HEXAGON PRODUCTION SOFTWARE issued a new edition to its NCSIMUL machining simulation — or "digital twin" — platform, with improved CNC program quality through automatic and predictive analysis. The developer emphasized that new and enhanced functions keep the simulation software at the forefront of Industry 4.0 Smart Factory technology.
NCSIMUL 2021 builds the real-life machining environment virtually, to avoid errors and decrease set-up times, as well as to switch CNC programs between machines.
The new release introduces a comparison mode that detects excessive material during a fast and hidden simulation, and it shows a solid comparison between the CAD/CAM models or previous cut stock and the NCSIMUL simulated model.
According to technical director Philippe Legoupi, NCSIMUL 2021's new functions offer the only way to detect unwanted rest stock on a large part. It presents a list of the excess material for the workpiece, which can be displayed in a 3D window linked to the list. Among the benefits are the abilities to find small, missing drill holes on large aerospace components and missing holes that need to be connected on mold bodies and hydraulic parts.
Integrated to NCDoc, "Dimensioning" is a new function that creates control instructions for operators during the CNC process. It defines a dimension checklist with user-defined tolerances, automatically defines the minimum measurement needed for each cut, generates a comprehensive view for the programmer and operator on the 3D simulation, and works with the NCDoc documentation template. This saves time and costs, particularly when using the Wizard to create the correct number of measurements, even when using a probe tool on the machine.
A new set of options quickly evaluate tools that can benefit from air-cutting optimization, with the ‘out of material working time’ in the sequence list. This works with the NCDoc documentation template, and customizes stock nearness values for each sequence; the optimization is automatically stored for future strategies.
Enhancements to editing the Setup function reduce simulation time by merging fixtures, parts, and rough stock elements from one (or multiple) CAD files read in NCSIMUL. “It creates simple, geometric rough stock – either cylinder or cubes – an automatic part envelope, and all setup elements can move up or down,” according to Legoupi.
Improvements to mill-turn tooling include management for ESPRIT CAM and TopSolid CAM interfaces: With a new ‘Configuration interface file’ associated to each digital twin, it is now possible to define the mapping of tool-assembly positioning – station number, turret and orientation – between the CAM system and NCSIMUL. This means the interfaces can create NCSIMUL projects ready to run the simulation.
A simplified 2D display for turning parts improves the analysis of dynamic rough stock. “It quickly displays the tool and toolpath next to the cut model and reference part profiles,” according to Legoupi.
The document center is available online now, and includes additional descriptions of the released versions, including more details under the ‘case studies’ and ‘focus on’ tabs.
Finally, for cutting-tool wear simulation as defined in the tool magazine, a button now runs the simulation for tools either ‘fresh out of the box,’ or ‘worn down.’ User-defined values apply for each cutting tool, and the system can check if a worn tool will generate alarms or collisions with unwanted rest stock material. This defines the sharpening rules, and decreases tool consumption.
“The enhanced functionality in NCSIMUL 2021 further increases shop-floor productivity and reduces manufacturing costs,” Legoupi said.
Learn more at www.ncsimul.com