Extending NX CAM with CNC Feedrate Optimization · Extending NX CAM with CNC Feedrate Optimization...

Extending NX CAM with CNC Feedrate Optimization

Lee Fowkes

CGTech UK

PLM Europe - Siemens PLM Connection 2018Berlin, October 2018

Last Revised LF 23-Oct-2018

Subjects for today

• Why is VERICUT the most popular Independent G-Code Verification product for NX users?– VERICUT plug-in for NX CAM– NX ConnectTM bi-directional interface– Teamcenter MRL Tool Library Interface– Teamcenter PLM Interface*

• Feedrate Optimization of NX Toolpaths• Verification of Additive Manufacturing

FOR PUBLIC USE

NX Connect

• Logger lists issues

• Highlights Operation to revise

• NC Programs - Right First Time!

10/23/2018 FOR PUBLIC USE

New Teamcenter MRL Interface

FOR PUBLIC USE10/23/2018

• VERICUT 8.2 reads tools directly from Teamcenter MRL

• Tooling stays stored in Teamcenter

• No duplication on local drivesTeamcenter MRL Tool Assy

Teamcenter MRL Workflow

10/23/2018 FOR PUBLIC USE

Siemens NX Mfg Project

Teamcenter DB

MRL

Teamcenter

Interface

VERICUT Tool Manager

Teamcenter

Connection

Siemens NX Tool Creation

Searching

FOR PUBLIC USE10/23/2018

• Search NX Tool assys

• Select to Import

Searching

FOR PUBLIC USE10/23/2018

• Search for NX Projects

– Manufacturing only

• Finds all NX Tool Assysin the NX project

• Select All or individual to use in VERICUT

10/23/2018 FOR PUBLIC USE

Teamcenter Revision Checking

10/23/2018 FOR PUBLIC USE

• Reopening a VERICUT session using tools from Teamcenter checks revisions of cutting tools

• Any ‘out of date’tool are flagged

• Tooling data always up to date

• Reduce machining time

• Faster time to market

• Avoid out-sourcing

• Improve part quality

• More consistent results

• Less time deburring

• Longer tool life

• Avoid tool breakage

• Stay competitive

Reasons to optimize

New Machine Tools

New CAM System or path strategy

New Cutting Tool Technology

Many strategy choices

Many strategy choices

• Will a cutter chip, or break?

• How long will your cutters last?

• Will excessive cutting forces damage, or move the part?

• Will a cutter load up with material, or stall the spindle?

Confidence in NC Program Feedrates

• Any existing, or future NC program, G-Code or CLSF, 2-5 axes

• Created by any CAM system or other source

• Run on any CNC machine tool• Cut by any brand cutting tools

Can be made to run faster and better!

Focus on NC optimization

Manufacturing Workflow

VERICUT Usage Flow

AUTO-DIFFAdditive Mfg.

OptiPath/Force

Grinder-Dressing

Optimization

Data

Optimized

Toolpath

CAD/CAM

Interfaces

CA

D/C

AM

Syste

m(s

)

Tooling

Interfaces

& Import

Tool M

gm

tS

yste

m(s

)

3D Models

Fixtures

Design

Machin

e S

hop

Control

Machine

Kinematics

Cutting

Tools

Toolpath

Reports

Screen Display

Stock

• Variables, Subprograms,

Macros

• Subroutines, Looping

and branching log

• Multiple synchronized

CNC controls

• Look-ahead or 3D cutter

compensation

• Tool tip programming &

tool length compensation

• Gage length reference

point programming

• Canned cycles and

fixture offsets

• Rotary axis pivot points

• Auxiliary mechanisms

• Force material

characterizations

• Known good cutting

conditions

• Data gathered from

learn mode

• Log file

• X-caliper results

• AUTO-DIFF report

• Tooling report

• Optimization results

• Inspection sequence

• Setup plan

• Reviewer (PC or iPad)

• Transfer from CAM

• Transfer from Tool

Management interface

• Download from “Cloud”

• Request from tool manuf.

• Model in CAD

• Model in VERICUT

• Obtain from MTB

• Obtain from CGTech

• Model from 2D drawings

• Measure machine

• Custom configuration made by CGTech

• Template VMC provided as-is

• Library VMC included with VERICUT

VERICUT Machine

Configuration (VMC)

Force

Calibration

OptiPath/Force

Optimization

Data

Optimized

ToolpathForce

Calibration

Methods of Optimization

Air Cuts Only – Increase feedrates when the tool is not in contact with material (cutting in air)

– No risk of changing cuts or machined finishes on part

OptiPath– Optimization based on Chip Load and Volume Removal, or both

– Relies on User knowledge of Material type and Cutting capabilities

– Easily manipulated with settings and limits

Force– Optimization based on optimal Chip Load, and considering Force or Power limits

– Relies on cutter-to-material “characterization” data obtained via dyno-testing

– Physics-based force calculations, also takes into account cutter rake and helix angles

Air Cuts Only Optimization

• Increases feedrates for off-part motions in air

• Reduces time of proven NC programs, without changing cuts or surface finishes

• Outputs new “optimized” NC program

• Available to ALL VERICUT users

Time savings can be substantial!

Air Cuts Only Optimization

How it Works

3 EASY steps:

1. Turn on "Air Cuts Only"

3 EASY steps:

1. Turn on "Air Cuts Only"

2. Simulate

How it Works

3 EASY steps:

1. Turn on "Air Cuts Only"

2. Simulate

3. View your savings!

How it Works

Optimized Results• “Compare Files” original v optimized NC program• Highlights changes

Red= original codes

that were modified in

the optimized file

Blue= modified codes

in the optimized file

Methods of Optimization

Air Cuts Only – Increase feedrates when the tool is not in contact with material (cutting in air)

– No risk of changing cuts or machined finishes on part

OptiPath– Optimization based on Chip Load and Volume Removal, or both

– Relies on User knowledge of Material type and Cutting capabilities

– Easily manipulated with settings and limits

Force– Optimization based on optimal Chip Load, and considering Force or Power limits

– Relies on cutter-to-material “characterization” data obtained via dyno-testing

– Physics-based force calculations, also takes into account cutter rake and helix angles

OptiPath Optimization

• Variety of strategies available• Control over chip loads, material removal rates,

adjustments available for “special” cutting conditions• Calculates optimized feedrates based on cutting

conditions encountered• Optimized programs are safer, faster, more efficient• “Learn Mode” availableMore (usually MUCH more) savings than Air Cuts alone

OptiPath Optimization

How OptiPath Works

• Each Tool is assigned an OptiPath record• OptiPath records describe how to optimize

feeds and speeds for various conditions• OptiPath micro-analyzes each cut, and

decides when motion break-up is beneficial

• Calculates new feedrates based on cutting conditions encountered

• Creates a new optimized NC Program (Gcode or CLDATA)

How OptiPath Works

How OptiPath Works

• Constant chip thickness and load extends tool wear and cutter life• Can take deeper cuts-remove more volume• Use more of the cutter = longer tool life High Efficiency milling• Smoother operation and less stress on CNC machine• Better utilization of current CNC equipment = increased capacity

Benefits beyond time savings

How OptiPath Works

• Status window (configurable)

• Graphs window (configurable) hover mouse over graph to display data

“Helpers” for Optimization

Methods of Optimization

Air Cuts Only – Increase feedrates when the tool is not in contact with material (cutting in air)

– No risk of changing cuts or machined finishes on part

OptiPath – Optimization based on Chip Load and Volume Removal, or both

– Relies on User knowledge of Material type and Cutting capabilities

– Easily manipulated with settings and limits

Force– Optimization based on optimal Chip Load, and considering Force or Power limits

– Relies on cutter-to-material “characterization” data obtained via dyno-testing

– Physics-based force calculations, also takes into account cutter rake and helix angles

Force Optimization

1. MATERIAL HARDNESS

Find the SFM range

2. CUTTING TOOL

Find the Chip Load range

3. CNC MACHINE LimitsHP, Torque, Max fpm, Max rpm

4. CNC PROGRAM

RPM (spindle speed)

FPM (feed rate)

CLASSIC MACHINING FORMULAS:

Feed per Tooth: IPT= IPM ÷ Z ÷ RPM Cutting Speed: SFM= D x 0.26 x RPMSpindle Speed: RPM = SFM x 3.82 ÷ D Inch (Feed) per Revolution: IPR (FR) = IPM ÷ RPMTable Feed: IPM= IPT x Z x RPM Metal Removal Cubic IPM: MR= IPM x RDC x ADC

Cutting Physics made Easy!

Force Optimization

• Maintains ideal chip thickness

• Limits forces on cutting tools, or spindle power

• Creates optimized NC programs that run as fast and efficiently as possible, without risk of tool breakage or spindle overload

Great for hard or difficult to cut materials!

How Force Works

PHYSICSBased

• Physics-based optimization uses dyno-tested data to know how the cutter will react in material

• Calculated force and chip thickness results are used to adjust NC program feedrates, so chip thickness will as close to “ideal” as possible, while not exceeding user-specified limits

Why is Chip Thickness important?

"Maximum chip thickness is the most important parameter for achieving a productive and reliable milling process.”

"Effective cutting can only take place when maximum chip thickness is maintained at a value correctly matched to the milling cutter in use.”

“A thin chip... is the most common cause of poor performance resulting in low productivity. This can negatively affect tool life and chip formation. A value that is too high will overload the cutting edge, which can often lead to breakage.”

Force Optimization Process

1. Gather Force Material data– Cutting tests conducted on specific stock

material, with specific cutting tools, to gather data on cutting forces

– Known as Force Material “characterization”

– Force Materials data used to create Force Material (.vcfm) files for VERICUT

1. Gather Force Material data

2. Supply Cutter information

– Cutter Material

– Edge Type: Straight or Serrated

– Helix Angle

– Radial Rake Angle

Force Optimization Process

1. Gather Force Material data2. Supply Cutter information3. Analyze current cutting behavior (Force

“Analysis” mode)– Interactive with mouse- Data Display

panel shows wealth of information

– Note values when program runs well

– Charts “Followers” show where you are in the cutting process

– “Spikes” reveal potentially severe or dangerous cutting conditions

– Integrated with NC Program Review

Force Optimization Process

1. Gather Force Material data

2. Supply Cutter information

3. Analyze current cutting behavior (Force “Analysis” mode)

4. Enter Tool Force Data settings for ideal Chip Thickness, and limits for max Force/Spindle Power, and max Feedrate

Force Optimization Process

1. Gather Force Material data

2. Supply Cutter information

3. Analyze current cutting behavior (Force “Analysis” mode)

4. Enter Tool Force Data settings for ideal Chip Thickness, and limits for max Force/Spindle Power, and max Feedrate

5. Run Force optimization

Force Optimization Process

• Force charts compare original vs optimized NC program data

• Blue graph- Original program

• Red graph- Optimized program

• Red dashed lines- Limits set by user

• Green fill areas- where Force increased chip thickness (= savings)

• Red fill area- potential tool overload condition avoided by Force

Force Optimization Process

“Intelligent” Cutting Tools

• Some tooling vendors and cloud-based distributors include performance values with tool downloads

• Imported cutting tools with performance parameters speed optimization setup

• Mfr recommended values are not always “optimal”

What about Additive Manufacturing?

Machines with Additive capabilities

Big Area Additive Machines

• X

Additive adds Challenges• High-speed multi-axis machines with high-

power lasers = Safety concerns• Powdered metals consistency of• AM machine functions to keep track of:

– Power/Laser: On/Off/Power wattage– Material feed: On/Off/Flow rate– Shielding gas: On/Off– Machine feed: corresponds to material feed

• Adding material (without leaving “Voids”)• Subtracting material• More adding, more subtracting… Keeping

track of current part “build” state

• New $$$ Additive/Hybrid machine

• New manufacturing methods

• New CAM system and programming methods

• New post-processor…

What could possibly go wrong?

VERICUT Usage Flow

AUTO-DIFFAdditive Mfg.

OptiPath/Force

Grinder-Dressing

Optimization

Data

Optimized

Toolpath

CAD/CAM

Interfaces

CA

D/C

AM

Syste

m(s

)

Tooling

Interfaces

& Import

Tool M

gm

tS

yste

m(s

)

3D Models

Fixtures

Design

Machin

e S

hop

Control

Machine

Kinematics

Cutting

Tools

Toolpath

Reports

Screen Display

Stock

• Variables, Subprograms,

Macros

• Subroutines, Looping

and branching log

• Multiple synchronized

CNC controls

• Look-ahead or 3D cutter

compensation

• Tool tip programming &

tool length compensation

• Gage length reference

point programming

• Canned cycles and

fixture offsets

• Rotary axis pivot points

• Auxiliary mechanisms

• Force material

characterizations

• Known good cutting

conditions

• Data gathered from

learn mode

• Log file

• X-caliper results

• AUTO-DIFF report

• Tooling report

• Optimization results

• Inspection sequence

• Setup plan

• Reviewer (PC or iPad)

• Transfer from CAM

• Transfer from Tool

Management interface

• Download from “Cloud”

• Request from tool manuf.

• Model in CAD

• Model in VERICUT

• Obtain from MTB

• Obtain from CGTech

• Model from 2D drawings

• Measure machine

• Custom configuration made by CGTech

• Template VMC provided as-is

• Library VMC included with VERICUT

VERICUT Machine

Configuration (VMC)

Force

Calibration

Additive Mfg.

Checklist for Additive Simulation Ability to Add, Cut, Add, Cut… in any order

Simulate same NC code that will drive the machine

Collision checking for machine and AM components

Verify important AM functions & parameters• Laser activity, power

• Material feed, flow rate

• Shielding gas activity

Combine Additive-Hybrid-Conventional machining setups in any order (verify the entire process)

Didn’t expect that!

54

Mismatch on inside wall Rotary tables went “Home” before tool did

Cladding in wrong location (subtractive didn’t clean up)

“Additive Build Model” Table setup won’t work

Verify the manufacturing process end-to-end

VERICUT Usage Flow

AUTO-DIFFAdditive Mfg.

OptiPath/Force

Grinder-Dressing

Optimization

Data

Optimized

Toolpath

CAD/CAM

Interfaces

CA

D/C

AM

Syste

m(s

)

Tooling

Interfaces

& Import

Tool M

gm

tS

yste

m(s

)

3D Models

Fixtures

Design

Machin

e S

hop

Control

Machine

Kinematics

Cutting

Tools

Toolpath

Reports

Screen Display

Stock

• Variables, Subprograms,

Macros

• Subroutines, Looping

and branching log

• Multiple synchronized

CNC controls

• Look-ahead or 3D cutter

compensation

• Tool tip programming &

tool length compensation

• Gage length reference

point programming

• Canned cycles and

fixture offsets

• Rotary axis pivot points

• Auxiliary mechanisms

• Force material

characterizations

• Known good cutting

conditions

• Data gathered from

learn mode

• Log file

• X-caliper results

• AUTO-DIFF report

• Tooling report

• Optimization results

• Inspection sequence

• Setup plan

• Reviewer (PC or iPad)

• Transfer from CAM

• Transfer from Tool

Management interface

• Download from “Cloud”

• Request from tool manuf.

• Model in CAD

• Model in VERICUT

• Obtain from MTB

• Obtain from CGTech

• Model from 2D drawings

• Measure machine

• Custom configuration made by CGTech

• Template VMC provided as-is

• Library VMC included with VERICUT

VERICUT Machine

Configuration (VMC)

Force

Calibration

Reports

Automated Reports

• Additive usually requires less material• Additive can make inexpensive tooling• Additive processes are typically slower

than subtractive processes• Additive equipment is often limited

• When more strategies are available, simulation and reports help you make informed decisions about which process plan is “optimal”

Free 3D Reviewer

• Windows PCs or tablets, iPad tablets• Capture the entire part manufacturing

process (all operations) so it can be reviewed by anyone

• NC Programmers save Review file after verification/optimization

• Operators and shop personnel preview setups and tool sequences

• QA and others can quickly identify source of non-conforming part features

• Share between departments, or shops