POCKET ROCKET GOES EVEN FASTER WITH hyperMILL

Vetech Hayabusa in Mini
Vetech Hayabusa in Mini

Vetech Company has applied its expertise to the motorsport sector, converting the Suzuki Hayabusa motorcycle engine for use in the Mini motorcar. Vetech gave the gear selector barrel to all the leading CAM vendors and asked them to program it. OPEN MIND provided the most efficient and productive solution with an intuitive presentation of hyperMILL CAM software.

At Vetech Product Design & Development, the designing and manufacturing complex aluminum mold tools, military sensors, and the innovative Hayabusa engine, the previous CAD/CAM system was struggling to cope with component complexity. It is here the expertise of hyperMILL CAM developer OPEN MIND Technologies has come to the fore.

hyperMILL BRINGS ANTI-COLLISION CONFIDENCE BACK TO VETECH

Vetech was using an outdated CAD package with an integrated CAM system for all machining tasks. One day the VMX42M machine did a rapid traverse between two points, crashing into the fixtures and ruining the spindle. The result was weeks without the machine whilst they had to install a costly new spindle. The lack of collision detection was their major cause for concern, so they wanted to change their CAM software. They were witnessed by hyperMILL CAM software.

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VETECH GETS INTO GEAR WHEN SELECTING THE hyperMILL

Mini with Hayabusa engine

When re-designing and re-manufacturing the Hayabusa 1300cc engine to fit into a Mini meant they had to re-position the gearbox and add a reverse gear. They tried to program a gear selector barrel but the task was almost impossible with their old package. They gave the gear selector barrel to all the leading CAM vendors and asked them to program it.

Collision prevention was definitely a critical factor. hyperMILL certainly convinced Vetech engineers at this point, providing the most efficient solution compared to other software. Furthermore, they needed to achieve faster programming times for aluminum mold tools – hyperMILL was once again streets ahead for mold tool programming.

THE FASTEST MINI RE-DESIGN IN THE WORLD…?

Programming the eleven core components of the re-modeled engine with hyperMILL, Vetech has certainly benefitted from the CAM system. The ability to program and machine complex parts with confidence in the collision avoidance system is important to Vetech. OPEN MIND has completely modeled the work envelope into the CAM system with fixtures, machine spindle, tool holders, and the 4-axis rotary table all factored into the model

Mini with Hayabusa engine machined with hyperMILL

From a time-reduction standpoint, they programmed an aluminum mold tool for Hayabusa inlet and exhaust caps. With the previous system, it took 20 hours to program and with hyperMILL, this same tool was completed in less than 10 hours. The upper housing of the engine consists of seven individual set-ups. With its previous CAM package, Vetech couldn’t carry the stock model from one process to the next.

hyperMILL has slashed off-machine programming times as well as on-machine cycle times. It has also improved the quality, surface finish, and consistency of our parts and mold tools.”

 – Andy Smith, Senior Design Engineer at Vetech

MOLDING A BETTER FUTURE

With over 60% of Vetech work consisting of aluminum mold tool production, it is important for them to reduce the lead times. In most cases, they are expected to design, program, and manufacture the mold tool (cavity and core) and then mold the plastic prototypes and conduct thermal and stress tests within 3-4 days. To achieve this, their programming and machining times have to be extremely efficient.

Hayabusa engine machined with hyperMILL
Hayabusa engine machined with hyperMILL

SLASHING OFF- & ON-MACHINE PROGRAMMING TIMES

The previous tool they manufactured took 8 days to program the mold tool (cavity and core). hyperMILL enabled programming the same tool in 3 days, which means an astonishing 60%+ programming time reduction. On the other hand, the machining strategies reduced the machining cycle times by an additional 50%

CAM programska oprema

In addition, it has also improved the quality, surface finish, and consistency of the parts and mold tools. OPEN MIND has achieved all of this whilst giving Vetech 100% confidence in the machining strategies and toolpaths, something that is credited to the exceptional anti-collision system.