Mimicking machines with simulation

Costly parts and complex machine tools require a G-code program to be verified prior to pressing a machine’s start button. If you are new to 5-axis machining, whether it’s with a milling or multitask machine, consider obtaining assistance from simulation software to efficiently set up a post-processor and verify the strategies coming directly from the CAM system. If you are already familiar with 5-axis machining, G-code simulation will help reduce noncutting time.

But how can you ensure 3-D simulation generates accurate results to entirely replace the prove-out process usually done on a real machine? The following information should strengthen your confidence.

Courtesy of SPRING Technologies

When the space becomes tight, such as on a DMG / Mori Seiki mill/turn machine, simulation software provides critical tooling details.

When done directly on a real machine, the G-code validation process involves three basic steps.

1. Identify program errors. When loading a G-code program for the first time in a machine, the control might provide alarms linked to code integrity. Errors, such as unknown codes, inconsistent motions and out-of-range movements, are identified and require a user to go back and work on the CAM system or post-processor or edit the G code to make it work properly.

2. Check collisions. A dry-run test can consume tedious hours when done directly on the machine. It involves loading the tools in their stations, setting up the fixture and potentially mounting a soft foam-like material as a test workpiece. Some complex programs demand hours of verification with slow motions, but, if executed too quickly, this exercise can cause a dramatic crash. Therefore, it’s risky and potentially expensive. Common errors occur from incorrect program origins, a cutting motion in material with the spindle stopped, insufficient tool length or a rapid motion to reach a tool-change position that generates a tool move across a part and damages it.

3. Inspect the first piece. This part inspection, for example, determines incorrect tool compensations or missing operations.