CGTECH will exhibit VERICUT 9.2 on stand H104 at the Advanced Engineering exhibition from 3rd – 4th November at the National Exhibition Centre (NEC), Birmingham. Advanced Engineering is the UK’s leading annual advanced manufacturing and supply chain event. It brings together the latest technologies and supply chain partners, and reaches into the key sectors of aerospace, automotive, civil, rail, transport and more.

VERICUT is the industry standard for CNC machine simulation to detect incorrect tool path motions, collisions, bugs and other areas for improvement. The latest version, VERICUT 9.2, increases productivity and sustainability with improvements to collision checking and overall performance, as well as enhanced support for “intelligent” cutting tools with cutting performance information and detailed tool reporting. Also added is a 3DLive interface to import GDML files, enabling users to quickly and easily create realistic digital machines and add other moving components (rotary tables, articulating heads, fixtures with moving clamps, etc.) for more realistic simulation.

VERICUT 9.2 also provides important advancements in optimization and monitoring machining processes. VERICUT Force is a physics-based NC program optimization module that can be used with optimize cutting operations. Force makes changes to the program based on the specific stock material, cutting tool properties, and machining conditions encountered during simulation. Force optimized program feed rates maintain an ideal constant chip thickness as much as possible, while simultaneously limiting excessive cutting forces or spindle power requirements.

“With VERICUT 9.2’s amazing improvements to optimization, cutting graphs and ability to import cutting tools with machining ‘intelligence,’ this newest version gives users more information and insights into machining processes,” says Gavin Powell, CGTech UK Technical Director. “Users can view combinations of Cutting Conditions and Force Conditions, and compare the original versus optimized values in new Graphs and Tool Use windows. These windows can also be docked in VERICUT’s desktop for constant monitoring of machining conditions in real time during simulations. This visibility allows them to spot potential flaws and inefficiencies in machining, so they can adjust their strategies or optimize them before running the programs on their NC machines.”

The latest version of VERICUT brings more options for optimization. Force can set a target Chip Thickness and any combination of Force limits such as maximum force, maximum power, and maximum tool deflection. Users can also choose to “Learn From Graphs” to send optimization settings to cutting tools, or change optimization settings for corresponding cutters.

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Note to Editors

About CGTech

CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimisation, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fiber-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has an extensive network of offices and resellers throughout the world. For more information, visit the CGTech website at www.cgtech.co.uk, call +44 (0)1273 773538, or email info.uk@cgtech.com.

Irvine, CA – CGTech is pleased to announce the latest release of VERICUT software, Version 9.2. VERICUT CNC machine simulation, verification, and optimization software simulates all types of CNC machining, additive, and hybrid manufacturing processes. The software operates independently, but can also be integrated with leading CAM systems.

VERICUT 9.2 increases productivity and sustainability with several new features that boost manufacturing efficiency, help preserve machines and cutting tools, increase machine capacity and dramatically reduce repair & scrap costs. Substantial speed increases to collision checking and overall performance, a New 3DLive™ interface, improved cutting tool support, and reporting enhancements are just a few of the notable features in this latest release. Hundreds of customer-driven improvements and software requests were also incorporated in this latest version.

“VERICUT has been designed to meet the needs of all types of shops – from small job shops to OEMs and Tier 1 suppliers that are regularly pushing the limits of CNC technology. The enhancements in version 9.2 provide the speed that shops of all sizes need to produce more efficient programs faster and get their products to market more quickly and competitively, while promoting conservation of valuable material and human resources,” says VERICUT Product Manager, Gene Granata.

CGTech’s integrated simulation-optimization solution, VERICUT Force, also benefits from these latest enhancements. Force drastically reduces machining times extends tool life up to 2x or more, prevents undesirable cutting conditions and improves part quality. VERICUT 9.2 provides Force optimization users with more options for setting and adjusting optimization limits, more comprehensive tooling data and greater customization options for Graphs and Reports.

“VERICUT Force is one of the most exciting new tools for predicative processes control I have utilized,” said Joshua Koch, Business Development Manager at Oregon Manufacturing Innovation Center (OMIC). “I’ve been in the industry for over a decade and programming for half of that, and it’s clear to see how the Force workbench is leading the way in predicative and optimization systems for manufacturing. The system changes the fundamental approach to NC program creation, reducing failure potentials while optimizing toolpath. I am excited to show manufacturers the opportunities for improvement and the potential savings that Force can uncover in their NC programs.”

Collision and Performance Improvements
VERICUT 9.2 brings significant speed increases and improved accuracy to collision checking and overall performance. Users gain substantial speed increases for deep concave collision penetration, turning operations (especially inside diameter work on large parts), and collision checking between highly detailed models such as those having high triangle counts. Simulate material removal at tight cutting resolutions up to 30% faster.

More Options for Optimizing
Optimize your programs by setting target Chip Thickness and any combination of Force limits, including Maximum Force, Maximum Power and Maximum Tool Deflection (*new in VERICUT 9.2). Force can now also control the Spindle Speed. OptiPath has a new “Learn” mode which enables users to choose how aggressively to learn from current cutting results. “Learn From Results” in Graphs can send Force or OptiPath optimization settings, or change optimization strategies for corresponding cutters.

Sandvik/Walter stock material (TMC) alias names have been added, enabling optimizers to search for material names known to them, and determine if suitable Force Materials exist.

Force Turning Improvements
Extend the life of your turning inserts with new ‘Adjust Turning Interrupted Cut’ settings that slow feed rates on motions through gaps or obstructions on turned parts.

New Assembly Manager
Manage libraries of component assemblies, such as robot end effectors, interchangeable machine heads, bolt-on rotary tables, part/fixture setups, and more- to use in other VERICUT projects, or be accessible to other users. Export/import assemblies via right-click options added to the Project Tree, or options in the Configure Component panel.

New 3DLive™ Interface
Simplify the VERICUT machine building process and create more realistic setups in a matter of seconds by importing 3DLive data. Import GDML format files containing 3D geometry, including colors for CNC machines, fixture components and cutting tool holders- along with kinematic information, travel limits, min/max feed rates for axes and initial machine position.

Enhanced Support for Cutting Tools – New Tool Types
VERICUT 9.2 features many new, easy-to-define cutting tools. A few examples are Conical End Mills, Spherical End Mills, and new Thread Mills. VERICUT checks for machining errors according to the specific tools’ capabilities and limitations. VERICUT’s dimensioning tool, X-Caliper, can be used to check the dimensions of drilled or threaded holes and also to display machining information for that related hole.

Enhanced Support for Cutting Tools – Hole Making Tools
New options for Hole Making tools enable users to specify how VERICUT will use Profile or Model File cutters. After choosing the cutter's use, enter any supporting values required to enhance its definition. VERICUT checks for machining errors according to the specific tools’ capabilities and limitations.

Enhancements for Tool Reporting
Create reports with detailed cutting tool information quickly using:
• Automatic Dimensioning for Mill and Hole Making tools, including parametric cutter values, Flute Length, overall Height, Stick-out and Gage distances.
• New Section capability in Tool Manager - Section tool holders or entire tool assemblies to ensure cutters and adapters fit properly inside the holder.
• New dimensioned tool images available in reports.

New Dockable Graphs and Tool Use Windows
The improved Graphs window combines Info Graphs and Force Charts in a new comprehensive and configurable Graphs window. Select any combination of Cutting Conditions and Force Conditions to view in graphs, display cutting limits, and compare optimized versus original values. A new Tool Use window provides convenient views of tool and program run times, as well as optimization savings. Dock either window in your VERICUT desktop to see the information in real time during simulations.

Report Enhancements
Detailed reports for tools using Multi-Tool Stations can now be documented. This includes the ability to store an image of a Multi-Tool Station, along with its orientation, that can be used in VERICUT Reports. There are also several new columns in Reports to describe the turret positions and multi stations used in your simulation. “Instruments” can now be defined in an Inspection Report. Measurements and tolerance values are all editable. Additional enhancements in VERICUT 9.2 reports include; table header and cell fill colors, table cell text coloring, additional control with table column widths, and the ability to copy and paste tables in reports.

About CGTech
CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimization, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fiber-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has offices worldwide. For more information: visit the CGTech website at cgtech.co.uk, call (949) 753-1050, or email info@CGTech.com

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EDITOR’S NOTE: Electronic image attached – VC92 Press Release.jpg

CGTech, VERICUT, and OptiPath are registered trademarks of CGTech.
AUTO-DIFF and X-Caliper are trademarks of CGTech.

G-Code Verification – What are you really checking?

With so much at stake, including the value of the raw or partially completed material, the cutting tools and workholding systems, as well as the structural integrity of the machine tool itself, any NC programming errors will always prove to be costly. Alongside the potential damage to your production capacity there is the prospect of negatively harming the reputation of your business.

While everyone involved with CNC machining understands the importance of checking and verifying the machining process before applying a cutting tool to the raw material, you should consider what are you really checking? More importantly what are you missing?

With multiple lines of code NC, program errors are a common cause of machine crashes and the two main sources of errors are programmer mistakes (we are only human) and errors introduce by the CAM system’s post-processor.

For programmers and machinists the task of manually proving out a process can be a slow – checking line by line, block by block to make sure there are no errors in the program. The machine is held up, production time is occupied and the chances of missing an error that could ultimately result in a very costly crash are extremely high. Especially on complex multi axis machining systems.

An alternative to the manual prove-out is to apply CAM simulation and verification software. Many CAM packages will accurately simulate machine motion and are often used to give feedback about the overall machining process. However, despite advances made within the CAM systems they are still limited when compared to independent third party simulation systems, such as VERICUT.

Limitations of CAM verification
CAM systems offer varying levels of verification based on CL data, that has been post-processed into machine specific G-Code. In reality, this means the CAM system is simulating something different to what the machine will actually run. This is, of course, one of the main hurdles for CAM simulation and verification.

Any simulation that runs on CL data cannot be fully trusted. It is not running the exact same thing that the actual machine is running so there will be differences – in essence it is guessing and projecting what the machine will do as opposed to representing what it will actually do.

In addition, getting true parameters from the machine such as rotary behaviour, shortest distance and so on, is problematic. While machine reference locations such as ‘going home’, where is ‘home’, how does it get there, as well as tool change locations including where does it need to go and how does it get there, are another major limitation of internal CAM verification systems.

The post-processor itself can also introduce errors that could damage the part or the machine. Most CAM verification will use component software for machine simulation, an outsourced generically integrated third party plugin to the software and it is mainly just for material removal and not actually simulating the actual machine motion.

There are some verification systems out there that state “we’re simulating the actual G-Code”. What they are actually doing is posting it and simulating it at the same time and they are projecting what their post is supposed to be doing. So, how can you trust a post-processor driven simulation? Who checks the validity of the post-processor?

Independent G-Code verification is the only way
Independent G-Code verification software, such as VERICUT, verifies post-processed G-Code instead of the CL data. This is the exact same G-Code that runs within the NC system of the machine, so the software is able to carry out a comprehensive machine simulation based on the same data that will operate the machine.

Unlike CAM verification, the machine features, components, fixtures and stock are identical to the physical process and it offers accurate feature-rich models, cylinders, cones and so on. Multiple setups are supported as cut stock is automatically transferred between set-ups in the proper orientation. All cut history is maintained from the first set-up to the second set-up and so on. This allows the user to quickly and easily identify problems, with a click of the mouse.

Measurement and inspection tools allow the user to check and verify the dimensional accuracy of cut models, something most CAM verification systems cannot do. With in-process measuring, known as X-Caliper in VERICUT, cut stock can be measured at any time, including hole depths, volume removal, model thickness, air distance, diameter/radius, centre of gravity and many more. While the AUTO-DIFF feature compares the CAD design model to the simulation to detect differences, gouges or excess material. This way the user can be certain that the final component precisely reflects the design intent.

VERICUT not only simulates and verifies the accuracy of the machining process, it can also optimizes the G-Code by adjusting the feed rates for each cut to make the process safer, faster and more efficient. It drastically reduces cycle times so inadvertently you get faster turnaround, less out-sourcing, reduced tool breakage and longer tool life.

The advantages of using independent G-Code verification
Simulating, verifying and optimizing the machining process with independent G-Code verification software, such as VERICUT, eliminates any fear of a new NC program and reduces setup time. The checking is done during production planning before any real machining starts. So, you never waste valuable machining time and you will be confident that the process will deliver accurate parts with no machine crashes, while adjusting feed rates to optimize machining time and prevent broken cutters.

Given the advantages of using an independent verification system you have to ask ‘is your internal CAM simulation good enough?’

About CGTech
CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimization, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fiber-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has an extensive network of offices and resellers throughout the world. For more information: visit the CGTech website at cgtech.co.uk, call +44 (0)1273 773538, or email info.uk@CGTech.com

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CGTech, VERICUT, and OptiPath are registered trademarks of CGTech.
AUTO-DIFF and X-Caliper are trademarks of CGTech.

Virtual Attendees of the VERICUT Force ‘Live’ event, due to be held on Thursday, 4 March 2021, at Seco Tools and broadcast in real time on LinkedIn, Facebook and YouTube by MTDCNC, will be equipped with the knowledge to make their businesses more efficient, more competitive and more profitable.

Running for 40 minutes, the ‘Live’ webinar will be delivered at 10am and again at 3pm (GMT) and will be a combination of real-world component cutting demonstrations and interactive discussion. The components under the spotlight for this event come from the medical and aerospace sectors. While both parts are relatively high value, but high volume, the expected savings will be a real eye opener for any machine shop looking to make significant improvements to their bottom line.

A tibial tray*, with a global market demand of around 5 million per year, is the medical component example and any savings achieved will be significant. Produced from a 3D printed titanium 64 near net shape blank, an expected Force optimised reduction in cycle time from 6 mins 30 secs to 5 mins 46 secs represents a saving of 11%. This seems meagre compared to the 20% plus often attained by the software. However, with the large volumes required the benefits soon add up. If a machine shop is producing 600,000 per year at an hourly machine rate of £100 it equates to an annual saving of £724,000 or 301 days.

The pylon bracket, a structural aerospace component produced from titanium 6Al-4V, is typical of the complex, high strength-to-weight ratio parts required by the industry. The CAM program will be optimised with Force to improve the cutting conditions and cycle times for each of the various Seco Tools used in the production of the pylon. With a cycle time saving of over 20% expected on this component, again it is easy to see how machine shops can dramatically improve spindle efficiency.

And, the impact of Force optimisation is directly measurable. With reduced machining time (by 20% plus in most cases) and longer tool life your shopfloor will subsequently have more machine capacity. Maybe you could even postpone the purchase of that expensive new machine tool.

An improved cutting action means machined parts are produced to a better quality resulting in less post-production clean up or deburring, saving even more time per part. CAD/CAM programmers also benefit from having correct speeds and feeds information to achieve consistent machining results.

Of course, all these positives feed back to the quoting and estimating department allowing your business to be more aggressive and competitive with schedules and bids.

So, VERICUT Force can be used by every machine shop, whether you are manufacturing large or expensive parts, or very simple widgets. Don’t miss out on this exclusive ‘Live’ event if you want to see how to significantly reduce cycle time, protect and extend the life of your tools and produce better parts with VERICUT Force.

*A tibial tray is part of an implant used for Total Knee Arthroplasty. The part is attached to the shinbone and supports the upper part of the implant. Typically, tibial trays are made from titanium, which exhibits higher tensile strength than the surrounding tibia bone.

To register for the event visit: https://www.cgtech.co.uk/empower-your-business-with-nc-optimization.html

Note to Editors

About CGTech

CGTech’s VERICUT® software is the standard for CNC simulation, verification, optimisation, analysis, and additive manufacturing. CGTech also offers programming and simulation software for composites automated fiber-placement, tape-laying, and drilling/fastening CNC machines. VERICUT software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; CGTech has an extensive network of offices and resellers throughout the world. For more information, visit the CGTech website at www.cgtech.co.uk, call +44 (0)1273 773538, or email info.uk@cgtech.com.