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CGTech’s machine building specialists even go as far as extracting parameter settings from the CNC and incorporating them into the digital twin for the most accurate ‘twinning.’” “Digital twin machines must accurately simulate machine motions, mimic tool and work offset handling, process subroutines and emulate complex control functions that change motion behavior on the machine.
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“Simulation the post-processed NC code that drives the actual machine offers the highest level of verification,” he noted. Today’s users need better digital twin virtual machines, Granata said. “Users want simulations to look more realistic and run faster, while still calculating extremely complicated material removal and collision checking.”
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Manufacturers are looking for improvements in simulation speed, visual quality and accuracy, noted Gene Granata, product manager for VERICUT NC simulation, verification and optimization software, developed by CGTech, Irvine, Calif. These give highly realistic visualizations of all the parameters in machining, from cutters to machine tool components and accessories-even the parts being cut. Users can also turn to third-party simulation packages that feature more accurate and sophisticated G-code simulations. Most CAD/CAM systems offer a basic level of simulation, based on cutter location (CL) data. Today’s simulation tools offer a variety of ways to prevent such costly programming errors. Ensuring top quality means using high-fidelity simulations to set up the cut. Even a minor error in, say, a titanium aerospace component can be a major expense. Manufacturers must avoid costly machine errors that cause catastrophic damage to both machine tools and expensive workpieces. Milling tool data can be freely assigned or imported from the CNC Simulator, while turning uses a predefined set of turning tools that cover a wide range of applications.The latest simulation packages offer CAD/CAM and NC-level code-checking to ensure fast, error-free machining processes The Reviewer App in VERICUT illustrates a program showing that the machine spindle will collide with the part during the process. The milling simulation includes a 21-tool changer and the turning simulation includes a 12-tool turret. Real-time collision detection uses visual and audio signals to notify users of collisions.
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The software also uses color- coded tool paths, back-plot and cut locations to make it easy for users to identify the tool, path and cutting result.
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Manual machine functions like jog, hand-wheel and reference cycles also work like a real machine.
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The simulation is based on actual CNC position data, not on the G-code program, this is intended to provide realistic simulation as the virtual machine reacts exactly as a real machine. Users can virtually manufacture parts in milling or turning environments with realistic kinematics and structure. The machining simulation component was developed in partnership with ModuleWorks. An integrated PC is embedded in the FANUC CNC Simulator to run the Fusion 360 and ModuleWorks simulation software. The FANUC CNC Simulator includes FANUC Manual Guide i conversational programming software for users who would like to learn shop floor programming. Users can run programs, manage tooling and make any modifications on the control as they would in a manufacturing environment. Based on the FANUC Series 0i-Model F, the CNC Simulator can be operated as a 3-axis mill or a 2-axis lathe.
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The core of the system is the portable FANUC CNC Simulator, which provides users with the experience of working with the real look and feel of a true hardware-based FANUC control. Students can easily import programs directly to the CNC using the FANUC FASBacCNC user interface and also back up the critical CNC data. The simulation system also includes a simple G-code editor for making modifications before the program is sent to the CNC.
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The CNC will use this G-code to command the machine tool. Students can use Fusion 360 to perform CAD/CAM work and the included post processors will convert designs into G-code suitable for the included CNC. The FANUC Machining Simulator comes with Fusion 360, a cloud-based 3D CAD, CAM and CAE software platform that helps bridge the gap between design and machining, and works on Mac and PC. The FANUC Machining Simulator features Autodesk Fusion 360 CAD/CAM/CAE (computer-aided design, manufacturing and engineering) software and a custom machining simulation program designed by ModuleWorks. FANUC America has developed a new machining simulator that encompasses the complete manufacturing process from part design and engineering to CNC programming to virtual production simulation.