AUTO-DIFF™ enables you to compare a CAD design model to a VERICUT simulation automatically detect differences. Using this module, anyone involved in the production process can identify incorrectly machined areas. AUTO-DIFF is also used to detect a possible weakness or mistake in the design.
Why Use AUTO-DIFF?
Often, from the time a part is designed to when it is ready to be machined, the design has passed through a number of different people, departments, companies, and CAD/CAM systems. In the end, it is difficult to tell if the tool path accurately reflects the original design intent. Without AUTO-DIFF, the only way to be sure is to cut the part and do a first article inspection.
By using AUTO-DIFF to compare the simulated model to the design model, you are assured the tool path accurately represents the original design concept. This reduces the time it takes to cut the first production-worthy part.
AUTO-DIFF also reduces the time it takes to prepare an NC tool path. Programmers check for gouges or excess material while working on the program. Problems are then identified and corrected before machining.
Solid Comparisons
Solid or surface models from most popular CAD/CAM systems can be used. The design model is compared to the simulated machined part to identify gouges and excess material. AUTO-DIFF also enables you to compare the cut model with another VERICUT simulated model. This function is useful for comparing different operations such as roughing cuts and finishing cuts.
Surface Comparisons
A surface, a set of surfaces or the skin of a solid model can be compared with the simulated part. The surface is overlaid on top of the simulated part, and gouges and excess material are displayed. Large amounts of data from very complex tool paths can be quickly compared. The design model does not need to be watertight, nor does the entire part need to be included.
Point Comparisons
When solid or surface model data does not exist, 3D points can be used. The points are overlaid on top of the simulated part. Inspection points from CMM or manual methods are compared to the NC tool path to accurately detect errors or out-of-tolerance conditions.
Constant Gouge Checking
AUTO-DIFF performs constant gouge checking during material removal simulations. It is not necessary to simulate the entire NC program before checking for gouges. With constant gouge checking, VERICUT enables you to identify and correct the problem immediately as it occurs.
Previous cutting operations can be ‘protected” from any further machining. Any material removed from a protected area is highlighted and reported as an error. Design models, rough stock, errors, and cuts are all assigned user-defined colors to more easily identify gouges, collisions, or excess material.
AUTO-DIFF Reports
AUTO-DIFF generates a comprehensive error report including information such as type of error, tolerance value, all tool path records out of tolerance, error location, and summary of AUTO-DIFF results. The report can be sent to a printer or saved as a text file. Reports and graphics can be generated interactively or in batch mode.
Airbus is selling so well that the demand to increase build rate has never been higher. BAE Systems (Filton, UK) needed a simple way to improve throughput - it found the answer in VERICUT.
With VERICUT, engineers at Stellex Monitor modeled the Sidewinder and Spar Mill machines.
Tell Tool of Westfield, Mass., has integrated VERICUT CNC simulation software into its numerical control program prove-out process.
VERICUT enabled us to start ordinary production after a minimum of time. Since this product is new for Volvo Aero Norge and our company had never before had parts with similar machining complexity, it is difficult to estimate the amount of cost saving.
Before implementing VERICUT, the company experienced the usual time-consuming and expensive manufacturing problems related to NC program prove-outs such as scrap loss, broken tooling, and a danger of occasional machine crash.
Over the last two years, AH has used Machine Simulation to speed the implementation of several new 5-axis machine tools.
VERICUT showed the NC programmers leftover or heavy stock." And the software detected a couple of places where the depth of cut was too large and tools were shanking out," said Collings. They then went back and corrected the errors in the tool path before
Dassault, Seclin initially purchased VERICUT in order to reduce the number of manual prove-outs using polystyrene material, which represented a significant expense in terms of time and money.
VERICUT enabled the designers and programmers see exactly what they were building as and in-process model in different stages of the machining cycle.
We utilized VERICUT to verify the CNC programs for cutting the tooling before they were sent to the machine control,
To protect their investment, they have been using VERICUT since 1996. They have two people to verify the accuracy of their G-code files.
"When we first started using OptiPath we concentrated on the feed rate option; now we use the constant chip thickness capability. With jobs up to 200 hours long, 50% saving is significant like having another machine tool."
The entire process took less than two hours and no manpower was required, whereas, creating the same pattern manually (the old way), would have taken one of our designers several days.
The verification process stays ahead of the actual machine position in the NC code being verified. Opera-tors can see errors before they occur.
The bottom line? Using VERICUT has made Supreme's existing machine tools more productive. Enthusiasm is up, delivery times have been reduced, and pricing is more competitive.delivery times have been reduced, and pricing is more competitive.
Using VERICUT to compare the electrode burn with the mold cavity ensures that we have all the correct clearances in the electrodes and that we have 100% clean-up." says Allen.
If I was using VERICUT at the time I would've caught the problem, and had a chance to fix it before it damaged the part.
Now I rarely see the potential crashes because the students find and correct them before I review the work. Catching those costly problems is a non-event now!
VERICUT can change speeds and feeds according to cutting conditions including difference in material and tooling. It is done automatically; the programmer does not have to make even one manual insert into the code."
Flying shrapnel from shattered cutting tools and components is avoided by using VERICUT to test student programs before they are run on NC machines.
The NC programmers at Ingersoll also rely on the simulation software to prevent mistakes when programming complex, five-axis parts.
After creating the NC programs in Mastercam, they began simulating the machining process in VERICUT by simulating the G-code data. There often can be a difference between the motion as programmed and the code after it's run through the post processor
After selecting VERICUT for third-party verification, each NC programmer attended two days of basic training where they experienced first-hand the type of results they could expect to achieve.
The program simulates milling, drilling, turning, wire EDM, and mill/turn machining operations using both G-codes and CAM output.
VERICUT provides simulation capabilities for the all the 3-5 axis and wire EDM parts, with focused control over the orientation of our 5-axis machine tool including the cutters used on that machine.
The inspection probe is created as a tool in VERICUT so the complete in- cycle gauging sequence is checked for collisions.
The bottom was machined first. This effort took about 24 hours from start to finish. By using VERICUT software from CGTech, Elliot was able to test the NC program for any problems before it was ever cut on the machine.
Cosworth Racing Integrates Walter TDM Tool Management into Manufacturing Systems
With data exported from NX, Vericut simulates the cutting process on the shop floor utilizing the machine G-code to detect any issues prior to NC Program release.
