(Irvine, California – Monday, June 5, 2006) – CGTech is now shipping the latest version of VERICUT CNC machine simulation and optimization software. VERICUT 6.0 has many new features designed to increase the ability of CNC manufacturing engineers to analyze and optimize the entire CNC machining process in order to increase manufacturing efficiency.
‘Due to global competitive pressures on our customers CGTech is increasingly challenged to simulate more complex processes and more complex machines,” said Product Marketing Manager Bill Hasenjaeger. ‘VERICUT 6.0 ties these complex processes together with the ability to simulate multiple setups in a single simulation session.”
VERICUT 6.0 also includes enhanced collision checking that monitors spindle states for milling and turning simulation, enabling VERICUT to catch common programming errors with spindle and cutting tool usage. Additionally, significantly enhanced simulation of complex cutting tool shapes commonly used in production processes shows the NC programmer or manufacturing engineer exactly what will happen when using the tool.
‘The result of this work is a tightly unified environment for simulating complex mill/turn multi-function machining centers for production processes,” said Hasenjaeger. VERICUT 6.0 leverages the results of simulating these complex processes with the ability to create inspection instructions, CNC inspection programs, and automated process documentation using the simulated workpiece. Because of VERICUT’s accurate feature-rich in-process model of the simulated workpiece, the inspection and process documents utilize and accurately reflect the state of the workpiece at any stage of the process.
To ensure VERICUT’s simulation is as accurate as possible, CGTech has partnered with many key machine tool builders, control manufactures and CAD/CAM companies. CGTech’s Technology Partner Program establishes a cooperative working relationship with a goal of helping mutual manufacturing customers maximize their success and productivity.
Some of the new and improved features users will find in VERICUT 6.0 include:
Multiple Setups in a Single Session With the new Project Tree in VERICUT 6.0, the manufacturing engineer can organize all his NC process steps in one place and the workpeice(s) transition from setup to setup automatically during the simulation. Each setup has its own CNC machine, fixtures, tools, NC programs and simulation settings. The cut stock moves from setup to setup, with automatic orientation. Once a user selects the CNC machine configuration, the stock, fixture and design component information is attached to the machine, ready to simulate the entire set of machining operations.
Simulate Machines with Multiple Synchronized Tools VERICUT 6.0 now offers the capability to synchronize up to 32 machine ‘channels” or machines with multiple synchronized CNC controls. VERICUT’s virtual machine is organized into multiple sub-systems that can all synchronize together seamlessly.
New Tool Manager Speeds NC Program Optimization VERICUT’s NC program optimization module–OptiPath®–is easier to implement thanks to a redesigned Tool Manager. OptiPath tooling data is now stored inside the Tool Manager. This simplifies the implementation by placing all relevant tool information in one place. Creating new tools has also been simplified. The new tool assembly wizard allows the user to create a new milling tool in one simple panel by answering a few questions.
Model Export Enhancements Model Export creates CAD models from the VERICUT ‘in-process’ cut model generated by simulating an NC program. The model includes machined features such as holes, ï¬llets, corner radii, pocket floors and walls – exactly as it is cut on the CNC machine. In VERICUT 6.0, Model Export outputs features where possible and also ’synthetic features” when individual features are not possible or desirable (such as ’scallops” created by a ball endmill).
Create CNC Probe Programs and Inspection Sequences VERICUT is an ideal place to create probing routines because of the ‘in-process’ model which is not available anywhere else in the CNC manufacturing process. Rather than having to create additional ‘manufacturing” CAD geometry that ‘hopefully” represents the as-cut workpiece, using VERICUT’s simulated in-process feature geometry to create the CNC probe program makes on-machine in-process inspection a practical reality. In addition to on-machine probe programming, VERICUT 6.0 allows the creation of customizable inspection reports in HTML or PDF format for use by machine operators or quality control staff.
Tool, Spindle, Cutter and Holder Enhancements VERICUT 6.0 detects incorrect tool & spindle cutting conditions before the NC program is run on the machine. For example, an error is reported during a turning operation if the cutter enters material and:
The turning insert in not properly centered on the material.
The drill is not on the turning center-line for the drilling operation.
The part is spinning in the wrong direction for the selected tool.
A milling tool will likewise report errors when:
The milling spindle is not spinning.
The milling spindle is spinning in the wrong direction.
A probe tool will also report collisions or errors when:
The probe tip contacts anything when not in probing mode.
The probe’s stem or holder contacts anything, whether probing mode is active or not.
The spindle is turned on, or is spinning about a maximum allowable speed for a probe.
Holder collisions in VERICUT 6.0 no longer remove material. All collisions create a volume that is available for later analysis in order to correct the NC program or process problem.
Inspection and Measurement Enhancements X-Caliper allows the user to measure thickness, volume, depth, gaps, distances, angels, hole diameters, corner radii, scallop heights, etc. It has been improved to optionally highlight features, such as all planes on the same level. The user can also now view and measure all tool collisions, even after subsequent machining operations have removed them from the screen.
Colors Up to 128 cutting colors may now be chosen. Additionally, the workpiece can be colored according to feed rates or tool color or tool sequence. Any color display may be chosen without re-running the simulation.
Minimum Cutter Height VERICUT 6.0 can automatically calculate the minimum cutter extension for all milling tools. This feature applies to the first two holders in the tool assembly, such as an extension and a holder body. At the end of the simulation the user will be notified of any tool assembly changes and prompted to save the modified tool library.
Constant Gouge Check Redesigned VERICUT’s constant gouge check is now much faster, simpler and more accurate than before. It also works on a single pass and requires less memory.
64 Bit Hardware Support VERICUT runs as a 64 bit application on Windows XP64. This increases virtual memory access from Windows XP 2GB application limit to the hardware’s maximum.
CAD/CAM Interfaces All interfaces have been updated to support multiple setups. The coordinate systems defined in the CAD/CAM software are used to locate models for each setup.
VERICUT runs under Windows and UNIX operating systems. With headquarters in Irvine, California, CGTech specializes in numerical control (NC/CNC) simulation, verification, optimization, and analysis software technology for manufacturing. Since 1988 VERICUT has become the world-wide industry standard for simulating and verifying CNC machining. With subsidiaries in the United Kingdom, Germany, France, Italy and Japan and resellers throughout the world, VERICUT software is used by companies of all sizes, universities and government agencies. For more information, visit the CGTech web site at or e-mail: info@cgtech.com
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For more information, contact: Bryan Jacobs (949) 753-1050 info@cgtech.com
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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.
