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The addition of CAD/CAM software to CNC machining has typically included simulations. These have helped in visualizing the part design with a 3D model that can be viewed from various angles. As CNC machining advances, so do the tools and software that support it. Simulation software is no exception. The latest advance in simulation software is about more than speed. What was once only available with expert simulation engineers is available to any machine shop to view part simulation including full machine and tool overviews.
CNC machines can now move tools at rapid speeds and change those tools almost as quickly. These advances have increased efficiencies, but also add some inherent risks when toolpaths become critical to avoid breakage or complete machine failure. Simulation software has advanced to address these new complexities of CNC machining.
History
The first modeling of a three-dimensional design from CAD software could plot G codes with its CAM software counterpart. This allowed the part to be viewed and changed in shape or design before machining. Viewing the part from various angles also allowed the machinist to plot the best toolpath and determine the best part holding approach.
G codes were then replicated or re-entered into the CNC machine. The machine, itself, does not respond to the CAM software. G codes for each machine manufacturer can vary slightly from standard codes, so this added step was circumvented by post processing software. This eliminated manual data entry, eliminating the potential for human error. And it saved time in transposing the design codes into usable machine codes for faster production.
The next phase in software simulation showed the moving toolpath on the 3D design. This allowed maximizing the cutting path and providing analytics at any point through the software. This improved accuracy and speed with even less room for toolpath errors.
As machines have increased in complexity and speed simulation software is keeping up by simulating the machine environment into the equation. This virtually replicates the entire machining process and can take in factors such as how moving parts interact with the workpiece, unwanted movement, and warping of material. Software developments like this provide full confidence on the shop floor with the faster and more complex CNC machines now available.
Application
This final level (for now) is the biggest change in simulation. It ties directly to feedback software utilized in production for a complete reporting loop. This ability to simulate the exact conditions of the workpiece as it moves through tooling operations affects efficiency, machine maintenance, tool and part wear, and design capability, but with the added benefit of simulated feedback on thermal, fluid, and material fatigue stresses. It can anticipate distortion to the part through the manufacturing process. And this data can be combined with reporting data from the physical manufacturing process for even more accuracy on both ends. It bridges the mathematical equations needed to calculate complex data with what seems like a simple on screen mockup.
Manufacturing software companies are investing more time and money in this new core of simulation. Applications include CHC machining, injection molding, and 3D printing. Accessibility is no longer a rare privilege for manufacturers with large technology budgets and trained simulation specialists. High-performance and supercomputer capabilities are now available through cloud hosting to a variety of clients. Ease of use and integration are key factors in making simulation software more accessible to CNC manufacturing.
CNC shops are quickly advancing into Industry 4.0 where computers are taking the lead in manufacturing. Changes in machine and software complexity still need to be intuitive for the user. Machinists will soon see that simulation software is about more than speed as their inherent knowledge is matched with intelligent systems that provide insight and knowledge transfer that results in precision tooling in machining times they could once never imagine.