CNC simulator pre-empts collisions
Second Quarter 2007
Other technologies
Frost & Sullivan Technical Insights
Computer numerically controlled (CNC) machines generally come with huge running and maintenance costs. One way to reduce the running cost is to simulate a process virtually to test its effectiveness before running it in the production environment. The process can be graphically simulated and tested remotely to the shop-floor.
Machine tool motions generally employ a post-processor. The graphical simulations should make use of identical mathematical outputs, which would be practically used on the shop-floor during machine tool motion generation.
Although simulations could effectively make use of the post processor output, in some instances the information provided by the simulator cannot be relied upon and so trial machining has to be performed with soft materials.
In a new development in simulators, Germany-based Open Mind Technologies has come up with a CNC simulator called the MachineSim. Unlike other simulators, this one has an enhanced feature of verifying a particular process before even executing the process directly onto a work-piece.
In the machining process, the simulator runs continuously and dynamically checks for collisions or gouging by rotating and zooming the 3D part design of both the machine and the work-piece. Apart from cutting tools, even the jigs, fixtures, and coolants are continuously monitored using this simulator.
Another interesting feature of this simulator is that every simulation can be paused, fast-forwarded, and rewound to better understand the machining process. This allows easy and quick machining of parts at different speeds, feeds, and depth of cuts.
The simulator is further enhanced with a patented collision avoidance technology, which helps not only in detection but also avoidance of a prospective collision. Traditional collision detection techniques would help in only tracking collision, whereas the rectification should be done manually by the computer-aided manufacturing (CAM) programmer. This enhanced feature further negates the need to verify tool path and machine tool simulation, as collisions and obstacles of any kind are intelligently avoided using this technology.
Primarily, there are three major collision avoidance strategies involved in this process. In case of a holder collision, the simulator might opt for aborting the machining calculation even before colliding with the first point of contact. Or else, it could continue the machining calculation beyond the prospective point of collision without producing any actual output or could continue calculating the motion of the part with which the tool is not included in the collision.
For more information on Frost & Sullivan Technical Insights contact Patrick Cairns at [email protected]
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