You make it, we simulate it. Call us today! (949) 753-1050

Header

Force FAQ

Introduction to Force

WHAT IS FORCE?
VERICUT Force is a physics-based NC program optimization software module that analyzes and optimizes cutting conditions throughout NC program operations.
WHY USE FORCE?
• Force makes the most effective NC program for the given material, cutting tool, and machining conditions. The results are significant time savings, and improved cutting tool and machine life.
• Machining improvements are a balance between tool life and speed. Force optimization provides the flexibility to tip the scales to match your machining goals.
HOW DOES FORCE WORK?
Force calculates new program feed rates and performs block break-up to remove material using a constant ideal chip thickness as much as possible. This is accomplished while simultaneously limiting excessive cutting Forces or spindle power requirements.
WHAT DOES FORCE COST?
Most users see a return on investment in just 3-6 months. Some of our customers have paid for VERICUT Force on their first optimized project.
HOW CAN I CALCULATE MY EXPECTED SAVINGS?
Try our savings calculator to see how much Force optimization can save you.
HOW DO I GET STARTED?
All it takes to get started is VERICUT, the Force module and a Force material.
HOW EASY IS FORCE TO SET UP AND USE?
The easiest in the industry.
CAN FORCE IMPROVE LEGACY PROGRAMS OR NC PROGRAMS WE HAVE ALREADY COMPLETED?
NC programs, new or old, can be optimized with Force to run as efficiently as possible, to achieve maximum safe cutting potential. Even the latest CAM-generated “dynamic” or “adaptive milling” toolpaths, or previously optimized NC programs, can be FURTHER enhanced by Force optimization.
WHAT TYPES OF ANALYSIS DOES FORCE PROVIDE?
• Force provides the user with a proactive analysis of NC programs, making them right the first time.
• A single click provides a visual analysis in the NC program and also in the graphic review window.
• Quickly and easily visualize what is happening cut-by-cut in the NC program as the tool contacts the material.
• Clearly see underutilized cutting conditions, excessive forces, metal removal rates, power, torque, and tool deflections.
• Force charts show cut-by-cut data of resulting Forces, Power/Torque, Chip Thicknesses, Material Removal Rates, Tool Deflections and Feed Rates for both the original and optimized programs.
• Force shows side-by -side comparisons of the original NC program with the Force optimized NC program.

Force Benefits

WHAT ARE THE BENEFITS OF FORCE?
VERICUT Verification and VERICUT Force are a powerful balance of machining optimization and prevention of collisions, scraped parts, machining excesses. Just some of the many benefits of Force include:

• Significant cycle time savings
• Prevent undesirable cutting conditions like excessive feed rates, Force, HP/Torque, and tool deflection
• Maximized and more consistent chip thickness throughout the machining process
• Improved cutting tool performance—utilize cutting tool technologies to their full potential
• User friendly (especially for NC Programmers)
• Effective with ANY CAM generated tool path
• Force charts provide cutting condition information for NC program analysis and data driven decisions
• FAST analysis and iteration for testing various cutting scenarios for optimal NC programs
• Machining improvements are a balance between tool life and speed. Force optimization allows the flexibility to tip the scales to match your machining goals.
• Predict Forces and power along with the optimal cutting condition before running on the NC machine. Predictive physics-based Force is proactive rather than reactive optimization.
• Force is the ultimate improvement of CNC programs for lights out machining.
HOW DO THESE BENEFIS IMPACT MY MACHINE SHOP?
• Faster delivery
• Increase capacity without adding another machine
• Improve margins
• Win more jobs
• Confidence when running lights-out machining
• Better cutting tool utilization
• Better Machine Tool utilization
• Improved part to part and job to job consistency
• Better utilization of CNC machinist time 6

Alternatives to Force

HOW IS FORCE DIFFERENT THAN ADAPTIVE/PROFIT/DYNAMIC MILLING?
• Adaptive milling does not maximize chip thickness or keep it constant, may have a lot of wasted motion, and is CAM System dependent.
• Force will break up the cutting motion into smaller blocks of code in order to add feed rates creating TRUE constant chip thickness cutting.
I USE CONSTANT SURFACE SPEED FEED RATES TO OPTIMIZE MY TURNING. CAN FORCE DO BETTER?
• Yes. Constant Surface Speed may work well for a straight line cut down a face, but will not provide constant chip thickness during contouring.
• Force provides constant chip thickness regardless of the type of cut being performed. Turning projects optimized with Force can see up to 25% time savings.
I THOUGHT OPTIPATH WAS GETECH´S OPTIMIZATION PRODUCT?
OptiPath has been CGTech’s optimization product for nearly 30 years. We have great experience with feed rate optimization and have developed VERICUT Force with different technology.
WHAT IS THE DIFFERENCE BETWEEN OPTIPATH AND FORCE? WHICH IS BETTER?
The Force module’s greatest benefits / differentiators from OptiPath are:

• Protection from catastrophic failure: tool breakage through limits (Force or Power)
• Force Charts: ability to REALIZE OPPORTUNITY / potential performance & time savings
• Utilize cutting tools to their full potential in regards to the actual material being cut
WILL OPTIPATH CONTINUE TO BE SUPPORTET?
Yes.
MY CAM SYSTEM HAS A FIELD FOR CHIP LOAD. HOW IS THAT DIFFERENT FROM FORCE CHIP LOAD?
The “CAM system” field for chip load is to set the feed rate. But CAM systems do not adjust for cutting conditions, compensate for chip thinning or keep the chip thickness constant. This is why feed rate optimization is needed.
WHAT ABOUT ADAPTIVE CONTROL?
You need to buy the adaptive software for each machine control and not just one product for all machines. Also, adaptive controls are reactive, sometimes adjusting for machining conditions after it’s too late. Force is proactive – all of the adjustments are made before going to the machine.

Force Process

HOW DOES FORCE MAKE MY PARTS CUT FASTER?
VERICUT Force maximizes the chip thickness, keeps it constant, matches the cutting conditions to the cutting tools performance parameters all while protecting the cutting from excessive Force, feed rates, spindle power requirements.
DOES FORCE OVERWRITE THE EXISTING NC FILE?
No. it creates a separate file with a “.opti” extension
CAN I SEE THE CHANGES THAT FORCE MAKES TO THE ORIGINAL NC FILE?
VERICUT Force has a feature to display the original and .opti file side by side and do a visual comparison. One click – compare files.
ARE FORCE GRAPHS ONLY AVAILABLE WITH THE FORCE MODULE?
Yes.
WHERE DO I GET CUTTING TOOL INFORMATION FROM?
Machining Cloud, Coro plus (Sandvik tools), Cutting tool manufactures web sites, Catalogs, etc.

Force Materials

WHAT IS FORCE MATERIAL?
A Force material is the file to be used in VERICUT Force optimization. These files are a characterization of Force interaction between a cutting tool and a given material. This Force material file can be used across all shapes and sizes of cutting tools and inserts. It also can be used in Milling or Turning.
WHAT FORCE MATERIALSDO WE HAVE?
CGTech has a catalog of over 100 Force materials consisting of steels, stainless steels, irons, non-ferrous alloys (aluminum alloys), super alloys (titanium’s, Inconel’s, etc.), and hardened materials.
CAN YOU MATCH MY EXOTIC MATERIALS? IF NOT, HOW DO I CHARGE?
Yes of course. Cost is per material to be tested and will be kept proprietary if needed.
WHAT ABOUT PROPRIETARY MATERIALS?
Yes, and we will ensure that they remain proprietary.
DO THE FORCE MATERIALS MATCH MY MACHINE TOOL, CUTTER BRAND/TYPE, MATERIAL, COOLANT, ETC?
Force Materials are not tied to machine tool cutter brand, type, coating, coolant, etc. What matters is that we use the Force Material that matches both the tool and cutting materials.
CAN FORCE CREATE MY MATERIAL REACORD FOR ME?
No. Force materials are an input to Force optimization, not an output.
CAN I CREATE MY OWN FORCE MATERIAL FILES?
It is possible, but not recommended.
WE CHANGE TOOLS A LOT, DO I HAVE TO CREATE MATERIAL RECORDS EVERY TIME?
Materials can be copied and pasted into the new tool.

Force Details

DOES FORCE SUPPORT MILLING, TURNING, MILL/TURN, MULTI-CHANNEL, DRILLING, ETC.?
• Milling, Turning, Mill Turn
• Multi-channel and drilling are in the planning stages
IS FORCE USEFUL FOR ROUGHING, SEMI-FINISH, AND FINISH?
Yes. All of these.
DOES FORCE WORK ON HARD MATERIALS OR IS IT BETTER ON SOFT MATERIALS?
VERICUT Force is for optimizing ANY NC machining that cuts a chip (milling or turning)

• ALL materials hard or soft – from Inconel to aluminum, CFRP and plastics
• ALL cutting tools any sized or shape – from micro milling to large multi insert pine cone cutters
• VERICUT Force can be said to be “better” for hard or unknown materials because the NC Programmer and/or machinist may have little to no experience with milling or turning this more difficult to machine material. VERICUT Force has done the hard-work for the user—we have tested the material and now have the calibrated material to utilize inside Force.
DOES FORCE CHECK FOR CUTTER DEFLECTION?
Yes. The acceptable deflection value is set in the tool manager and will send a warning to the logger if exceeded.
• Deflection is also charted in the Force Charts and can be analyzed in conjunction with the chip thickness, Force, material removal and feed rate.
I HAVE OLDER MACHINE TOOLS. WILL FORCE WORK?
Force optimization should work with older machines, but it can depend on how old and how fast the control can pass data, and how fast the machine can react.
WILL MY CUTTING TOOLS WEAR OUT FASTER?
No. Force keeps the chip thickness constant, typically resulting in 2x improvement in tool life or more.
DOES FORCE REQUIRE AN ACCURATE STOCK MODEL (SCANNED MODEL ARE SOMETIMES PREFERRED FOR FORGINGS/CASTINGS?
Accurate stock models are preferred but we have ways to compensate if it’s not possible.
DOES FORCE WORK WITH THE INVERSE TIME FEED RATES?
Yes.
DOES FORCE WORK WITH POLAR MACHINING?
Yes.