ところが、BAE Systems のフィルトン事業所では、エアバスの翼構造にある重要部品の工程を最適化しようとして、この機能が阻害要因であることを見つけました。最初から簡単な話ではなかったのです。制御パラメーターのスイッチを切って事態が改善されることを期待する、というほど単純なことではありません。まったく予想のつかない状況に陥るかもしれません。そこで、BAE Systems は代わりに、解決策を求めて工具会社やソフト会社に連絡を取り始めました。その結果、CGTech とKennametal を巻き込み、プロジェクトは成功へと導かれることになったのです。
この2社はセル F での最適化にとりかかりました。ここでは森精機の SH-50 マシニングセンターを使い、主にエアバス A330/340 のアルミ製Aフレームの切削を行っています。これらのフレームには60のバリエーションがあり、翼の前縁部に使われます。基本的なセットアップは変える必要がありませんでした。材料は事前にブロック化され、表面加工され、治具用の穴が開けられ、ジャスト・イン・タイム方式で到着しています。そこで、送りと回転数の最適化に戻ります。オプティパス（OptiPath）モジュールで様々な制御パラメーターを上書きし、Kennametal の工具で高速な送りと回転数での
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.
ところが、BAE Systems のフィルトン事業所では、エアバスの翼構造にある重要部品の工程を最適化しようとして、この機能が阻害要因であることを見つけました。最初から簡単な話ではなかったのです。制御パラメーターのスイッチを切って事態が改善されることを期待する、というほど単純なことではありません。まったく予想のつかない状況に陥るかもしれません。そこで、BAE Systems は代わりに、解決策を求めて工具会社やソフト会社に連絡を取り始めました。その結果、CGTech とKennametal を巻き込み、プロジェクトは成功へと導かれることになったのです。
EITチ－ムリーダーのMatt Godfrey が言います。「CGTechはNCプログラムをベストなものにするために我々を助け、フィルトン事業所の従来の考え方を変えてくれました。工具を刃長の長いものに取り替え、切削深さを大きくして、仕上げは良くなりました。部品プログラムの変更は一切、必要ありませんでした。我々に代わって、オプティパスが送り速度の面倒を見てくれるのです。我々は上限設定をプログラムの送り速度で毎分7m、薄い切削で毎分16mにしただけです。この値だと、これまでなら航空機部品としての表面仕上げは不合格になったはずです。元のプログラムでは毎分1m近辺で切削するようになっていました。今では精度が上がり、より効率的に工具を使えるようになりました。」