New machining techniques and control capabilities require greater simulation capabilities. VERICUT supports:
CNC control features which rotate or define 3D coordinate systems and offsets Some newer CNC controls provide transformation routines that enable the NC program to be independent of the machine’s physical axes configuration. These features require VERICUT to read the NC program and do the same transformation in order to move the "virtual" axes. Some of these complex transformations establish a new secondary coordinate system, such as TRANS, ROT, ATRANS, and AROT on the Siemens 840D control, or CYCLE DEF 19.1 on the Heidenhain TNC control.
Some transformations allow programming in a virtual "workpiece" coordinate system, such as TRAORI on the Siemens 840D control, or M128 on the Heidenhain TNC control. Other control transformation features enable work offsets to dynamically adjust axis positions based on rotary axis positions, such as Fanuc’s G54.2.
Automatic part transfer between fixtures Machine tools that automatically transfer the workpiece from one fixture or machining station to another (such as between the main spindle and sub-spindle of a lathe, for example) require a more complex simulation. Clamp and unclamp the workpiece with fixtures or other automatic work holding devices. VERICUT also has the ability to simulate automatic transfer of the machined stock between fixtures. In turning operations, the stock can be divided into two pieces, such as when a piece is clamped in a turning center’s sub-spindle and cut-off.
The Index mill/turn machining centers use a unique programming approach to control and synchronize different axes groups, called "channels." Index’s multiple channels are programmed using a main program which calls sub-programs for each channel. In the VERICUT simulation, the axes for each sub-system (channel) is driven by a sub-program which is synchronized with another sub-system driven by a different sub-program.
Facing head (or "programmable boring bar")
A facing head is a milling machine head or spindle attachment containing a programmable linear axis perpendicular to the spindle axis. A facing head is usually used on large horizontal machining centers, such as machines from Giddings & Lewis, DS Technologies, Ingersoll, Waldrich Coburg, and others. The tool attached to the facing head is a single point turning tool or boring bar. Simulation of the facing head motion requires VERICUT to spin all components connected to the spindle, and remove material with the spinning tool.
CNC controls which allow programming of the tool axis using IJK tool axis vectors
Some newer CNC controls allow programming a machine tool’s rotary axes by specifying the cutting tool’s orientation relative to the workpiece using IJK vectors, rather than the traditional direct programming of the A, B, or C axis angles. The CNC control is doing the work typically done in the post-processor. Simulation of this motion requires the equivalent calculation to drive VERICUT’s virtual machine axes. Advanced Machine Features enables VERICUT’s IJK-to-ABC calculation function.
Turning operations which are not symmetric about the lathe spindle, such as crankshaft turning
Special turning operations not symmetric about the lathe spindle are used in some machining operations. These asymmetric turning operations, such as when turning the connecting rod pin on an automobile engine crankshaft, can be simulated in VERICUT. This also supports non-turning material removal using a non-rotating tool, such as when broaching.
Parallel kinematics machines
Some machine tools orient the tool axis using a linkage mechanism rather than the traditional rotary axes. This is commonly called "parallel kinematics." VERICUT specifically simulates the Ecospeed® tripod head from DS Technologies. Other kinematics are available upon request.
Stop on contact
VERICUT supports commanding machine components to move until they contact other components. For example, using this feature it is possible to simulate a turning center bar feed action where the workpiece feeds out until it contacts a bar stop, or simulate automatic workholding devices such as a programmable steady rest that advances it’s rollers until they touch the workpiece.
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, GE Aviation (formerly Aerostructures Hamble) 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.
VERICUT software removes this potentially hazardous stage by allowing ReedHycalog to do all of their prove-outs on a computer.
VERICUT verification detects errors such as: inaccurate programming, incorrect tool path motions, rapid motion contact, collisions with fixtures and clamps, tool shank and holder collisions, & CAD/CAM and post processor bugs.
VERICUT Machine Simulation supports G-codes and Multi-axis (5-axis or more) support for milling, drilling, turning, grinding & EDM machines
