Simulation in the CAM system: machine and material removal
There are sound economic reasons for performing a collision check during NC programming. A collision can result in material damage to the component and the machine tool, and time delay during service. The resulting downtimes often lead to delivery delays and reduced customer satisfaction.
Because subsequent manual collision avoidance is not usually feasible. hyperVIEW® accounts for collision checks: a machine simulation with material removal simulation that is a fixed component of the hyperMILL® CAM software. This high-performance control tool allows the user to precisely visualise the generated milling paths.
There are a variety of different application areas for machine simulations that all make different demands on the performance of these systems. General application areas include:
- Calculation and visualisation of the material removal for checking, evaluating and optimising the machining process
- Visualisation of machine movements when planning machine purchases and machine allocations, preparing bid proposals, in the programming environment and in the production environment
Details for Simulation
- High level of process reliability (collision, workspace)
- Flexible manufacturing by means of fast machine replacement
- Reduced setup costs using workspace analysis
- Interactive tool engagement possibilities in cases of collision or limit switch problems
- More accurate estimation of costs in the offer phase
- Support during the supply of new machines
- Complete integration of all functions during the calculation
On-screen simulation: hyperVIEW®. The simulation software provides fast and dynamic simulations of all your tool movements before the final NC program is generated. Thanks to the intuitive user interface, the application is both simple and reliable. The model can be rotated or enlarged for the simulation. Models can be loaded and saved at any time.
Using machine simulations to control the machining process
Machine simulations can be used to control, evaluate and optimise the machining process. This also includes the calculation and visualisation of the material removal. Here, a number of individual operations must be machined from different directions and in different clamping positions and may include complex undercuts. To guarantee maximum process reliability, the machine and material removal simulation for a defined machine model takes into account not only the workpiece, tool and tool holder, fixtures and clamps, but also the traverse paths of the different machine axes.
Visualisation of machine movements:
- for offers, machine purchases and machine allocations
- in the programming environment
- in the production environment
Some machining conditions, such as an asymmetric spindle housing may not be checked during hyperMILL calculations. A graphic simulation is used to increase process assurance in these cases.
Machine and removal simulation: Reliable monitoring – reliable milling
Based on the stored machine model, workspace monitoring checks whether any limit switches are traversed by the 2D, 3D, 3+2 or 5-axis simultaneous machining movements. The movements of both the linear axes (X, Y and Z) and the circular axes (A, B and C) are checked, and clamps and clamping systems are included. Error messages and colour highlighting in the graphical overview alert the user when a limit switch is traversed. Workspace monitoring is available in the following simulation mode:
- with machine
- with machine and material removal simulation.
In addition, hyperMILL®’s unique best fit function automatically optimises the machining operation to match the available workspace. Workspace monitoring is thus able to indicate that limit switches have been traversed but that the actual workspace is still sufficient for machining. In this case the best fit function automatically determines the optimal workspace utilisation – taking into account the clamps and the tools used but without recalculating the corresponding machining steps. As well as providing better process reliability, this also increases machine efficiency and precision – particularly for small-scale and limited-function machines – as unnecessary set-up changes and downtimes are avoided.