FIVE-AXIS MACHINING SUPPLEMENT
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Connecting the real world to the
virtual world with VERICUT
As machining gets more complex and customers expect more for less, the need to simulate, verify and
optimise the machining process has never been more necessary, in order to ensure reliability and effi ciency,
and to maximise productivity
The highest level of NC simulation
and veri cation is achieved
using a highly accurate
digital twin representation of a
CNC machine, which is driven
by the same post processed
NC G-code that the machine
itself employs. A digital twin
sees the real-world
component manufacture
processes digitally replicated
within software.
There are two critical
issues – is the virtual model
correct, matching the physical
one, and are the subroutines and
parameters available in the
machine CNC being used.
It is key that virtual models of all
machine components, attachments,
xtures, clamps, cutting tools etc match,
as closely as possible, to what is being
used on the shop oor. The more accurate
the simulation is, the more reliable it will
be in providing dependable outcomes.
If shortcuts are taken – like omitting
input data, relying on rough block sizes or
using generic tools – it’s likely that
surprises, issues and errors will arise later
– inconvenient and expensive on the
shop oor. This is where CGTech’s
VERICUT’s connectivity comes in.
Second, the virtual machine should
use the actual parameters, subroutines
and probing logic taken from the machine
tool, making the digital twin behave in an
identical fashion to that of the real
machine tool.
VERICUT has access to the most
current information available and ensures
that the virtual machine and simulation
correspond as closely as possible.
VERICUT can directly connect and
communicate with multiple sources of
software, including CADCAM, tool
management systems and data from
vendors and the cloud.
Using direct interfaces with all leading
CAM systems, VERICUT creates a
seamless integration between the CAM
system and simulation software, which
streamlines data ow, avoids replication,
eliminates human error and makes the
transfer for multiple set-ups and
operations quick and easy. Different stock
models, design or nished parts and
xtures can be selected and imported into
VERICUT ready to run a simulation.
Likewise, with connections to various
tool management systems, including
Machining Cloud, Novo and Zoller etc,
VERICUT can access a central source for
cutting tool information and obtain highly
accurate tool models. Other
information such as speeds and
feeds can be brought into
VERICUT from the TDM system
and used by programmers as
a guideline to ensure that
tools are not being over- or
under-utilised, or as a
starting point for
optimising programs.
Connectivity also goes
beyond the information
imported into VERICUT,
extending to the resulting
simulation data that can be
shared with other departments
in order to improve ef ciency.
VERICUT has various tools that
streamline communication and
connectivity throughout the
manufacturing process.
As well as reports that can be
con gured to run automatically after the
simulation, log les, cutting data and
images, VERICUT offers a complete
Reviewer le. This is a le that can be
opened by any Windows PC or tablet and
allows users to view the full simulation.
It’s a 3D representation of the simulation
that can play forward and backward while
removing and replacing material. The user
can rotate, pan and zoom, just like
normal VERICUT, and the cut stock can be
measured using all the standard X-Caliper
tools. Tools such as Reviewer and Reports
allow complete visibility throughout the
manufacturing process of how parts
should be produced and connects the
entire work ow together.
Accurate simulation data means that
the planning and scheduling department
will have a better indication of cycle
times, tool life information will be
available for pre-setters, machinists will
have con dence that the xtures and
VERICUT offers seamless integration with
various sources of digital information,
such as CAM systems and tool
management systems, as well as cloudhosted
data services
38 September 2020 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets
/www.machinery.co.uk