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Четверг, 04 июня 2020 16:39

Achieving process optimization through simulation

Force IcebergProcess optimization links all the machining operations end-to-end to evaluate and improve the entire manufacturing process. Each step along the way, through engineering, design, CAM programming and machining and up to the final quality and inspection phase, can and should be optimized. Simulation ensures programs are error free and all operations work together as intended, but optimization ensures the whole process is operating as efficiently as possible to save time and money.

As machining gets more complex and customers expect more for less there is room for improvement in any manufacturing process. These improvements, which are not just about reducing costs, might include reduced NC program runtimes, increased throughput, making parts cheaper or getting a product from start to finish and out to market faster.

There are some very significant warning signs that will indicate when process optimization is clearly a must in a manufacturing business – missing delivery dates? Losing out on bids or not as competitive as rivals? Lost contracts and unsatisfied customers? Or declining profits?

Every level of the manufacturing process that a job goes through requires careful planning and communication and the aim of manufacturing is to make it through each step as quickly and efficiently as possible, with the least cost incurred.

In a typical manufacturing workflow VERICUT resides between CAM programming and machine set up.

Manufacturing workflow with VERICUT

Typical Manufacturing WorkflowCAM programmers know that modern machines move so fast it’s pretty much impossible to stop them before a crash occurs. VERICUT CNC simulation and verification software does a superior job at finding problems lurking in NC programs and warning of unexpected machine behaviour, even those occurring between multiple setups. It lets programmers resolve these issues before they reach the shop floor, crash the machine and waste valuable machine time.

With VERICUT the shopfloor can be confident that programs will run correctly. Verification will show if there are any errors or any areas that can’t be reached by the machine or the tools due to fixturing interference. Machinists don’t have to worry about crashes and they don’t have to waste time proving out because it’s already been done between the VERICUT and programming stages.

Having access to the free VERICUT reviewer at the machine tool to check the simulation against reality at anytime is a huge benefit to both shop floor and programmers as it avoids the “what happens next” disturbances during one off or first off production.

There’s also a positive ripple effect for other departments that coordinate with programming. Engineering and design can learn through verification if parts can be manufactured or if changes need to be made before metal cutting. Planning and scheduling will have more accurate cycle times and they won’t have to schedule prove-out times on the machines. The quality control and inspection team can expect higher levels of conformance and fewer issues which makes it easier to approve parts and get them delivered.

These are all areas where VERICUT is helping save time and money.

Silent Killers of NC manufacturing

But there are also the hidden issues, inefficiencies and missed opportunities to optimize processes that erode profit margins. Things like poor cutting methods, non-optimal feedrates in new and existing NC programs, over or under utilizing cutters and/or machine tools, all of which can be draining money with every part made. Some companies work really hard and very diligently optimizing programs but there are opportunities and savings to be had for all machine shops.

This is where Force and Force analysis charts come in.

Force Analysis and Charts

Force Fill ComparisonVERICUT Force recalculates feedrates to maintain ideal constant chip thickness while simultaneously reducing feedrates when needed to maintain safe cutting forces and spindle power, and it does this for each tool. Force is based on calculations and proven cutting data that’s been gathered from tooling manufacturers, material specifications and dyno testing.

It uses very specific cutting parameters, takes into consideration what kind of material is being used, as well as tool type and geometry. It couples this with the cutting conditions that VERICUT collects to give the best data that can be used to analyse and optimize the NC program.

Force charts visualize what’s happening during the machining process and expose areas of opportunity that exist in each NC program, such as erratic chip thickness, chip thinning and inefficient CAM paths that can all be resolved by optimizing feedrates. The charts also show areas of concern, for instance where the force exceeds what the tool capable of, such as excessive cutting conditions or potential for chatter, broken/chipped cutters or damage to part of the machine. In these instances VERICUT Force will lower the federate to keep the force under the limit that of the tools capability.

The impact of optimizing is dramatic, including reduced machining time and longer tool life, which will help the shopfloor by giving more machine capacity and maybe even postponing the purchase a new expensive machine. There will be less post machine clean up because produced parts will be better quality saving even more time per part. Programmers are going to benefit from having correct speeds and feeds information to achieve consistent machining results. All these positives reach all the way back to the quoting and estimating and mean manufacturers can be more aggressive and competitive with schedules and bids.

Simulating, verifying and optimizing simultaneously with VERICUT Force equates to a cumulative effect on process optimization resulting in significant time and money savings.

Published in Press Releases 2020
Четверг, 20 февраля 2020 10:13

CGTech releases 9.0 ready for exhibition showcase

The highly anticipated release of VERICUT 9.0 is here.

X caliperVERICUT is already an advanced piece of software which has become industry standard for simulating CNC Machining. VERICUT CNC machine simulation, verification, and optimisation software simulates all types of CNC machining, additive, and hybrid manufacturing processes. The software operates independently, but can also be integrated with leading CAM systems.

The launch of VERICUT 9.0 has brought with it several new enhancements designed to increase power and improve efficiency. The new features and benefits will be showcased at the Southern Manufacturing Exhibition on 11th – 13th of February. CGTech will be presenting VERICUT 9.0 at stand C215.

Gavin Powell, CGTech Technical Director said: “VERICUT 9.0 is ‘smarter’ than previous versions, offering more robust connections to tooling databases and the latest CAM systems.

“Most users will experience gains in performance, as well as sharper, clearer and more realistic views of machines and the machining process. Enhancements to VERICUT’s free Reviewer app also lets programmers share with others (like machinists or quality assurance personnel) how parts are manufactured.”

The new features include:
Enhanced Graphics Display
VERICUT 9.0’s greatly enhanced image quality makes it easier to spot problems and imperfections in machined parts. Switch seamlessly between Workpiece, Machine or Profile views, or combine them in a variety of view layouts.

Streamlined Verification
Any of VERICUT’s major functions, such as AUTO-DIFF, Section, and X-Caliper, can be used in any view which streamlines the verification effort and increases productivity.

Force Optimization
Use Force “Analyze”, without any prior configuration, to spot potentially dangerous machining conditions or identify underutilised tools. Force Charts has a new “Fill Comparison” option to help visualise the changes made by Force optimisation to feedrates and chip loads.

Appearance Settings
Appearance settings accompany the “Colour” option for components and models, and can be used to add realism to objects in VERICUT simulations. Machined parts look more lifelike and identification of errors or incorrect cuts has become easier.

Enhanced Translucency and New Stock/Design View
New features are available to quickly display the Design part embedded in translucent Stock, and show AUTO-DIFF Gouge or Excess errors in relation to the Design part or cut stock model.

X-Caliper
X-Caliper has several new measurements and features that provide greater control over how measurements (dimensions) are shown. Images with dimensions can be printed, saved to an image file, or utilised in Setup Plans.

Setup Plan
A new Setup Plan capability makes it easier than ever to create images from the simulation with dimensions or notes that help others understand the manufacturing process. Setup Plans are easily incorporated in VERICUT’s reports to document operation setups, or how machined parts should look at various stages.

Multi Tool Station
The new Multi Tool Station tool component has been added in Tool Manager, enabling users to setup an apparatus that holds multiple tools, attached to a single turret station.

Tool Change List Panel
Tool Change List Panel is enhanced with capabilities to graphically setup tools on turrets, in tool chains, define orientations for “Flash” multi-function tools, and more.

Reviewer App
VERICUT’s Reviewer application is powered by the same enhanced graphics engine featured in VERICUT Verification, and users will also immediately notice the dramatic boost in performance.

New Section Window
The new Section Window is easier to use with dynamic section plane locations and angle adjustments.
For more information about VERICUT 9.0 visit CGTech at the Southern Manufacturing Exhibition or visit www.cgtech.co.uk

VC90 Sample

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Note to Editors
About CGTech
CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimisation, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fiber-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has an extensive network of offices and resellers throughout the world. For more information, visit the CGTech website at www.cgtech.co.uk, call +44 (0)1273 773538, or email info.uk@cgtech.com.

Published in Press Releases 2020
Пятница, 24 января 2020 16:44

CGTech to brings Force Optimization to Ireland

CGTech is powering into the National Manufacturing & Supply Chain Conference, which will take place on the 29th & 30th January at Citywest Exhibition Centre, Dublin, with its physics-based feed rate optimization module, VERICUT Force.

As the world’s most advanced independent CNC machine tool simulation, verification and optimization software, VERICUT it as at the heart of the CNC manufacturing process for all leading engineering businesses in all industry sectors across the globe. The latest version of VERICUT, version 9.0, offers new powerful and easy-to-use features to improve simulation performance and help streamline each user’s verification process.

Its optimization module, VERICUT Force, reduces machining times by 15-25%, sometimes more, while extending tool life and improving surface finish.

On milling and turning applications alike, Force optimization works by analyzing cutting conditions encountered during simulation and looking for opportunities to increase feedrates where possible, slowing down when cutting forces or spindle power demands are excessive, and breaking up motions into smaller blocks as needed to both maximize chip thickness and keep it consistent throughout the cut.

CGTech also offers Additive Manufacturing capabilities as well as VERICUT Composites application for programming and simulation of Automated Fibre-Placement and Tape-Laying Machines. See the entire VERICUT suite on stand Z19 at the National Manufacturing & Supply Chain Conference & Exhibition 2020


Note to Editors
About CGTech
CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimization, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fibre-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has an extensive network of offices and resellers throughout the world. For more information, visit the CGTech website at www.cgtech.co.uk, call +44 (0)1273 773538, or email info.uk@cgtech.com.

 

 

 

 

Published in Press Releases 2020

JEC WORLDFrom the 3 to 5 March 2020, Paris Nord Villepinte exhibition centre in France will become the focal point for the global composites industry with over 1,300 exhibitors demonstrating the very latest engineering and technological innovations at JEC World. At this year’s international composites trade show CGTech, developers of the world’s most advanced independent CNC simulation and optimization software, VERICUT, will be hosting its ‘Composite Manufacturing Symposium’.

Mark Forth, Global Business Development Manager, asks: “Are you ready for the future of composite manufacturing? CGTech has assembled an international panel of composite manufacturing experts to discuss the challenges facing the industry today and present their experiences across multiple industries. So, attendees can glean practical knowledge and even benchmark their own progress and preparation for the predicted growth of the high-performance lightweight materials sector.”

The symposium sessions will take place in Room 513 within the Paris Nord Villepinte exhibition centre on the first day of the show, on Tuesday, 3 March, at 10:30 am to midday with a free buffet lunch until 1 pm. They will then be repeated in the afternoon from 1 pm to 2.30 pm. For more information, or to register for the symposium, contact Jodie.cosby@cgtech.com

With 44,000 visitors expected at this year’s show the organiser, JEC Group, aims to bring together the decision-makers of the end-user industries from around the world with a range of conferences and discussion groups covering the whole supply chain. This year, the organiser’s focus falls on the automotive, aerospace, and sports & health industries, covering all issues relating to composites in these strategic sectors.

“For these, and many other industry sectors, new technologies, materials and processes are transforming how components are manufactured,” Mark Forth points out. “If you are shaping the future of your company's composite manufacturing, then our Composites Symposium event will inspire and engage you with informative keynotes, a focus on innovation and will also provide networking opportunities. It really should be seen as an unmissable ‘knowledge grab’ for anyone attending JEC World.”

Visitors to JEC World can also call onto the CGTech stand, P30 in Hall 5, where live demonstrations of the latest CNC simulation software, VERICUT Version 9.0, will be offered alongside the opportunity to discuss productivity and efficiency gains.

VERICUT offers specific modules to support manufacturers in the composites sector; VERICUT Composite Programming (VCP) and VERICUT Composite Simulation (VCS).

VCP gives composite part designers complete control over their part. With a wide variety of path laying algorithms, engineers can ensure that they capture the design intent of their composite work piece. Using tools inside of VCP, the part designer or engineer can easily create and experiment with various Automated Fibre Placement (AFP) path options. They can also evaluate the effects of AFP manufacturing on a composite part’s design intent.
The user can measure and evaluate the effects of AFP path trajectory, material steering, surface curvature, course convergence and other process constraints as they would be applied in manufacturing.

VCP can be used to program any number of machines. It includes support for probing, knife trimming paths, laser projection, and Automated Tape Laying (ATL) machines. Reading CAD surfaces and ply boundary information for fibre placement from leading software systems, including CATIA, STEP, Siemens NX, Pro E, Creo, SolidWorks, or ACIS surface models.

VCS gives an entire organization the confidence needed to run composite NC machines correctly the first time. Regardless of the programming system used (VCP or others), users can verify NC code to identify issues, such as: collisions, NC syntax errors, and material placement quality. Because the material is applied to the layup form via NC program instructions in a virtual CNC simulation environment, the simulated part can be measured and inspected to ensure the NC program follows manufacturing constraints. A report showing simulation results and statistical information can be created automatically to help build confidence with operators and management. VCS can be used to simulate any number of machines, and includes support for probing, knife trimming paths, laser projection, Automated Fibre Placement (AFP), and Automated Tape Laying (ATL) machines.

For manufacturers applying robotic automation to cutting and trimming, drilling and fastening, as well as fibre placement, VERICUT simulates 6-axis articulated-arm robot motion from leading robot machine builders including Fanuc, KUKA, ABB, Kawasaki, Motorman and others. VERICUT also supports robots that have additional ‘external’ axes such as those mounted on a linear rail.

Mark Forth concludes: “Implementing automated composite manufacturing requires a significant investment, both in capital equipment and staff knowledge. This might inhibit many manufactures from applying automation, despite the clear advantages.

“To address this, we have produced a ‘Roadmap to Automated Composites’, and this paper provides a business case for adopting automated composites, pointing out considerations when deciding upon a machine. By shedding light onto these specific considerations, informed and successful steps can be taken to implement this constantly evolving technology. JEC World visitors, to our symposium or our stand, can access this information and discuss their composite challenges in confidence with CGTech staff.”

The ‘Roadmap to Automated Composites’ can be downloaded at https://cgtech.com/images/pdf/Roadmap-to-Automated-Composites_final.pdf

VCS 90 EI Spar

Note to Editors
About CGTech
CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimization, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fibre-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has an extensive network of offices and resellers throughout the world. For more information, visit the CGTech website at www.cgtech.co.uk, call +44 (0)1273 773538, or email info.uk@cgtech.com.

 

 

 

 

Published in Press Releases 2020
Вторник, 25 февраля 2020 13:56

MACH 2020 20 to 24 April NEC Birmingham

Disruption is sometimes the only way forward says CGTech (Hall 17 Stand 330)

X caliper‘If you always do what you’ve always done, you’ll always get what you’ve always got’ is a truism that CGTech, developer of VERICUT – the world’s leading CNC simulation, verification and optimization software - has been stating to manufacturers in many industry sectors since 1988.

Visitors to the MACH 2020 exhibition (Hall 17 Stand 330) can find out from the renowned global leader in NC code simulation how the software can improve (disrupt) their business. With VERICUT, CGTech offers a wide range of products and solutions that ensure CNC machine tools run collision-free and manufacturing processes operate more efficiently with increased profit levels. Machine shops can take back control and get ahead with VERICUT.

Demonstrations of the latest features in version 9.0 of VERICUT CNC machine simulation and optimization software will be conducted on the stand, by the company’s knowledgeable technical staff. VERICUT software is the industry standard for simulating CNC machining in order to detect errors, potential collisions, or areas of inefficiency. It operates independently; but can also be integrated with leading CAM systems.

Technical Director, Gavin Powell, says: “Faster is better, with the development of our new graphics display providing significant gains for users. You can render faster with more realistic and crisper views of cutting processes and machines. With dramatic improvements in the view environment; rotate or zoom while cutting, seamlessly switch view types or layouts, and change model translucency, colours or other appearance properties at any time. New flexibility to use major functions (like Section, X-Caliper and AUTO-DIFF) in any view will help programmers get things done faster.”

‘Restart’ and ‘Stop At’ capabilities quickly verify changes made to an NC program, and have more control over the simulation. Initiate Restart action on any line in the NC Program window and the simulation quickly processes up to the restart line, then the display updates to show the result. A new Stop At Line Number/Count option enables programmers dealing with looping and branching logic to stop at a specific occurrence number of processing a line in the NC program.

Force aerospace bracket V90a

CGTech will also demonstrate VERICUT’s Force optimization module at MACH. VERICUT + Force provides an integrated simulation-optimization solution that can significantly reduce machining times, improving cutting tool and machine life. New and legacy NC programs can be optimized with Force to run as efficiently and safely as possible. Force is available for milling, turning, and mill-turn machines.

Force is a physics-and mathematics-based module designed to optimize machining feed rates. The software uses actual data for cutting tool forces and spindle power readings to calculate maximum chip thickness and feed rate.

Stock Design view V90 relnotes

Sales Engineer, Scott Ravenscroft, explains: “VERICUT covers the obvious and visible production elements, such as crashes, scrap, gouges and prove outs; Force addresses the hidden opportunities. These include inefficient programming and suboptimal feedrates caused by the CAM system’s inability to adjust cutting feedrates for varying cutting conditions.”

Force relies on proven technology to maximize program efficiency and productivity and typically achieves savings of 8 to 15 per cent on aluminium and 15-plus per cent on difficult to cut materials. Return on investment can often be as little as one production component, with the opportunity to analyze cutting conditions, improve tool life, protect CNC machine tools and reduce operational costs.

Gavin Powell concludes: “Companies now more than ever are realizing the importance of simulation and the digital twin model. We are working closely with our customers and partners around the world to understand their exact needs, we deliver superior technical and economical solutions through the use of advanced technologies.”

Published in Press Releases 2020
Вторник, 25 февраля 2020 13:41

Take back control and stay one step ahead

VERICUT Force revolutionizes NC program optimization – interview with Gavin Powell

Gavin PowellVERICUT Force is new and is leading the way. The physics based software module for NC program optimization analyzes and optimizes cutting conditions during the entire NC program operation. Taking into consideration the respective material, cutting tools and the machining conditions, VERICUT Force generates the maximum reliable feed. Current users see it as one of the best tools in the world of machining in terms of effectiveness and usability. Gavin Powell, Technical Director at CGTech Ltd. comments on VERICUT Force in an interview.

What is Force?
Gavin Powell:
VERICUT Force is a physics-based NC program optimization software module that analyzes and optimizes cutting conditions throughout NC program operations.

Why use Force?
Gavin Powell:
It is by far the best optimization solution on the market. 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 can these benefits help my machine shop?
Gavin Powell:
The benefits of Force are endless - better cutting tool and machine utilization, as well as better utilization of the machinist’s time, so you can increase capacity without adding another machine and have greater confidence when running lights-out machining. There are also significant improvements in part to part and job to job consistency. All this ensures reduced cycle times, faster delivery and improved margins – ultimately making you more competitive.

How can I calculate my expected savings?
Gavin Powell:
Most users see a return on their investment in just 3-6 months. Some of our customers have paid for VERICUT Force on their first optimized project. We have a handy Force Calculator on our website so you can see for yourself exactly what Force could save you.

How does Force make my parts cut faster?
Gavin Powell:
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.

Force Turning

How easy is Force to setup and use?
Gavin Powell:
Easier than any other type of NC program optimization process. User knowledge or software tests are not necessary. Force can optimize every material, on any machine tool, with any cutting tool, using any NC program – whether it’s newly created or old. We have successfully Force optimized many parts improving them further than had already been optimized by other methods.

Does Force overwrite the existing NC program
Gavin Powell:
No. it creates a separate file with a “.opti” extension. Force has a feature to display the original and opti. file side by side. With the Force graphs you can see things like cutting conditions, excessive forces, machining rates, power/torque, chip strength, material removal, tool deflections and feeds for the original and optimized program.

Force Aerospace Bracket V90a

CGTech will be demonstrating VERICUT Force at MACH between 20th – 24th April on stand 17-320. For more information visit: https://www.cgtech.co.uk/products/product-line/92-force.html

Published in Press Releases 2020

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