S L Meena

Assistant Professor
Rajasthan Technical University

November 14, 2019

• NC Simulation provides a virtual preview of a
computer programmed machining process.

• Useful in performing virtual NC programme

validation & it gives ability to control & simulate
machine tool motion.

• It ensures high quality & optimized NC programme

by finding potentially damaging collisions, excessive
non- value added machining motion.

• Detects possible collision, missing operations etc.

November 14, 2019

1. Helps in performing more complex operations.
2. Automatically reports the details of accidents when
collision occurred.
3. Generate “fault list”, which can be analyzed at end
of the process.
4. Collision detection.
5. Cycle time calculation.
6. Provide Critical workflow support for Programmer.

November 14, 2019

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 1. Geometric Simulation
 Used for verifying graphically the absence of interferences and
collision and others aspects of tolerance imposed by designer.

2. Physical Simulation
 Used to reveals the physical aspects of machining such as-

• Cutting forces
• Vibrations
• Surface finish
• Machining temperature &
• Tool wear

November 14, 2019

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• Kinematic Simulation provides complete quantitative
information about the kinematics-including position,
velocity and acceleration, & dynamics –including
joint reactions, inertia forces and power
requirement of all the mechanism.

• It can calculate the effect of:

 Forces
 Springs
 Gravity
 Contacts b/w components
 Bushings

November 14, 2019

  There are different ways of classifying Volumetric NC
Simulation:-

• Wireframe based
• Solid based
• CSG based
• B-Rep-based
• Object space based

• Wireframe based

 The trajectory and the shape of the machined work piece are
displayed under shape of wire.
 It has been applied extensively in the beginning of the
machining simulation.
 This model remains applicable to parts of simple geometry

November 14, 2019

• Solid based

 The solid-based simulation is a 3D volumic

representation.
 It is used for the geometric and the physical
simulations.
 This model permits a very accurate geometric
representation but expensive.

• CSG based

 It defines the constructive form of a 3D model

using primitive volumes such as cylinders,
spheres etc.
 CSG uses Boolean operations and data analysis
may require a transformation into another B-Rep
model.
November 14, 2019
• B-Rep-based

 This model is suitable for viewing.

 Unlike the CSG model, the B-Rep model explicitly
defines the volume by a list of surfaces, edges
and vertices.
 The computational cost is high in terms of time,
storage of data and complexity.

• Object space based

 The parts are represented by a set of discrete

points with vectors or surfaces with vectors or
some volume elements.
 There are three main decomposition methods for
machining simulation patterns for object based
space model
November 14, 2019
1. For operator safety - first level of safety
priority
2. For Machine tool safety – second level
of safety priority
3. For Workpiece safety – third level of
safety priority

November 14, 2019

 The verification of NC programs is very
necessary to detect the mistakes while
running the programs and to correct them
otherwise it may result in a severe damage
(to operator/workpiece/machine tool).

November 14, 2019

Steps for Verification Of NC programs
1. The machine lock dry run
2. Free flowing dry run
3. Normal air cutting cycle execution
4. Running the first workpiece

November 14, 2019

• Greater flexibility
• Reduced lead times
• Reduced inventories
• Increased Productivity
• Improved customer service
• Improved quality
• Better product design
• Greater manufacturing control
• Supported integration
• Reduced costs
• Increased utilization
• Reduction of machine tools

November 14, 2019

• Multi-axis milling, drilling, turning, mill-turn, EDM.
• Simultaneous mill/turn on different spindles and
work pieces.
• Machines with multiple synchronized CNC controls.
• Auxiliary attachments: tail stock, steady rests, part
catchers, bar pullers, pallet changers, etc.
• Automatic work piece transfer to pick-off or sub-
spindles

November 14, 2019

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