Since 1988 CGTech’s product, VERICUT software, has become the industry standard for simulating CNC machining in order to detect errors, potential collisions, or areas of inefficiency.
It is used by companies of all sizes, universities/trade schools, and government agencies in more than 55 countries. VERICUT enables you to reduce or eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish.
VERICUT simulates all types of CNC machine tools, including those from leading manufacturers such as Mazak, Makino, DMG / Mori Seiki, Okuma, etc. VERICUT runs standalone, but can also be integrated with all leading CAM systems.
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VERICUT is a 3D solids-based software program that interactively simulates the material removal process of an NC program. The program depicts multi-axis milling/drilling as well as multi-axis turning and combination mill/turn machining. It enables you to verify the accuracy and quality of your NC program. Inefficient motion or programming errors that could potentially ruin a part, damage the fixture, or break the cutting tool can be corrected before the program is run on an CNC machine tool.
Feed Rate Optimization
VERICUT is equipped with NC program optimization capabilities. Based on initial programmed feed rates, VERICUT automatically determines the optimum safe feed rate for each cut. Cycle time can be reduced significantly. Optimized feed rates also result in longer cutting tool life, fewer broken cutting tools and scrapped parts, better quality parts due to minimized cutter deflection, and a better finish on part surfaces and edges due to constant tool pressure.
CNC Machine Simulation
VERICUT shows material removal at the workpiece level, but can also simulate entire machine tools as they appear on a shop floor. Machine Simulation detects collisions and near-misses between all machine tool components such as axis slides, heads, turrets, rotary tables, spindles, tool changers, fixtures, work pieces, cutting tools, and other user-defined objects. A user can set up near-miss zones around the components to check for close calls, and detect over-travel errors.
Check out a few of the advanced machine features that VERICUT supports
CNC control features which rotate or define 3D coordinate systems and offsets
Some newer CNC controls provide transformation routines that enable the NC program to be independent of the machine’s physical axes configuration. These features require VERICUT to read the NC program and do the same transformation in order to move the “virtual” axes. Some of these complex transformations establish a new secondary coordinate system, such as TRANS, ROT, ATRANS, and AROT on the Siemens 840D control, or CYCLE DEF 19.1 on the Heidenhain TNC control.
Some transformations allow programming in a virtual “workpiece” coordinate system, such as TRAORI on the Siemens 840D control, or M128 on the Heidenhain TNC control. Other control transformation features enable work offsets to dynamically adjust axis positions based on rotary axis positions, such as Fanuc’s G54.2.
Automatic part transfer between fixtures
Machine tools that automatically transfer the workpiece from one fixture or machining station to another (such as between the main spindle and sub-spindle of a lathe, for example) require a more complex simulation. Clamp and unclamp the workpiece with fixtures or other automatic work holding devices. VERICUT also has the ability to simulate automatic transfer of the machined stock between fixtures. In turning operations, the stock can be divided into two pieces, such as when a piece is clamped in a turning center’s sub-spindle and cut-off.
Index® mill/turn machining center’s multi-channel programming & synchronization
The Index mill/turn machining centers use a unique programming approach to control and synchronize different axes groups, called “channels.” Index’s multiple channels are programmed using a main program which calls sub-programs for each channel. In the VERICUT simulation, the axes for each sub-system (channel) is driven by a sub-program which is synchronized with another sub-system driven by a different sub-program.
Facing head (or “programmable boring bar”)
A facing head is a milling machine head or spindle attachment containing a programmable linear axis perpendicular to the spindle axis. A facing head is usually used on large horizontal machining centers, such as machines from Giddings & Lewis, DS Technologies, Ingersoll, Waldrich Coburg, and others. The tool attached to the facing head is a single point turning tool or boring bar. Simulation of the facing head motion requires VERICUT to spin all components connected to the spindle, and remove material with the spinning tool.
CNC controls which allow programming of the tool axis using IJK tool axis vectors
Some newer CNC controls allow programming a machine tool’s rotary axes by specifying the cutting tool’s orientation relative to the workpiece using IJK vectors, rather than the traditional direct programming of the A, B, or C axis angles. The CNC control is doing the work typically done in the post-processor. Simulation of this motion requires the equivalent calculation to drive VERICUT’s virtual machine axes. Advanced Machine Features enables VERICUT’s IJK-to-ABC calculation function.
Turning operations which are not symmetric about the lathe spindle, such as crankshaft turning
Special turning operations not symmetric about the lathe spindle are used in some machining operations. These asymmetric turning operations, such as when turning the connecting rod pin on an automobile engine crankshaft, can be simulated in VERICUT. This also supports non-turning material removal using a non-rotating tool, such as when broaching.
Parallel kinematics machines
Some machine tools orient the tool axis using a linkage mechanism rather than the traditional rotary axes. This is commonly called “parallel kinematics.” VERICUT specifically simulates the Ecospeed® tripod head from DS Technologies. Other kinematics are available upon request.
Stop on contact
VERICUT supports commanding machine components to move until they contact other components. For example, using this feature it is possible to simulate a turning center bar feed action where the workpiece feeds out until it contacts a bar stop, or simulate automatic workholding devices such as a programmable steady rest that advances it’s rollers until they touch the workpiece.