They decided to implement OptiPath®, the NC program optimization module of VERICUT software. OptiPath is a knowledge-based machining package that essentially adds intelligence to the cutter. During the simulation, VERICUT learns the exact depth, width, and angle of each cut. The software also knows the exact shape of the in-process material during each and every second of the entire machining operation. And it knows exactly how much material is removed by each cut segment.
With this unique knowledge set, the OptiPath module determines the best feed rate for each cutting condition encountered, taking into account volume of material removed, chip load, and accel/decel control. Where necessary, the software can also divide cuts into smaller segments and vary the feed rates accordingly in order to maintain a consistent chip load or volume removal rate. It then creates a new tool path, with the same trajectory as the original, but with improved feed rates. “The application of the software seemed very practical for our situation,” says Hetrick. “And the software has exceeded our initial expectations.”
The first job they optimized was a wheel mold machined from hardened steel (38-42 HRC) and cut using carbide inserted end mills. After letting the software analyze the tool path and insert more appropriate feed rates they could immediately tell the difference. “The tool load sounded a lot more consistent,” says Hetrick, “and the surface finish was often better, even with the increased feed rates.” But the real surprise was in how much more efficiently the part ran – cutting 150 minutes from a program that, otherwise would have taken 467 minutes – a 32% savings.
Reaction from the machinists on the shop floor has been enthusiastic. “There is a definite peace-of-mind now. Prior to using VERICUT, machine operators would always have to keep an ear open, listening for the tool to break, or for whatever else might happen. Since we’ve been using the software, and everyone is convinced of the reliability and consistency of the product, machine operators can now start a program, and go work on other tasks in the shop, knowing that the software is looking out for the ‘hard parts’ and adjusting the feeds accordingly.”
Machinists at Ultra Wheel Co. have also noticed other benefits from the software. Tool life has increased. “I used to have to break-up my programs to allow for tool changes. Now I can run much larger programs, and the tools don’t wear-out near as fast.” And although he hasn’t noticed any less wear on the machines themselves, “if prolonged tool life is any indication as to how much less stress is being transmitted to the machine, than I would say there is definitely less wear and tear on the machine.” Surface quality has also improved significantly in most cases.
But the bottom line is in the bottom line. And how much more profitable is Ultra Wheel Co. as a result? “The software has already paid for itself. For example, I documented the job we just pulled off the machine. We took 34.62% off the machining time, and increased the profit margin by more than $1,300 on that part,” says Hetrick. “Management is very impressed. Not so much at the tooling savings, or lack of machine wear and tear, but more so with the quicker build times we are seeing on our molds.”
They were also somewhat surprised to find that their biggest timesavings occurred on finishing operations. “On average, I’m cutting 30% to 40% out of all my finishing times. Keep in mind that finishing is about two-thirds of the overall mill time. 1/4" and 1/8" ball end-mills that used to run at 60 ipm, (and the operator would usually override down to 40 ipm on the hard parts) now run between 40 ipm, and 130 ipm, usually staying somewhere between 90 and 130 ipm. I recently finished a typical mold, which I had to run 5/8", 1/2", 1/4", and 1/8" ball end-mills. A mold similar to this without OptiPath probably would have been on the mill a week, to a week-and-a-half. This mold ran in a little less than 4 days! That’s pretty much the scenario I’m seeing on everything I do."
Airbus is selling so well that the demand to increase build rate has never been higher. BAE Systems (Filton, UK) needed a simple way to improve throughput - it found the answer in VERICUT.
With VERICUT, engineers at Stellex Monitor modeled the Sidewinder and Spar Mill machines.
Tell Tool of Westfield, Mass., has integrated VERICUT CNC simulation software into its numerical control program prove-out process.
VERICUT enabled us to start ordinary production after a minimum of time. Since this product is new for Volvo Aero Norge and our company had never before had parts with similar machining complexity, it is difficult to estimate the amount of cost saving.
Before implementing VERICUT, the company experienced the usual time-consuming and expensive manufacturing problems related to NC program prove-outs such as scrap loss, broken tooling, and a danger of occasional machine crash.
Over the last two years, AH has used Machine Simulation to speed the implementation of several new 5-axis machine tools.
VERICUT showed the NC programmers leftover or heavy stock." And the software detected a couple of places where the depth of cut was too large and tools were shanking out," said Collings. They then went back and corrected the errors in the tool path before
Dassault, Seclin initially purchased VERICUT in order to reduce the number of manual prove-outs using polystyrene material, which represented a significant expense in terms of time and money.
VERICUT enabled the designers and programmers see exactly what they were building as and in-process model in different stages of the machining cycle.
We utilized VERICUT to verify the CNC programs for cutting the tooling before they were sent to the machine control,
To protect their investment, they have been using VERICUT since 1996. They have two people to verify the accuracy of their G-code files.
"When we first started using OptiPath we concentrated on the feed rate option; now we use the constant chip thickness capability. With jobs up to 200 hours long, 50% saving is significant – like having another machine tool."
The entire process took less than two hours and no manpower was required, whereas, creating the same pattern manually (the old way), would have taken one of our designers several days.
The verification process stays ahead of the actual machine position in the NC code being verified. Opera-tors can see errors before they occur.
The bottom line? Using VERICUT has made Supreme's existing machine tools more productive. Enthusiasm is up, delivery times have been reduced, and pricing is more competitive.delivery times have been reduced, and pricing is more competitive.
Using VERICUT to compare the electrode burn with the mold cavity ensures that we have all the correct clearances in the electrodes and that we have 100% clean-up." says Allen.
If I was using VERICUT at the time I would've caught the problem, and had a chance to fix it before it damaged the part.
Now I rarely see the potential crashes because the students find and correct them before I review the work. Catching those costly problems is a non-event now!
VERICUT can change speeds and feeds according to cutting conditions including difference in material and tooling. It is done automatically; the programmer does not have to make even one manual insert into the code."
Flying shrapnel from shattered cutting tools and components is avoided by using VERICUT to test student programs before they are run on NC machines.
The NC programmers at Ingersoll also rely on the simulation software to prevent mistakes when programming complex, five-axis parts.
After creating the NC programs in Mastercam, they began simulating the machining process in VERICUT by simulating the G-code data. There often can be a difference between the motion as programmed and the code after it's run through the post processor
After selecting VERICUT for third-party verification, each NC programmer attended two days of basic training where they experienced first-hand the type of results they could expect to achieve.
The program simulates milling, drilling, turning, wire EDM, and mill/turn machining operations using both G-codes and CAM output.
VERICUT provides simulation capabilities for the all the 3-5 axis and wire EDM parts, with focused control over the orientation of our 5-axis machine tool including the cutters used on that machine.
The inspection probe is created as a tool in VERICUT so the complete in- cycle gauging sequence is checked for collisions.
The bottom was machined first. This effort took about 24 hours from start to finish. By using VERICUT software from CGTech, Elliot was able to test the NC program for any problems before it was ever cut on the machine.
Cosworth Racing Integrates Walter TDM Tool Management into Manufacturing Systems
With data exported from NX, Vericut simulates the cutting process on the shop floor utilizing the machine G-code to detect any issues prior to NC Program release.
Machinists at Ultra Wheel Co. have also noticed other benefits from the software. Tool life has increased. “I used to have to break-up my programs to allow for tool changes. Now I can run much larger programs, and the tools don’t wear-out near as fast.” And although he hasn’t noticed any less wear on the machines themselves, “if prolonged tool life is any indication as to how much less stress is being transmitted to the machine, than I would say there is definitely less wear and tear on the machine.” Surface quality has also improved significantly in most cases.