Based in Velbert, Germany, Volker Gehlen Werkzeugbau GmbH (VGW) has a 30-year history of providing innovative solutions for challenging stamping and forming applications.
Moreover, the company is going from strength to strength, with the acquisition of a stamped-component manufacturing company and new machines — plus the addition of new products.
Managing director Volker Gehlen says a vital factor in the company’s success has been changing all CAD/CAM operations to VISI’s integrated 3-D tool-making solution (
www.visicadcam.com).
Indeed, it was the software’s ‘consistent operating philosophy’ for CAD and CAM that initially made it a front-runner when VGW was looking to upgrade.
Mr Gehlen says: “We made the final decision after a trial installation and training from VISI’s German
reseller, Mecadat AG. VISI proved to be so easy to operate; it was also so intuitive that it was giving us a high level of efficiency after only a few days.”
VGW’s turn-key solutions for customers throughout Europe include technological advice and prototype construction, as well as tried and tested full suites of tools.
However, Mr Gehlen says that investing in technology helps the company to stay at the top of its game. “We’ve invested heavily in CAD/CAM, and we use VISI exclusively to design our tools. We can’t imagine doing it any other way now.”
Three designers each have a workstation equipped with VISI Modelling, plus the VISI Progress stamping-die module for strip layout and 3-D tool construction.
Lukas Gehlen, who is in charge of design and production, says: “The hybrid modelling combines a Parasolid kernel with surface modelling, giving us a faster and more flexible work-flow that can handle any geometry type.”
Two additional workstations feature VISI Modelling and 3D Machining to provide NC programs for the company’s four CNC milling machines.
A more recent acquisition is the VISI PEPS licence, which was bought to support the generating of NC programs for three of the latest Sodick wire-cut EDM machines; one of these — an AQ 1200 L — can process material that is more than 1.4m wide and weighing up to 4 tonnes.
Other software modules used by VGW include VISI Compass for manufacturing automation; this uses pre-set processing definitions to automatically create feature-based NC programs for drilling, milling and wire erosion operations. The shopfloor also runs VISI Viewer for checking CAD models in a paperless environment, to verify where each component fits.
Customer support
However, Mr Gehlen says his company offers much more than just high-quality tools. “We support our customers from the original idea right through to the finished product; and VISI plays a key role at the start of that process by helping us carry out a feasibility study and 3-D evaluation to confirm that the parts will function correctly.”
VISI is also used to edit 3-D CAD data supplied by customers, which is then transferred to VGW’s ProJet HD3500 3-D printer.
This produces fully functioning acrylate components for prototype and pre-series parts. “We can print entire assemblies, including moving parts, with a maximum size deviation of 0.2%. If a preseries part is ordered, we 3-D print it first so the customer can test it in terms of size, form and function.
“We then supply the first 50 metal parts, so the client can fully test the form and fit during the development stage without having to pay for costly prototype tools and modifications.”
VGW’s traditional tool-making and stamped-part production has been strengthened by the purchase of a 200-tonne press. This high-tech machine, which has a servo drive that gives full control over the ram speed and acceleration, gives 60% more parts while saving power at the same time.
“We can test and optimise the newly developed tools under totally realistic production conditions, giving the customer a tool that can be used immediately.”
In conclusion, Mr Gehlen says: “With VISI, we can design and produce our tools much more efficiently, and we can react more flexibly to customer requirements. Being able to seamlessly import data into the core VISI Modeller means that there are no problems with customers’ files; this saves a tremendous amount of time compared to how long projects used to take.
“Indeed, VISI makes it significantly easier for us to implement ideas; and as tool optimisations can be made in a shorter time, we can significantly reduce the overall cost of projects for our clients.”