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October 2019 www.machinery.co.uk @MachineryTweets
AEROSPACE SUPPLEMENTAEROSPACE SUPPLEMENT
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Keeping pace
with aerospace
Of course, simulation technology
6
must keep pace with rapid
advances in manufacturing so that
businesses can learn to use and protect
new equipment. Recent advances in
VERICUT include support for additive
manufacturing and hybrid manufacturing
methods, robotic welding and laser
sintering, as well as grinding while
dressing to change the shape of the
grinding wheel, including for creep-feed
grinding used to produce fan blade roots.
Explains Mr Powell: “Simulation data
can come from many sources, such as
CAD/CAM systems, tool data
management systems, PLM systems and
the Internet. Interfaces provide quick
access to these sources to streamline
simulation set-up, create more robust
simulations, run faster and catch
potential problems.
“The optimisation of the cutting
process is achieved with VERICUT Force,
using multi-channel dyno-tested and
proven cutting data to predict cutting
forces, de ection potential and spindle
loads through
simulation. It works extremely well with
the range of dif cult-to-cut materials used
in the aerospace sector. The Force
module calculates ideal feed rates for
each cut while simultaneously limiting
cutting forces and spindle power
demands to safe levels. Interactive Force
Charts show trends, expose overload
conditions and identify underused tools
with the potential for optimisation.
Within the aerospace sector, as well
as other advanced manufacturing
industries, simulation, veri cation and
optimisation have become critical. Onmachine
prove-outs are time-consuming
and visibility is often poor. With
simulation, users get clear views of the
cutting process, regardless of machine or
set-up complexity. By using digital
machines to simulate the NC programs
that will run on real machines, customers
eliminate potential crashes and tool reach
problems, analyse cutting methods and
prove out new NC programs faster;
keeping CNC machines free to produce
parts.
“New CNC machines cost
more, move faster and are more
capable than older generation
machines,” Mr Powell adds.
“For new CNC machines,
simulation plays a vital role in
post-processor development
and preparing NC programs in
advance for when the
machines come online.
Simulation can prevent
problems such as: machine
crashes; improper code use; set-ups,
cutting strategies and tools that do not
work; and incorrectly machined parts.
“Machine shops need to make parts
faster and with cost in mind. NC program
optimisation enables cutters and
machines to be used to their full
potential, increasing throughput and
ef ciency. As companies acquire new NC
equipment, simulation helps evaluate part
manufacturing strategies to determine
which equipment will work best even
before production starts.”
So, what can these simulation and
veri cation techniques offer today that
was not possible a few years ago? Says
Mr Powell: “Simulation incorporates digital
twins of CNC machines to show how
machines will react to the codes in NC
programs and more accurately predict
machining times. Simulation that also
incorporates a machine’s subroutines,
cycles and parameter settings improves
digital twin accuracy by accounting for
machine limitations and nuances.
“Meaning users can simulate entire
NC manufacturing processes end-to-end,
not just one operation or program. By
linking manufacturing operations (set-ups)
and transferring the stock workpieces
between them, users see the effects of
all operations applied in the order planned
to produce parts.
“Cloud-based repositories and some
tooling manufacturers’ websites also offer
‘smart’ tooling; tool assemblies
accompanied by recommended cutting
feeds, speeds and usage parameters.
With an ongoing demand to improve both the effi ciency of the fi nished
aircraft, as well as the manufacturing process, to meet order books
that stretch out years ahead, businesses in the aerospace sector are
constantly striving to gain any advantage. NC simulation, verifi cation
and optimisation software VERICUT provides many with the
opportunity to improve. Machinery spoke to CGTech’s Technical
Director, Gavin Powell, about the latest software developments
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