A heat-shrink tool presetting and measuring solution
from Zoller is integrated into the digital manufacturing
chain. The actual measured 3D data from the cutting
tools is transferred to VERICUT as a 3D DXF layer fi le,
so Trumpf always uses the correct cutting tool data
PROCESS SECURITY
Trumpf uses TopSolid CAM software for
both mechanical production and tool
making. The Linz software and technology
company Techsoft, which also provided
support with the introduction of VERICUT,
is the supplier. “Although TopSolid does
provide simulation, it does not tell me
whether, for example, a pallet collides
with the machine structure. You can also
de ne safety distances in VERICUT. In this
way, errors that occur in CAM
programming are immediately and clearly
visualised,” Andreas Mayrhofer says about
the use of in-built simulation software.
Collisions are not only displayed in red,
they are also precisely logged as plain
text. He continues: “For me, this
separation is absolutely perfect; a
program for programming and a program
for simulating, since the transfer of all
data from TopSolid to VERICUT works
without any problems.”
Adding a tool presetting device is also
included in this digital cycle: “All our tools
are measured on a Redomatic 600 from
Zoller and the 3D scan is transferred to
VERICUT as a 3D DXF layer. We therefore
always work with the real tool data,
including length, diameter and overhang.”
CGTech’s VERICUT is used to simulate
programs for all components at Trumpf.
“We are talking about components that
are manufactured to customer
speci cations. In total, that’s around
3,000 milled parts per year, with cycle
times of between 2.5 and 10 hours,”
Production Manager Bernhard Zipko
clearly underlines.
The processing time of a machine
frame, regardless of the model, is a
maximum of 2.5 days, including painting.
“We only have six frames as a buffer,
so just two days of production, we are
therefore dependent on absolute process
reliability,” says Bernhard Zipko,
underlining the tight time constraints in
production. Andreas Mayrhofer adds:
“We are talking about around 80 CNC and
100 subroutines that we are constantly
updating. Minor design changes or a new
model version mean continuous updates.
In addition, the components are optimised
in terms of production technology, which
ultimately leads to several program
changes per day. And VERICUT helps us
with a fast and reliable simulation, so
collisions are de nitely excluded.”
VERICUT PROVIDES SECURITY
CGTech’s simulation software VERICUT
has been an ef cient tool when it comes
to simulating, verifying and optimising
CNC machines since 1988. For the user,
it is the safest way to simulate the real
machining situation with a virtual machine
on the desk. The simulation software is
completely independent of the control,
CAM system or CNC machine.
The complete machine environment,
including the clamping devices, tools and
zero points, are transferred from the CAM
system to VERICUT via an interface. This
transfer only takes a few minutes, and if
an error is detected, the simulation can
be continued from that point, after the
issue has been recti ed.
REDUCED DOWNTIME
Thanks to the process reliability gained
through VERICUT, Trumpf was able to
reduce downtime due to repairs caused by
collisions to zero. In addition, unmanned
production over the weekend is also an
At Trumpf Maschinen Austria, frames and
pressure beams for the bending machines
produced in Pasching are manufactured
on one of two large 6-axis horizontal
machining centres
issue at Trumpf in Pasching:
“This is supported by VERICUT’s ability to
ensure the validity of the CNC program
before it is run on the shop oor, providing
everyone with the con dence that the
machine tool and workpiece will be safe
to run unmanned,” Andreas Mayrhofer
enthusiastically points out.
He concludes: “We are currently in the
process of converting to the latest
VERICUT software version. The new
version offers even faster rendering with
much more realistic and detailed views of
the machines and the machining process.
“The enormous increase in performance
in the NC program review and the free
VERICUT Reviewer will ensure signi cantly
shorter test times. We are also interested
in the feed optimisation capability offered
by the VERICUT Force module, with which
we expect to achieve a further leap in
productivity.”
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | November 2020 35
/www.machinery.co.uk