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Program, simulate, start: How virtual machines make work easier
More efficient production thanks to virtual tests: Continuously optimizing machine processes - a must for high-volume manufacturers in machining technology. But carrying out the entire optimization process on the real machine? This is too expensive due to the downtimes. A provider of optimization and digitalization services shows how it can be done better and what role NC simulation plays in future-proof CNC production. "You can't do it without NC simulation", Christian Heiß, who has worked in mechanical engineering for over twenty years, knows what he's talking about. He knows the time and cost pressures that manufacturers in the machining industry are under. He sees a particular need for large-scale production with the shortest possible cycle times, such as in the automotive sector: "Manufacturers are investing in ultra-modern 4- and 5-axis machine tools in order to be able to produce faster and more efficiently. However, experience shows that there is often a lack of time or personnel to design the machining process optimally from the outset and to demand the best from the machine. This deficit must then be compensated for by continuous process optimization. Because with the high quantities involved, even minimal delays in the machining process add up."
However, it is not only the necessary process analyses and optimizations that are time-consuming, but above all the subsequent tests of the optimized programs. In order to avoid crashes of the usually expensive special tools, the new, as yet unsimulated NC programs can only be run in very slowly on the machine. Such downtimes cost money, as the expensive lathes and milling machines are not available for production during this time.
HeMuTec has developed a solution for this and offers series manufacturers the entire package: revision of the fixture, tool and program strategy, digitalization of the process components, electronic analysis of the process machining forces and, as the end result, the most efficient component production. A powerful simulation tool plays a key role here. How else could the optimized programs be tested without occupying the machine tool?
Heiß opted for the NCSIMUL software. This allows the NC code to be simulated directly and not just the source code as is usual in CAM systems. This is a crucial prerequisite for being able to edit and simulate existing NC programs. The same applies to conventional high-level language programming using an editor, which is used to make the NC files more intelligent, clearer and, above all, more efficient.
The 3D models initially required for simulation can be imported into the simulation program in a user-friendly way and freely positioned there. Suitable tools can be generated via NCPROFIL.
During the simulation, the processes are then checked for crash safety and optimized. Additional NC functions such as the plausibility check of zero points and tool lengths, automatic block entry and the use of touch probes ensure a completely crash-safe process design. Color displays for material removal illustrate the result. "The analysis tools are particularly helpful," adds Heiß.
Visualization and player function:
In addition to the range of functions, clear structure and stability, it is above all the visualization that the experienced mechanical engineer appreciates about the program. Because while you can hardly see anything on a real machine due to the use of coolant and safety covers, you can move through the virtual simulation process with almost surgical precision: "The graphical resolution is unusually high, I can zoom into practically every single NC block, scroll forwards and backwards, extract sectional drawings and thus adjust travel paths and tool lengths," explains Heiß. "Collision displays are also very detailed and already include the assignment to the corresponding NC block."
The simulation sequence can be exported and used with all functions via the freeware NCSIMUL Player. This proves to be a suitable tool for the operator at the machine or to give potential customers an initial impression based on comparable production processes. "It's so clear and concise that people immediately want to work with the program themselves," says Heiß.
This is exactly what many users do afterwards. Two days of training are usually enough to be able to work with NCSIMUL. The program offers extensions that allow existing programs to be transferred to other machines with just a few clicks, as well as real-time monitoring of the entire machine fleet for better machine utilization.
The future of CNC manufacturing: Production preparation and machine tests on the virtual machine
Heiß also sees the future of CNC production in the fact that the preparatory processes are increasingly being taken over by virtual machines: "Program - simulate - then implement on the machine. The machine tool should be available for production around the clock. Suppliers to the automotive industry are particularly affected by the pressure to be efficient. "The electric motor, powered by batteries and fuel cells, will ultimately prevail," says Heiß, "If many of the components currently used in the combustion engine become superfluous as a result, the pressure on suppliers will increase even further. Only those with automated and truly efficient production will be able to keep pace - and that simply requires professional simulation software."
With this in mind, his company is already planning expansions: Based on a newly ordered 5-axis machine, a separate virtual machine is being set up for this purpose. This will allow complete new component and production processes to be developed and tested at the customer's request, right through to prototype and pre-series production.
Christian Heiß Managing Director of HeMuTec GmbH Image sources : HeMuTec GmbH
It's so clear and concise, people immediately want to work with the program themselves to work with the program themselves"
Summary
Company: HeMuTec GmbH
Business: Provider of optimization and digitization services
Successes with NCSIMUL
Significantly shorter downtimes
Automated and efficient processes
Complete development of component and production processes according to customer requirements
