Precision Machinery Maker Verifies Innovative Programs

NCSIMUL enables operators to view a simulation of an operation and verify its performance. “Then they can have a better, warm-and fuzzy-feeling about a process that may seem a little bit off the wall,” Moran said. “That’s where NCSIMUL helps us go above and beyond what the CAD/CAM software can do. It has enabled us to implement innovative, outside-the-box processes. One of the biggest advantages is that there’s less dry run time because the operators can trust what’s being put out. NCSimul really helps with our first runoff.”

Bretting employs NCSIMUL on three CNC machines: A five-axis machining center, a gantry machining center with a 3+2 rotary head, and a second gantry machining center. The three machines are the ones most used for “off the wall, tight tolerance work,” Moran said.

Initiating the verification process is quick and simple, according to Moran. When part models, fixturing, and tooling are defined in the CAD/CAM program, the information can be directly selected and exported to NCSIMUL. After adjusting for details such as the position of the part on the table and various clearance aspects, the operator can load the CAD/CAM program and begin verification.

NCSIMUL also provides accurate estimates of total process run time. The software records factors that often aren’t included in run time calculations, such as rapid feed rates and tool change times. “You do get a much better sense of when a job is going to be done and off the table,” Moran said. In some cases the software can be an aid to constructing accurate quotes, but the nature of the production scheduling at Bretting means that the software isn’t normally used that way, especially when making parts for the company’s product lines, Lizak said, “Usually it’s ‘okay guys, we have to have this out the door today.’"

It is difficult to quantify savings that can result from incidents that the software prevents from occurring. However, Lizak said, “Use of the software has helped us identify potential collisions between the workpiece and machine, with absolutely zero risk to the machinery. With its abilities to verify some of the tight clearances that we have to deal with, I feel it has paid for itself.”

Moran concluded that the NCSIMUL software has been a key factor in maintaining Bretting’s manufacturing momentum. “The ability to use creative programming strategies and verify them is providing the next step as far as our company’s desire to set a tone and continue to be an innovator,” he said.

Read the full article here: http://advancedmanufacturing.org/precision-machinery-maker-verifies-innovative-programs/

NCSIMUL OPTITOOL | Air Cuts Only Optimization

Enhanced CNC Optimization in NCSIMUL

from SPRING Technologies

Minimizes Air-Cutting Motions and Reduces Machining Times

Boston, MA July 26, 2017 – SPRING Technologies, developer of advanced software for CNC machine tools, has enhanced the optimization capabilities of its flagship NCSIMUL package. The improvements are contained in the NCSIMUL OPTITOOL module of NCSIMUL MACHINE, SPRING Technologies’ CNC machine verification software for simulating, verifying, optimizing, and reviewing machining programs.

The new capabilities include algorithms that transform working feed rates into rapid feed rates or specified maximum feed rates for approach and retract motions in both circular and linear toolpaths. The software’s Air Cutting Optimization mode can enable users to reduce machining times by 4 – 25 percent by minimizing air-cutting motions and optimizing entry and exit feed rates. This results in immediate and automatic savings on every part produced, even on existing programs. 

Simple, one-click implementation requires no alteration to the toolpath or CAM system. The software is effective in Fanuc, Heidenhain, Siemens and any other standard CNC control languages. NCISMUL OPTITOOL also enables users to test different optimization strategies and provides graphic analysis comparing initial and optimized feed rates. Further, this optimization can be applied (repeated) on every machined part currently in process, multiplying the gains.

“Optimization of non-cutting motions, as provided by these enhancements of NCISMUL OPTITOOL, represents a major opportunity for significant savings in machining time,” said Silvère Proisy, North American Operations Director for SPRING Technologies.

NCSIMUL MACHINE is an innovative CNC software solution providing realistic CNC simulation of the machining process. Users can simulate, verify, optimize and review machine programs based on the actual characteristics of the machine tools. Three-dimensional graphics help to avoid machining crashes while powerful algorithms and embedded process-based knowledge enable cutting conditions to be optimized. NCSIMUL MACHINE provides machining verification in three steps: it investigates and corrects coding errors, simulates to locate collisions and correct motion errors, and validates the part cut and machining result. The benefits are many, including reducing the time spent on debugging programs; preventing the costly risk of spindle collision, tool breakage and scrap; and improving cycle times and process optimization efficiencies.

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