The Importance of Control Emulations Role in NC Program Simulation David Sutkay, CGTech

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The Importance of Control Emulations Role in NC
Program SimulationDavid Sutkay, CGTech
Since 2004
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Who is CGTech?

• Worldwide leader in CNC machine simulation and NC
  program optimization software with VERICUT

• Privately held, established in 1988
• Headquarters in Irvine, California
• Offices in UK, France, Germany, Italy, Japan,
  Singapore, China

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Why Simulate?

• NC programs often inherently contain errors
• Programmers can make mistakes
• (or spend excessive time avoiding them!)
• CAM systems canintroduce errors
• Post-processors canintroduce errors

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Generic Verification Technology

• Faceted poly-cut
• Inaccurate model
• Poor image quality
• Slows down while cutting
• Prone to failure

Millions of triangles
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VERICUT Verification Technology

• Feature rich models
• Accurate
• One model for all operations
• Fast and consistent processing time

Real Features
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CNC Machine Simulation
The cost of an NC machine has gone up
considerably in the last 5 years. Manufacturers
need to protect their investment. --
Modern Machine Shop
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Why Simulate the Machine?

• Detects collisions and near-misses between
  machine components
• Eliminate costly machine repairs and delays
• Increase shop safety
• Improve process efficiency
• Reduce the time it takes to implement a new
  machine

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Machine Simulation

• Supports multi channel processing
• Parallel kinematics
• Unlimited number of axis
• Auxiliary attachments tail stock, steady rests,
  part catchers, bar pullers, etc. 
• Automatic workpiece transfer to pick-off or
  sub-spindles

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Machine Simulation Technology

• Continuous collision checking
• All moving components swept through space
• Easy job setup and use
• Logical separation between machine configuration
  and job-specific information
• Accurate configurable machine and control
  models
• Emulation of complex control features

Step
Continuous
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Requirements for Achieving an Accurate NC
Machine Simulation

• Machine models
• Define in software or Import CAD models
• Machine kinematics
• Define in software
• Control File

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What is a Simulation Control File?

• File that contains
• a list of machine codes, machine code format
• Information about various control states
• Rules for grouping machine codes, executing those
  codes, and how to simulate them

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Control Types

• ISO Standard Fanuc, Yasnac, Mitsubishi and many
  other controls that follow standard word-address
  syntax
• Siemens 840D, also older Sprint, 8-series, and
  840C
• Heidenhain Conversational and ISO modes
• NUM French-made control
• Mazatrol ISO mode
• Toshiba
• Many others

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Special NC Program Features

• Variables, Subprograms, Macros
• Subroutines, Looping and branching log
• Multiple synchronized CNC controls
• Look-ahead or 3D cutter compensation
• Tool tip programming tool length compensation
• Gage length reference point programming
• Canned cycles and fixture offsets
• Rotary axis pivot points

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Simulating with the 840d Virtual NC Kernel (VNCK)

• Standalone Windows program containing the NC
  kernel of the 840D control
• VNCK reads and processes an 840D NC program,
  sending axis position information to machine
  simulation software

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Benefits of Using VNCK

• Your virtual CNC machine simulation is driven by
  the same 840D control software that drives the
  actual CNC machine
• Complete coverage of the 840D programming
  language. This includes
• axis acceleration behavior
• unique motion algorithms
• ORIVECT, ORIAXES and COMPCURV, etc.
• 840D procedural language (PROC) processing

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Machine Simulation Examples

• New machining techniques and complex control
  functions require sophisticated simulation
  capabilities.
• Following are a few examples showing what can be
  achieved

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Example Mazak Integrex 300
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Example Mazak Integrex e800
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Hermle c30
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Example DMG DMU60T
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SNK RB200F
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Example Dixi DHP40
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Example Mori Seiki MT2000SZ
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Example Head Changer
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Example Index G200
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Many Machine Tool/Control Simulations Available
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Why Optimize?

• Reduces machining time
• Faster time-to-market
• Increased productivity
• Prolongs cutting tool life
• Reduces machine tool wear
• Improves finish quality
• Produces consistent results across machines,
  shifts, operators, and programmers (even if the
  expert isnt around)

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Optimization Methods
Improper feed rates can damage the machine,
cutter, and/or the part

• Optimize by hand
• Very time-consuming error-prone
• Not all programmers have proper expertise
• Difficult to visualize the cutting conditions for
  each cut
• Use CAM software
• CAM software doesnt know the in-process material
  for each cut
• Adaptive controls
• Reactive vs. pro-active
• VERICUT software

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How Optimization Works
faster and better NC Programs!
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Extra Optimization Benefits

• Decreased Cutter Wear

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Tool 1 Optimization Results
Ingersoll 2 FormMaster Wave
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Tool 2 Optimization Results
Ingersoll 1 FormMaster Wave
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Tool 3 Optimization Results
Ingersoll ¾ Finish Ball Backdraft
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Tool 4 Optimization Results
Ingersoll 2 FormMaster Wave
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OptiPath Results
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Questions to Ask when Choosing Simulation Software

• Does it verify the G-code program?
• Does it support advanced CNC features?
• macro language, probing, branching, variables
• How much experience does the developer have in NC
  verification/simulation?
• Does it create an accurate in-process model?
• Can it optimize NC program feed rates making
  your machines run more productive?
• Can it verify cuts with different tool
  orientations and tool axis changes?

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Summary

• Machine simulation software, with a properly
  configured control
• Ensures programs will not scrap the part, break
  cutters, crash the machine, etc.
• Eliminates the need for prove-outs
• Protects your machines, parts, and processes
• Lights-out, first run machining
• Ensures that the part is dimensionally accurate
• Increases your competitive edge!