CGTech USA CGTech UK CGTech France CGTech Germany CGTech Italy CGTech Japan CGTech China      

VERICUT User: Ingersoll Cutting Tools

Simulation Software Keeps Tool Maker On Cutting Edge

As a supplier of metal-removal tooling for more than 100 years, Ingersoll Cutting Tool Company (Rockford, Illinois) has sought to help manufacturers remain competitive by providing innovative and productive metal-removal solutions. Since the early 1990s, the company has used VERICUT software from CGTech (Irvine, California) as a component of its manufacturing process.
 
"We have had Vericut in production for so long, I think that it is taken for granted," says Paul Gerardy, systems engineer. "With our shop primarily running five-axis programs, machine crashes were a factor in our decision to implement the software. It keeps the spindles in the shop turning. Now, we rarely have crashes, and we no longer provide setup pieces for NC program prove-out."
 
The NC programmers at Ingersoll also rely on the simulation software to prevent mistakes when programming complex, five-axis parts. The verification software that simulates from post-processed code allows the user to detect errors before they happen on the shop floor. Many CAD/CAM systems output program data as an APT/CL translator program or in ASCII neutral format. This data defines the principal tool path, speeds and feed rates as a machine tool-independent generic NC program. The post-processor receives this file and converts it to the specific machine tool instructions required to control the axis motion, tool changes, cutter compensation, coolant pumps and more. Unless discovered by the independent verification software, errors that are introduced at this stage will go undetected until a machine crash occurs or during a manual prove-out run, the company says.
By Incorporating full machine simulation software, Ingersoll has the programming process for a new setup before the machine tool hits the floor.
 

Vericut can prove-out the machine and post-processor before they arrive in the shop. "We try to have the programming process for a new machine setup before the machine tool hits the floor," Mr. Gerardy says.

The capability to simulate NC programs from post-processed code became critical when the company was forced to change CAM systems from a mainframe-based APT system to Pro/NC. The time frame for the transition was tight, because the company had just 3 months before it would lose access to the mainframe. Because the software was independent from the CAM system or post-processor, it facilitated a smooth transition.
 
"It was like Y2K all over again, except we knew exactly what we were up against," says Mr. Gerardy. "Not only did we lose our CAM system, but we also lost all of our post-processors. After that, we purchased ICAM to post-process Pro/NC CL data. It was nice to have at least one component of the NC programming process that we could count on. You could say that the software was a firewall between the office and the shop, and it smoothed out the transition to Pro/NC."
 
The software is a key part of the company’s tool assembly building routine. Ingersoll does not use pre-defined tool assemblies, but rather, it relies on the software to determine the minimum extension length for each tool assembly. That information, along with minimum and maximum gage-length information that is output from the post-processor, enables the company to select the most rigid tool assembly for the job.
 
"The machine operators are confident about this method because they know the tool assembly we specify will not cause a collision," says Mr. Gerardy. "As a systems engineer, I like the ease with which I am able to configure the software for automation. We like to automate everything we can for the NC programming group. Vericut allows us to do just that."
According to the company, the capability to automate the verification process is crucial because the company’s NC programmers create numerous programs per day. So it is imperative that the software is not a cumbersome part of the process.
 
A small reduction in machining time can translate to substantial savings over the course of a single production run, the company adds. Mr. Gerardy and System Engineer Pete Risley implemented the NC program optimization software into their manufacturing processes. As a result, every NC program sent to the shop is first optimized using the OptiPath module. Consequently, a few extra minutes spent early in the programming stage can save time at the machine.
 
OptiPath works by analyzing either the post-processed NC program (G-codes) or the direct CAM system output. It then divides the tool motion into smaller segments determined by user-defined settings in the software. By analyzing the amount of material removed in each segment, the software assigns the ideal feed rate for each cutting condition encountered, says the manufacturer. It then outputs a new NC program, which is identical to the original one but features improved feed rate settings. The software does not alter the toolpath trajectory.
 
The software detects a collision before the NC program is sent to
the actual Mazak Multiplex 6200 on the shop floor.
 
"When we first implemented the module, our operators were skeptical," says Mr. Gerardy. "However, it wasn’t long before the operators were calling the NC programmers and telling them when they forgot to optimize the tape. Our NC programming group pumps out a lot of programs every year. We have implemented OptiPath in such a way that it only adds a few minutes to their programming process, if anything."
Even though the optimization process may seem like an extra step, it can simplify programming. "With OptiPath, the programmers do not have to be quite as picky about inefficient portions of the tool path because the module will take care of it," Mr. Gerardy says.
 
In addition to more efficient feed rates, optimized NC programs typically result in parts with better surface finishes, the manufacturer says. Additionally, the optimized programs are said to produce constant chip load. Therefore, tools may last longer, and machines can run smoother.
 
"It seems like the more complicated jobs are the ones that we really see big savings," Mr. Gerardy adds. "When we first implemented OptiPath, we had the NC programmers record time savings for every job that they processed for about a year."
 
"It seems like the more complicated jobs are the ones that we really see big savings," Mr. Gerardy adds. "When we first implemented OptiPath, we had the NC programmers record time savings for every job that they processed for about a year."
 
   
Pictured here is a cut part after
a simulation of the material removal in Vericut.
 
  
 
 
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, GE Aviation (formerly Aerostructures Hamble) 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.
VERICUT software removes this potentially hazardous stage by allowing ReedHycalog to do all of their prove-outs on a computer.
Regional Offices: CGTech USA CGTech UK CGTech France CGTech Germany CGTech Italy CGTech Japan CGTech China