Extensive range of CAD interfaces and powerful modelling

Visi can work directly with Parasolid, IGES, CATIA, Creo, UG-NX, STEP, Solid Works, Solid Edge, Inventor, ACIS, DXF, DWG, JT Open, STL, and VDA files. The extensive range of translators ensures users can work with data from almost any supplier. Companies working with complex designs will benefit from the simplicity with which their customer’s CAD data can be manipulated. Visi can work directly with wireframe, solid, surface and mesh data or a combination of all four, providing users with tools to work with any CAD data or to quickly re-model parts ready for machining, fully using the power of true hybrid surface and solid modelling.

Tooling

Comprehensive Tool library with holders, cutting parameters and sister tooling - Catalogues of tools, holders, extensions, adapters, storing speeds, feeds, optimal cutting depth, stepover values and tool offsets along with tool and gauge lengths can be selected from user definable libraries. For longer machining cycles, Visi will keep track of the amount of machining completed. When the specified tool life has been reached the system will automatically call for a sister tool, minimising the risk of damage to the part being machined, by worn or broken tooling.

Tapered tools supported on all cycles

Where models have no draft, it is possible to use tapered tools to machine draft directly onto the model. Straight tooling will require modification of the model to add the correct draft angle before machining can start. Adding draft to imported geometry can often be a very difficult and time consuming task.

Tool holder collision checking

Checking the tool and the holder against the model provides a warning of a potential collision, together with relevant information about the tool length required to complete the job. By limiting the Z cutting envelope for the tool, it is possible to use several tools to machine a cavity, taking advantage of the rigidity of shorter tools to remove most of the material.

Machining

Intuitive interface

A simple tree structure makes it easy to navigate around the machining operations. Machining parameters for depth of cut, step over, ramp angle etc. are input using a graphical user interface. Commonly used values can be stored as default settings enabling the operator to use a consistent method of machining.

Multiple roughing toolpaths

A combination of constant Z roughing, adaptive roughing, core roughing and rest roughing, combined with intelligent ramp, helical and planar entry methods provide operators with the freedom to produce efficient NC code to suit any component. Combined with smooth corner radii and smooth transitions between passes, the tool will maintain the maximum feed rate on the machine tool and prevent the cutter from dwelling in corners. For subsequent roughing operations, Visi will remember where remaining stock is left on the component and only machine in those areas. Wasted air cutting will be minimised and unnecessary rapid movements will be eliminated, while the cutter will avoid digging into areas where there is excess material, which could result in tool breakage. Where the starting billet is pre-machined, or possibly a casting, Visi will recognise and machine only where material exists, again eliminating wasted movement, and keep cycle times to a minimum.

Adaptive clearance

Adaptive clearance toolpaths enable roughing the part from bottom to top. This machines large steps using the full flute length of the tool with a small stepover and then machining the intermediate levels back up the part. The tool remains on the part as much as possible and the toolpath automatically switches to a trochoidal motion when required. This ensures there are never any full width cuts and guarantees a constant tool load. Tool wear is spread evenly across the cutting surfaces, and the center of force is half-way up the tool, reducing deflection and the potential for vibration Using adaptive roughing, the cycle automatically adjusts the toolpath for efficient and safe machining, improving cutting conditions and enabling higher machining speeds. The result saves up to 40% in actual cutting time.

ISO-Machining

ISO-Machining is based on single or multiple surfaces and machines the surface directly instead of creating a triangulated mesh. This is ideal for machining groups of surfaces that make up radii as the contact point of the tool machines to the full edge of the geometry. This flexible strategy is also extremely useful for picking out small areas without having to machine the entire component. All toolpaths are fully gouge protected against neighbouring surfaces with multiple collision detection options available.

Flat surface machining of planar surfaces

For flat part areas, Visi automatically detects these areas and machines them using a flat-bottomed tool. The machining time for these areas is significantly reduced, and the surface finish is greatly improved by using a flat tool.

3D stepover finishing

The 3D stepover toolpath provides a constant surface finish regardless of the component shape. By morphing the toolpath across the component’s surface, one toolpath will finish the entire job, minimising retract movements and eliminating duplicate cutter paths. As the toolpath step over is adapted to the part’s shape, shock loading of the tool will be minimised, enabling the machine tool to run at the optimum feed rate.

True spiral / radial finish machining

Both toolpaths make an ideal finishing strategy for circular components as they are based on an inner and outer circular limit. The spiral tool path has only one start and finish point guaranteeing the tool remains on the component, eliminating any redundant moves or sharp direction changes. This toolpath enables the machine tool to run at very high feed rates as it eliminates the acceleration and deceleration caused by sudden changes in direction. The radial toolpath enables upwards only, downwards only or zigzag machining parameters providing complete strategy control.

Parallel plane finishing

Unidirectional and zigzag toolpaths can be set at any angle. Angle limits can be set for steep and shallow areas, eliminating the need for complex geometry boundaries. Optimised cross-machining can be applied to steep areas within one toolpath. This automatically creates additional toolpaths at 90 degrees to the original toolpaths, machining the areas only where necessary to produce a constant surface finish across the entire component. Roughing mode within the Parallel Plane tool path can rough and finish the part in one operation. Smooth stepovers and tangential extensions to the passes can produce a better surface finish and smoother running of the NC file on the machine tool.

Constant Z / combined finishing

For components with steep walls, cutting in Z slices provides a good surface finish. Visi provides many options within the constant Z strategy to produce the best performance from this toolpath. Where the angle of the walls change, Visi can automatically adapt the slice heights of each level for shallow areas. Wireframe geometry can also control the slice height and angle limitations, and can eliminate passes in shallow areas. A helical option enables creating one continuous toolpath, eliminating witness lines on the part and improving the surface finish. Additionally, a combined constant Z toolpath is available for finishing steep and shallow areas in one toolpath. This strategy enables machining steep areas using a constant Z method. Shallow areas are machined using a 3D constant stepover method. This method operates as a one-stop finishing toolpath.

Leading curve machining and 3D curve machining

The operator controls the cutting area by machining between two driving curves across a model. Parallel machining morphs between the curve geometry using the curve shape as a toolpath guide. Perpendicular machining runs normal to the guide curves, giving a choice of cutting directions, enabling more control of the machining method. 3D curve machining forces the cutter to run along the 3D curve in open space, without model geometry, making the strategy ideal for scribe lines and engraving onto the surface of the model.

Rest machining of fine details

Small features on a model usually require rest machining with a smaller tool to completely finish the detail. The rest machining command reliably detects areas left by previous tools so they can be re-machined. For very fine details, this process can be repeated as required to successfully machine with very small cutters. The toolpath can work from the outside to the center or from the center to the outside of small blends. For features, which are close together, the toolpath will morph and blend together around obstacles providing a smooth and flowing toolpath without any sudden direction changes. This minimises the number of retract movements and helps to eliminate shock loading on the tool and keep feed rates as high as possible.

Short calculation times and batch processing

New algorithms provide fast calculation times even for the most complex parts. High speed machine tools require huge amounts of data to keep them running efficiently. By keeping the calculation times as short as possible, unscheduled machine stoppages are kept to a minimum. Visi uses multi-threading technology to enable calculating multiple operations at the same time and batch processing to enable jobs queuing for unattended calculation, out of normal working hours. To further speed program preparation, individual operations can be postprocessed separately, so machining can start on roughing operations while finishing operations are still being calculated.

Graphical toolpath editing and reordering

Once the toolpath is calculated, users can easily trim toolpath sections and edit movements to optimise the cutting method to suit individual components. The sequence of operations can also be easily changed. A simple drag and drop can modify the operation order. Toolpath editing provides the freedom to quickly arrive at the preferred machining method and sequence of operations.

Smooth point distribution and smooth transitions

Visi creates each toolpath with an even distribution of coordinates. By sending smooth and efficient CNC code to the machine tool control, it reduces unnecessary machine acceleration and deceleration, making it possible for the machine to operate as close as possible to the programmed feed rate. All toolpaths have smoothing radii in the corners, smooth transitions between passes and options for looping movements linking the ends of each pass. These elements help the machine tool run faster, prevent sudden direction changes, and eliminate excessive strain on the tool.

Template machining

To speed up programming, templates containing tooling, operations, feeds, speeds, and depth of cut, can be stored for reuse on similar or families of parts. Applying them to a new part automatically creates a new set of toolpaths using the same settings, greatly reducing programming time and using company standard feeds, speeds, methods and tooling which have been proven on a previous job.

High-speed machining and hard metal machining

Many Visi toolpaths are tailored towards high-speed machining and hard-metal cutting. Smooth corners, smooth stopovers and arc fitting minimise sudden direction changes. Eliminating tool retracts, maintaining a constant tool load, and optimising NC code make it easy to successfully program high speed machine tools with Visi.

2D machining and manufacturing feature recogniition

Toolmaking applications often contain components requiring 2D machining. Visi makes it easy to manufacture individual plates using feature recognition. Drilled hole features and apertures are automatically selected with the correct drilling cycles and 2D milling routines applied creating practical CNC code for the most complex plates.

Full gouge protection

All 3D toolpaths are gouge checked against neighbouring surfaces to eliminate possible tool collisions. Small smoothing radii are automatically added to internal corners. These movements stop the tool from dwelling in the corners which can cause the tool to pull into the job creating an unexpected gouge, which would not be detected by toolpath verification.

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