mill-turn only) interpolated
output is supported for controls with these capabilities. No machining from 3D geometry (limited),
surfaces or solids. Rotary Mill is not good with floor
tapers. It is limited to rotation about the X or Y axis
at Z0 on a mill, the C axis at X0 Y0 on a mill-turn.
Post processors require the Rotary Mill upgrade.
GibbsCAM 4-Axis–machines from 3D geometry
(perhaps extracted from solids) with selected face
and surface controls for tool angles. It supports any
wall angle, Y offsets, pocket style roughing, lead/lag
tool angle control, good with tapers, screws, etc. A
variety of functions focus on the needs of 4-axis radially prismatic parts. Output is non-analytic small
tolerance controlled 4-axis moves; Polar or
Cylindrical output is not supported. Post processors require
the 4-Axis/5-Axis upgrade.
GibbsCAM 5-Axis–machines
directly from solids, with 3D
geometry control. It supports
full 5-axis machining functions, which can be limited
to 4-axis output. Output is
non-analytic small tolerance
controlled 4-axis moves;
Polar or Cylindrical output is not supported. Post
processors require the
4-Axis/5-Axis upgrade.
Rotary Mill and 4-Axis/5-Axis post modifications can be combined and added to any mill,
mill-turn, or MTM post processor. Similarly, buying
one or more of these 4-axis options adds these milling
capabilities to mill, mill-turn, and MTM parts on
the seat(s) with the option(s).
Another module that has changed its name is
Advanced CS. It used to be the Advanced Mill option.
The Advanced CS option adds user-defined CS’s
(Coordinate Systems) to GibbsCAM CAD. It is a
pre-requisite for solid modeling, rotary milling, and
rotary positioning. Only 5-axis rotary positioning
needs an Advanced Mill post upgrade. The post
upgrade name has not changed.
On a related topic, Development has a prototype
post processor combining 5-axis rotary positioning
(Advanced Mill) and the Rotary Mill upgrade in a
single Mill post processor. The inability to combine
both in one post has been a thorn in our side for
some time. While we can add the 4-Axis/5-Axis post
upgrade to either, we have not been able to combine
the Rotary Mill upgrade and the Advanced Mill
upgrade in the same post. Why? Because it’s hard.
But as soon as the prototype has passed testing, we
will be able to offer this combined function post to
customer who so desire these combined functions.
3
GibbsCAM Support for Windows Vista
With the newly released GibbsCAM 2007, v8.5,
Gibbs and Associates now supports the new Microsoft
Windows Vista™ operating system. This release began
shipping to all GibbsCAM customers with current
maintenance agreements worldwide on
April 25, 2007. With this new release,
GibbsCAM has achieved Microsoft
certification under their “Works with
Windows Vista” program.
There are a number of differences introduced by
Windows Vista that have required changes to
GibbsCAM which are described in this article.
What does Windows Vista mean to GibbsCAM
customers? Initially, “Works with Windows Vista”
means that GibbsCAM is fully supported under the
new Microsoft operating system (OS) and that any
customer who is running Windows Vista can now install and run GibbsCAM on that computer with the
confidence that the product will run reliably. It also
means that GibbsCAM Technical Support will help
with any issues a customer running Windows Vista
may encounter, just like any other supported OS.
What is different about running on Windows
Vista? A number of things change when running on Windows Vista. Most of the changes
involve things like networking, security,
file management, and the graphical user
interface when working directly with the
OS. Most of the differences do not materially affect how
GibbsCAM works or what you can do with the product.
One big change is the amount of computer resources
required to run the Windows Vista environment with
reasonable performance. It is highly recommended that
you upgrade your computer CPU speed and memory
when you move to Windows Vista. This is absolutely
required in order to get the same GibbsCAM runtime performance as you have when running on other
Microsoft environments.
GibbsCAM Modules
PC Configuration
Mill, Lathe, Mill/Turn, Advanced CS, Solids
Import, Wire-EDM, 4-Axis
Minimum: 1GB RAM, 800MKz processor
Recommended: 1.5GB RAM, 1GHz processor
MTM, 2.5D Solids, SolidSurfacer, TMS, Machine
Simulation
Minimum: 1.5GB RAM, 2GHz processor
Recommended: 2+GB RAM, 3GHz processor
Please review the GibbsCAM 2007 Release Notes for more detailed information on GibbsCAM and
Windows Vista including recommended hardware specifications and installation.
OpenGL – GibbsCAM support
for OpenGL on Windows Vista
has been implemented in two steps.
The first step is software-only
OpenGL, the second is hardwareaccelerated OpenGL. The softwareonly OpenGL support in Windows
Vista was initially released in the
first GibbsCAM release with Windows Vista support, GibbsCAM
2007, v8.5.0. The hardware-accelerated support was released in the
GibbsCAM 2007, v8.5.5 version,
which can be downloaded from
the Maintenance section of the
GibbsCAM website. OpenGL
support on Windows Vista has been
something of a challenge for most
software application developers,
primarily because of the wide
variations of OpenGL video card
performance, reliability, and
functionality available on Windows
Vista. Gibbs has been working
closely with the two primary PC
video card manufacturers, nVidia
and ATI, to ensure a high-quality
and well-performing implementation. Gibbs is confident that these
initial releases of Windows Vista
OpenGL support will perform
satisfactorily, and we are continuing
to improve our implementation
with each successive web update
release.
Future Plans for GibbsCAM
and Windows Vista – Windows
Vista provides a number of interesting capabilities that we will be
looking at over the next few months.
Gibbs is planning a number of new
user interface and display-related
improvements to the product for
the next major enhancement
release of GibbsCAM targeted for
later this year. Most of these will
be available under both Windows
Vista and the other supported
operating systems, Windows 2003
Server, Windows XP and Windows
2000, but may look a little different
on Microsoft Vista. One of the
goals for this next GibbsCAM
release is to achieve the highest level
of Windows Vista compliance,
“Certified for Windows Vista”.
With the initial Windows Vista
release behind us, we are well on
the way to achieving this goal.
Reverse Engineering Paves the Way
For Scott Tudury, co-owner of Apex CNC in
Morgan City, Louisiana, the key to the future was
a broken rocker arm on a Harley-Davidson
Knucklehead motorcycle engine. Built from 1936
to 1947, the Knucklehead (so called because of the
design of its valve covers) is an overhead valve VTwin prized by collectors and enthusiasts.
An online search for parts revealed that the sole source was a
company called Flathead Power
located in Sweden. “This is ridiculous, the part is for an
American motorcycle,” said
Tudury.
Founded by motorcycling
enthusiast Anders Nygren
and his father in 1994,
Flathead Power quickly
became known to owners
of Knucklehead and the
earlier Harley Flathead
bikes around the world.
Tudury’s initial contact with
Nygren quickly grew into an extended correspondence. Realizing that Flathead Power’s largest market was located in the United States, it was
only reasonable to move the manufacturing and
export to Apex CNC. Tudury and Associates subsequently purchased the company moving Flathead
Power’s operations to the US.
The corporate assets of Flathead Power included
CNC programs, tooling, casting patterns, and
prints for both Knucklehead and Flathead engine
parts. To Tudury’s shock, there were no prints for
more than 50 of the parts. Programs had been created
years ago in G-Code without software interface,
and manufactured parts were checked against masters.
To make matters worse, all comments were noted
in Swedish. It became immediately apparent that the
entire line would have to be “reverse engineered”
to be capable of production on modern equipment.
Tudury’s first thought was to outsource digitally
scanning the parts and, at IMTS 2004, he interviewed a number of sources. Most proved either
too expensive or technically incompatible with
modern manufacturing software.
Seeking another solution, Tudury consulted with
his local SolidWorks and GibbsCAM resellers. It
was decided that the most efficient solution would
be an in-house digitizing system capable of linking
to the in-place software.
The DezignWorks digitizing software interfaces to
a digitizing arm. DezignWorks operates inside of
SolidWorks and enables all the data from the scanned
parts to appear in the assembly or part document
ready for immediate use. Once the solid model is
created, measurement verification (and/or modifications) can be performed. The solid model is then
transferred directly to the GibbsCAM system using
the SolidWorks/GibbsCAM plug-in.
According to Tudury,
“Apex CNC has a network license that lets us
utilize GibbsCAM anywhere on our network. We
have PC’s at every CNC
machine to allow the
operators to do their own
programming or corrections.
GibbsCAM’s simulation
graphics are superb, and once
the point of origin is decided,
we can generate the most
effective tool path and either
work around or revise the fixturing. Likewise, if changes or
improvements to the part are needed, they can be
incorporated immediately. By working directly at
the machine, we literally “do it right the first time”
and end up producing the parts faster. The
GibbsCAM system extracts the geometry, does the
math and lays down tool path.”
Other advantages to GibbsCAM involve tooling
and estimating. Operators at Apex CNC are experienced in utilizing conventional tooling to generate
shapes that would otherwise require more expensive
custom form tooling. The ability to quickly and
accurately simulate cutting is used to approximate
time and tool costs and deliver faster and more
accurate estimates to customers.
Tudury’s comments are verified by the Technical
Support Manager at Gibbs and Associates. “It’s
critical that production software be designed for ease
of use and a shorter learning curve. The user friendly
approach enables our customers to get up and running faster and to quickly educate new operators.”
Tudury states, “We initially performed the milling,
drilling and tapping on a 4-axis machine, but by
utilizing GibbsCAM, we could see some definite
advantages on the operational side as well as in fixturing by moving to 5-axis. All told, we were able
to reduce cycle time by 50% in some instances.”
The methodology used for reverse engineering has
become standard operating procedure for other
parts. Since the installation of the fully integrated
system and the ability to deliver parts quickly, business has grown rapidly for Apex CNC. The company
now supplies parts to an increasing
number of motorcycle manufacturers, as well as aftermarket suppliers.
Tudury sees his business plan and
integrated technical approach as an
example for other North American
shops. The ability to offer off-site
scanning with the digitizing arm
has led to additional customers.
He is also emphatic on the need
for partnering with qualified suppliers, and his
selection of SolidWorks and GibbsCAM software,
as well as Haas machines, derives from the fact that
his local resellers and representatives have consistently
provided ongoing support & service. He states,
“Service doesn’t mean just answering a call, it means
being proactive. For instance, when GibbsCAM
comes up with a new feature or modification, I am
contacted right away so that we can incorporate it
to our advantage as soon as possible.”
With regard to the global market
and increased competition, he
comments, “We need to forget
about the huge quantity orders.
Those are the contracts that are
going offshore to low cost labor.
Concentrate on US companies with
high-value, low-volume parts that
customers want just in time. By
moving in this direction and using
the best of technology, we’ve doubled our business in the
past year, and we expect it to double again next year.”
Reprinted in part by permission of Modern Machine Shop, copyright
2007, Gardner Publications. A full version of this article can be found
at www.GibbsCAM.com.
GeoEdit
GeoEdit is a plug-in which was developed and sold
by Productec as one of the ProAXYZ modules.
This plug-in adds six (6) special function geometry
creation and/or modification tools to GibbsCAM’s
modeling functionality. Though offering a powerful set of tools for 2D lines, circles and points,
GeoEdit was primarily designed to aid with creating and manipulating of 3D shapes, especially those
created from B-splines. Additionally, GeoEdit is
very useful for repairing bad and/or missing surfaces
and surface-edge data.
3D along with GibbsCAM 4-Axis and 5-Axis options.
Based upon this, we have licensed this technology
from Productec and have incorporated this expanded
geometry functionality as a standard feature.
Customers who are current on GibbsCAM
Maintenance will automatically get this functionality
as part of their standard Maintenance. When offered
by Productec, GeoEdit had its own Maintenance
cost. As a standard part of GibbsCAM, there is no
longer any additional charge for maintenance for
the GeoEdit functionality.
Gibbs decided that GeoEdit has significant benefits
for all GibbsCAM customers, especially those utilizing
For additional information about GeoEdit, please
refer to the Plug-Ins manual.
Introducing the New GibbsCAM 5-Axis Option The new GibbsCAM 5-Axis option allows users to
program parts which require 5-axis simultaneous
machining. The option can be used for milling only
or in conjunction with GibbsCAM MTM.
There are three primary markets for the new
GibbsCAM 5-Axis option.
The first market is for 5-axis simultaneous milling
only where a great portion of the work is mold, tool
and die oriented.
The second market includes manufacturing environments where the customer does 5-axis simultaneous
machining of production parts such as turbine
blades, propellers, impellers, or engine block
ports. There’s also a lot of production 5-axis work
required for all kinds of structural aerospace parts,
which are primarily machined from aluminum and
titanium, such as struts, fuselage components, and
galley parts.
The third market segment, which is relatively new
and growing quickly, is 5-axis on MTM machines.
Since most of the MTM machines are production
oriented, an increasing percentage of new MTM
machines from Mazak, Okuma, Mori Seiki and
others include 5-axis simultaneous capabilities.
Note: The new GibbsCAM 5-Axis option will also
supp o r t s t a n d a r d m i l l - t u r n p r o g r a m m i n g
requirements. GibbsCAM 5-Axis FAQ
1)How is this new option different than ProAXYZ 5as
and 5as+?
To begin with, the new option is the first time that
Gibbs is offering a 5-Axis simultaneous capability
which is sold, serviced and supported by Gibbs
worldwide. GibbsCAM 5-Axis addresses many of
the 5-axis cutting conditions which were not
initially targeted by ProAXYZ. ProAXYZ, is a 5-axis simultaneous option for
GibbsCAM developed by Productec, a Gibbs
partner. ProAXYZ remains as the better solution for
jewelry, engraving and other specialty applications. 2)What is the plan for ProAXYZ 5as customers who
want to still have ProAXYZ 4as functionality for 4 axis simultaneous off-centerline programming?
ProAXYZ 4as, now named the GibbsCAM 4-Axis
option, was a subset of ProAXYZ 5as. GibbsCAM
users who purchased ProAXYZ 5as effectively got
ProAXYZ 4as functionality included in the
ProAXYZ 5as price. While the new GibbsCAM
5-Axis option also supports 4-axis off-centerline
programming, it is important to note that those
capabilities are designed to work from solid or surface
models, whereas GibbsCAM 4-Axis is designed to
work from wireframe geometry models. So a customer might keep ProAXYZA 5as to use the 4as
capabilities or may elect to purchase the GibbsCAM
4-Axis option. Only the GibbsCAM 4-Axis option
will be updated by Gibbs in the future. 3)What should be ordered from Gibbs to get post processors
for the new GibbsCAM 5-Axis option? New 5-Axis customers should either order a Gibbs
Advanced Option post processor and an upgrade to
support 5-Axis, or a Driver from Productec. Existing
5-axis capable Drivers and GibbsCAM post processors for ProAXYZ 5as will work with the new
GibbsCAM 5-Axis option. GibbsCAM customers,
who already own an advanced option post, will only
required ordering an upgrade for their existing post
processor to output 5-axis simultaneous G-code. 4)Can the new GibbsCAM 5-Axis option be used in an
MTM configuration as is the case with ProAXYZ 5as?
Yes, it is configured exactly the same way.
5)How much is the new GibbsCAM 5-Axis option and
how much is a post processor upgrade? Pricing for the new GibbsCAM 5-Axis option as
well as post upgrade pricing is available from your
local Gibbs Reseller.
6)Does a Gibbs customer who previously purchased
ProAXYZ, get any special consideration for adding
the new GibbsCAM 5-Axis option? Existing ProAXYZ customers have a few extremely
attractive choices whether they prefer to use
ProAXYZ 5as, or the new GibbsCAM 5-Axis, or
both options going forward. All existing ProAXYZ
5as users, including those which might also have
5as+, under GibbsCAM Maintenance will receive
for free one copy of the new GibbsCAM 5-Axis
option for each ProAXYZ 5as “base” option they
have purchased. This includes all customers who
order ProAXYZ 5as up until the new GibbsCAM
5-Axis option begins shipping in 2007. ProAXYZ
customers who own 5as and 5as + will only receive
one copy of the GibbsCAM 5-Axis option. These
customers may try out the free GibbsCAM 5-Axis
option in their own shop for at least one month or
longer depending upon when each individual customer’s Maintenance is payable to determine
(continued on page 7)
7
Customer Showcase
Are you doing some really cool programming with
GibbsCAM? Would you like to show off your stuff
in front of other GibbsCAM customers?
If your answer is “Yes!” then forward your VNC
files to us, along with pictures and other interesting
information about the job. A panel of qualified
experts will select winners to be published in the
next customer newsletter. Entries that get published will receive a free GibbsCAM baseball hat.
But here’s the best part: all submissions will be
reviewed for potential selection as a case study
story that may be published in a national manufacturing trade publication. Interested? Then e-mail
[email protected] or call us at (805) 523-0004.
Company: Blue Chip Engineering
Location: Ramsey, Minnesota
URL: www.bluechipeng.com
GibbsCAM User Since: 2000
Blue Chip Engineering, established in
1994, is a high precision machine shop that
covers the full spectrum of machining. Their
services include: Engineering, Tooling, 4 to
5-axis Machining, Rapid Prototyping and
Production. They manufacture components
for industries including medical, aerospace,
computer and automotive.
Part Description:
The machining of such a large, thin-walled surface was a great challenge to overcome and this
non-functional part has been produced purely for its aesthetic beauty and symbolic meaning
behind its design. The three overlapping ripples represent the effects of the recipient’s good
deeds. Produced for the arts industry, the prize is awarded by the Ted Community annually at
the TED Conference. Each winner is awarded the commemorative sculpture designed by artist,
Tom Shannon, featuring a sphere which hovers magnetically in mid-air above a wooden base.
The TED prize winners selected are individuals who have used their specific talents to influence
society for the better and included in 2007 President Bill Clinton, among others.
GibbsCAM 5-Axis Option (continued from page 6)
whether they want to use the new option, ProAXYZ
or both options going forward. At the time that the
customer’s Maintenance is due for renewal, they
will only have to pay Maintenance on the option(s)
they choose to continue to use. GibbsCAM 5-Axis
Maintenance is ordered through Gibbs. As has been
the case, Maintenance for ProAXYZ is ordered
through Gibbs or Productec (Europe, China and
Japan) depending on where the customer is located.
7)Are customers who purchased ProAXYZ 5as directly
from Productec still eligible for the free new GibbsCAM
5-Axis option?
All ProAXYZ customers, whether the ProAXYZ
was ordered from Productec or Gibbs directly,
who are current on GibbsCAM and ProAXYZ
Maintenance and have ordered ProAXYZ 5as before
the release of the GibbsCAM 5-Axis option are
eligible for the free GibbsCAM 5-Axis option.
8)When will customers still purchase ProAXYZ 5as and
5as+?
Once the promotion mentioned above is completed
and the new GibbsCAM 5-Axis option is released,
ProAXYZ will primarily be selected for applications which focus upon jewelry, engraving and
other specialty applications.
PRSRT STD
US POSTAGE
PAID
OXNARD CA
PERMIT #110
Gibbs and Associates
323 Science Drive • Moorpark, CA 93021-2092
Mail Room Attendant:
If the person listed on the address is no longer with the company, please forward to the NC Programming Department.
GibbsCAM Training
Need to learn a new GibbsCAM module you’ve just
bought or brush up on one you already have?
P
Track 2: June 14-15 & 18-22
P
Advanced Training: June 25-29
“We have seen employee productivity increase by 50 to
100 percent after training.” –Bryan Provo, Alliance Machine
For additional information about Training Classes, please visit
www.GibbsCAM.com, or contact the Sales Department
at [email protected] or (805) 523-0004.
See GibbsCAM at These Upcoming Trade Shows
P PTC/USER
World Event 2007 • June 3-6, 2007 • Tampa Convention Center • Tampa, Florida • Booth: # 609
P EPHJ
• June 5-8, 2007 • Beaulieu • Lausanne, Switzerland • Stand 817 / Hall 7
P EMO
2007 • September 17-22, 2007 • Deutsche Messe AG • Hannover, Germany • Stand G12 / Hall 6
P AMMO
2007 • September 18-20, 2007 • Las Vegas Convention Center • Las Vegas, Nevada • Booth: # 544
Additional exhibitions and events are listed on www.GibbsCAM.com.