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Other simulation options include the recently updated CAD/CAM simulation modules from Aachen, Germany-based software components developer ModuleWorks.
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NCSIMUL 2021 provides an improved user interface and full integration of CAD and CAM connectivity with CAD native format reader, simplifying the data transfer for the end user.” “By providing G-code simulation since the beginning of the ’90s, NCSIMUL provides true digital twin machines, with all the functionalities CNC users will find on the real machines. “NCSIMUL is a direct slice of the company vision,” said Proisy.
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He said NCSIMUL provides a platform of solutions, from design to metrology, including the full process of engineering and manufacturing. “Hexagon is helping improve quality and productivity for NCSIMUL users with accelerated implementation, working with cutting tool and CNC machine providers,” added Silvere Proisy, NCSIMUL U.S. The Hexagon NCSIMUL full G-code simulator showing a mill-turn machining process simulation. A graph shows the evolution of the power on the tool, so it can be limited to avoid possible flexions, overheating and premature deterioration. “It takes into account the type of material, the chosen tool, and the definition of its angles,” Legoupi said. Hexagon Technical Director Philippe Legoupi said it is used as a limiting parameter, which optimizes the program and limits power, avoiding risks of breakage. Optipower compliments the Optitool module by adding the necessary power and torque to remove material.
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Helping manufacturers bring their factories in line with the Industry 4.0 philosophy of smart production, Hexagon said its NCSIMUL 2020.1 simulation update introduces an additional parameter to NCSIMUL Machine. Hexagon’s latest NCSIMUL CAM simulation in the company’s Product Software portfolio adds new features to its Optipower and 4CAM programs, as well as many interface enhancements. Third-party simulation systems like CGTech’s VERICUT and the NCSIMUL package offered by Hexagon Manufacturing Intelligence Division, North Kingstown, R.I., typically feature higher-fidelity visualizations of the entire machining process based on the actual G-code running the process rather than on CL data. CGTech’s machine building specialists even go as far as extracting parameter settings from the CNC and incorporating them into the digital twin for the most accurate ‘twinning.’” “Digital twin machines must accurately simulate machine motions, mimic tool and work offset handling, process subroutines and emulate complex control functions that change motion behavior on the machine.
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“Simulation the post-processed NC code that drives the actual machine offers the highest level of verification,” he noted. Today’s users need better digital twin virtual machines, Granata said.
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“Users want simulations to look more realistic and run faster, while still calculating extremely complicated material removal and collision checking.”
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Manufacturers are looking for improvements in simulation speed, visual quality and accuracy, noted Gene Granata, product manager for VERICUT NC simulation, verification and optimization software, developed by CGTech, Irvine, Calif. These give highly realistic visualizations of all the parameters in machining, from cutters to machine tool components and accessories-even the parts being cut. Users can also turn to third-party simulation packages that feature more accurate and sophisticated G-code simulations. Most CAD/CAM systems offer a basic level of simulation, based on cutter location (CL) data. Today’s simulation tools offer a variety of ways to prevent such costly programming errors. Ensuring top quality means using high-fidelity simulations to set up the cut. Even a minor error in, say, a titanium aerospace component can be a major expense. Manufacturers must avoid costly machine errors that cause catastrophic damage to both machine tools and expensive workpieces. The latest simulation packages offer CAD/CAM and NC-level code-checking to ensure fast, error-free machining processes The Reviewer App in VERICUT illustrates a program showing that the machine spindle will collide with the part during the process.