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Case Studies
Stamping-Tool Supplier Uses Integrated CAD/CAM
Suite to Work More Closely, Effectively with Customers
Rosell Werkzeugbau & Stanztechnik
GmbH, a metal-stamping tooling company,
serves the automotive industry
mainly, but also other sectors. Working
closely with the customer is an
important part of tool development
for Rosell. That was more difficult a
few years ago, when the company
communicated with clients through
A0 drawings. Seeking design and manufacturing
software that would better
represent the toolmaker’s ideas in customer
meetings, Rosell settled on the
VISI integrated CAD/CAM system
from Vero Software plc. The company
credits its business progress since
2003 in part to its use of VISI products.
Explains Franz Rosell, managing
director of Rosell GmbH: “Once the
order has been received, we complete a
strip layout and preliminary design for
all forming stations and present the
data to our customer.” Back when such
presentations centred on drawings,
they didn’t really make very clear to
the customer how the tool would
operate. These days, the meeting lasts
longer, but the 3D representation of
the tool that is shown gives the customer
a much clearer idea of the tool
mechanics. Technical discussions conducted
at this stage now can go into
much greater detail.
All tool design and manufacture at
Rosell is performed using VISI, which
represented a “quantum leap” from its
previous software, according to Franz
Rosell, “All our designers are fully
22 European Tool & Mould Making ■ September 2009
trained, but almost all staff members
are able to work with VISI,” he says.
About eight or nine other engineers
can use VISI to extract the information
they need from a model.
The initial tool design process has
three typical steps. First, the 2D blank
shape is developed from the 3D model
using VISI Blank, an integrated solution
that analyzes material behaviour
during the forming process so as to
ensure accurate identification of potential
problem areas prior to design of
the actual die. After blank development
is complete, the designer uses
VISI Progress for designing the bending
and forming stages and undertaking
production of the 3D strip. The software’s
step-by-step unfolding capability
gives the designer complete
freedom to experiment at this stage.
When the customer is satisfied with
the process plan, 3D tool design begins.
Customer approval of the design
is based on a presentation of the individual
plate components, whose 3D
details, now that VISI is used, Rosell
and its customer can adjust together in
real time.
Tool manufacture follows. The
forming tools that shape the component,
hardened after premilling with a
material oversize allowance, are hardmilled
to size using VISI Machining, a
3D CAM solution that can be used in
the CAD/CAM office or on the shop
floor. A VISI viewer enables the engineer
to check relationships among the
individual parts of the tool assembly
in the 3D model in order to prevent
problems during assembly. Fine-tuning
of the tool begins with data produced
using VISI Blank. Then a prototype
is created for simulation purposes
before the completed tool is assembled
and tried out for the customer.
“It is easy to notice the progress we
have made since switching to VISI and
3D tool design,” says Franz Rosell.
Vero Software plc
CHELTENHAM, GLOS, UK
www.etmm.info/2009/09/034