NC Machine Simulation

NC Machine Simulation
CimatronE 10.0 User Guide

CimatronE 10.0 NC Machine Simulation User Guide ⎪i
Table of Contents
Standard Machine Simulation ................................................................................................................1
What's New...............................................................................................................................................1
Feature Description ...............................................................................................................................26
Windows .............................................................................................................................................39
New Machine Setup ...............................................................................................................................74
CimatronE 10.0 NC Machine Simulation User Guide ⎪1
Standard Machine Simulation

The Standard simulator provides a simulation of the whole machining environment, the cutter,
holder, stock, machining table and CNC machine.
What's New
What's New
Release 2008.12
Simulation
• MachSim GUI (toolpath): a new toolbar for toolpath analysis and rendering has been added,
and it makes available for the user the following actions:
display the tool path corresponding to tool center.
display the tool path corresponding to tool tip.
display the entire tool path.
display only the current operation.
display the tool path in 'follow' mode.
display the tool path in 'trace' mode.
display the tool axis vectors.

display the tool path points.
• New features have been added to MachSim toolpath analysis UI, for:
1. adjusting the graphic toolpath colors inside a defined range
2. autoadjust the graphic toolpath colors inside the minim, maxim values valid in the current
simulation.
This modes are available for:
-rotary axis values change
-rotary axis values scale
• MachSim is now able to load the CutSim plug in twice to simulate multiple spindles.
• Additional view position accessible via the view toolbar
• A global tool bar button allows now direct reset and restart of the machine and material
simulation.
• Added new 'simulation modes' concept. These are predefined sets of items and functionalities
to be displayed and activated in the simulation window. The modes should help the user
examine the three main components of the simulation: tool path (with collision check),
material verification (with gouge check) and kinematic motions (without collision checking).
1) Tool Path Backplot Mode: Tool path visible without material removal at this stage
2) Material Removal Mode: Only material removal is visible, no tool path at this stage
3) Machine Kinematic Mode: No tool path backplot and material removal at this stage.
• Bounding cylinder around drive surface, can now be used as initial stock.
What's New
Release 2009.06
Simulation
• A new tool path colorization mode "Height Change"is available. In this mode the analysis is
reflecting the "plunge" and "retract" moves of the tool.
• A new toolpath analysis mode "with collision checking" is available. The collision checking
is performed at run-time. The tool path will reflect the status of each move (checked in
collision, checked collision free, and not checked), with 3 distinct colors, and the colorization
of the tool path will be done while the tool will move forward/backward during simulation.
Not simulated moves are not checked.
• A new tool path analysis mode "Feeds" is available. It will colorize the current tool path
depending on each move feed rate, machining rate or rapid rate.
• New data model, 3+2, for CutSim available. This data model is optimized for prismatic (3+2)
parts.
• New edge highlighting for CutSim material removal is available. The edge highlighting is
available for the 3 axis and the new 3+2 axis data model.
What's New
Release 2009.09
Simulation
• 'Show/Hide Tool' and 'Show/Hide Machine Housing' buttons have the drop down menu with
three items: - Show - Transparent - Hide
• Hotkey layout will be saved within the layout file.

• The tool path analysis 'Height Change' has been modified to reflect the following tool action:
1) Plunge - tool moves almost vertical in range [0, +/-3] degrees 2) Down - tool moves in
range [+/-3, +/-87] deg. 3) Horizontal - tool moves almost horizontal between [+/-87, +/-90]
deg. 4) Up - tool moves upwards between [-/+3, -/+87] deg. 5) Retract - tool moves almost
vertical upwards between [0, +/-3] deg.
• New key dialog has been modified and new assignments have been implemented.
1) Tool Path Backplot Mode -->'b'

2) Material Verification Mode -->'v'
3) Machine Kinematic Mode --> 'k'
4) Tool Focus --> 't'
5) Workpiece Focus --> 'w'
6) Machine Focus --> 'm'
7) Step forward --> 'Page Down'
8) Step backwards --> 'Page Up'
9) Run --> 'r'
10) Stop --> 's'

11) Pause --> 'p'
12) Previous Opertaion --> 'Backspace'
13) Next Operation --> 'Enter'
14) Restart --> 'Home'
15) Loop --> 'l'
16) Fast Run --> 'Space'
17) Speed up --> '+'
18) Speed down --> '-'
• The machine definition has been extended with a new dynamic element, the fixture. Now it is
possible to put a fixture on the table, beside the workpiece.
• Machine editing has been improved. If the 'Edit machine' button is pressed, a property list of
the selected element appears. Settings can be made directly to that list.
What's New
Release 2009.12
Simulation
• Enable the hourglass cursor during initialization of a stock.
• New method to interactively remove waste material / free workpiece parts after the removal
simulation. It is called 'Delete/Keep parts' and is available under the measure tab.
• A new toolbar with a new button “Make Gouge Report” is introduced to initiate the deviation
mechanism and update the Report pane. This new button will have two distinctive figures on
it:
- Main color Red - no deviation check was done after CutSim removed material.
- Main color Green - CutSim did not remove material after the last deviation check.
• Simulation of Stock removal now offers improved zoom options allowing detailed definition
of small areas to be shown with full definition of sharp edges where present.
What's New
Release 2010.03
Simulation
Multi core calculation support for material removal simulation

Simulation without multi core calculation: Simulation with multi core calculation:
Simulation without multi core calculation:
Simulation with multi core calculation:

Manual dragging of the tool
The repositioning can be done in the plane orthogonal on the tool's orientation (Ctrl+Shift+left
mouse button), along the tool axis (Ctrl+Shift+right mouse button) or through teleport
(Shift+left mouse button double click).
Show and hide slider in manual axis control
It is now possible to hide the slider of an kinematic axis in the manual slider window. It will
be set by 'Show slider' flag. This feature comes in very handy in case you have too many
manual axes defined, eg. doors, which you actually don't want to see in the manual axis slider.
In case it is set to false the slider will disappear.

Python scripting for non post relevant kinematic axes is available
With the python script it is possible to apply a motion to an axes which is not used for posting.
The following animation shows a portal machine with a very long Z axes range. This Z axis
can only be reached with 2 Z axes moving simultaneously, the one extending the other. Via
posting it is only possible to control the main Z axis. But for the simulation it is necessary that
2 axes are moving together.
Saveuistate flag is available inside machsim.ini file
The flag indicates whether or not a latest UI state should be restored in the next session.
Improved control for 3D devices

Getting Started
Navigation inside the simulation window
It is necessary to navigate in the simulation window in order to observe the model and simulation
process.
Panning:
Panning (2D shift) involves having the geometry traverse across the screen. This can be
accomplished by holding the CTRL button and dragging while pressing the middle mouse
button . Any movement of the mouse will traverse the geometry accordingly.
Zooming:
Zooming involves having the geometry appear closer or farther away on the screen. This can
be done by using the mouse wheel to zoom in or zoom out.
Rotation:
Rotation involves having the geometry spin on the screen. The geometry will rotate around the
mouse pointer. Rotation can be accomplished by dragging after the left mouse button click.
Navigation inside the simulation window
The machining simulation is visualized in three main 'simulation modes' and three 'simulation focus'.
• The modes are predefined sets of items to be displayed in the simulation window. The modes
should help the user examine the three main components of the simulation: tool path (with
collision check), material verification (with gouge check) kinematic motions (with collision
check).
• The focus gives user the opportunity to directly zoom and observe the elements tool, work
piece and machine. Each element then is in stationery position at any time.
So the simulation will always be a combination of one mode and one focus. This gives quick
access to one of the simulation components with only necessary elements on the screen. Select the
combination from following modes and focus:
1. Tool Path Backplot Mode: Tool path visible without material removal at this stage
2. Material Removal Mode: Only material removal is visible, no tool path at this stage
3. Machine Kinematic Mode: No tool path backplot and material removal at this stage.
1. Tool Focus: Only tool and work piece visible. Tool is stationary, work piece moves
around tool
2. Work Piece Focus: Only tool and work piece visible. Work piece is stationary, tool
moves around work piece
3. Machine Focus: Machine and work piece are visible. Machine is stationary, work piece is
mounted on the table
Control
Run: Starts the simulation.
Step Forward/backwards: Step forward/backward allows steps through the tool path
to the next/previous single tool path segment
Next/Previous Operation: Next /previous operation allows to navigate to the

next/previous operation.
Fast Run: Whenever '' Fast Forward Button '' button is pressed, the simulation starts from
the selected step and goes to the last step without showing the simulation precess on the
simulation window. Note that if any collision is happened during this operation, then this
collision will be reported
Reload: When this button is pressed the machining starts over again from the beginning.
Loop: When this button is activated then the machining starts over again once it is
finished.
Simulation Speed: The '' Simulation speed '' control bar allows the user to run the
simulation faster/slower or to show simulation with some steps on the display screen. The
slider is divided in two parts since the speed slider is set on the middle by default. The slider
has double functionality:
Time based machining: The machining simulation will displayed with real time feed rate
motions. Machine motions a very fluent, machining time is exact.
Nc based machining: The machining simulation only uses the NC code positions from the
move list. Machine motion jump from one position to the next.
Feature Description
Description of User Interface
With the Machine Simulation application loaded you see the Machine Simulation Window. The
window itself can be defined into different desktop elements:
Simulation Window
Tool Bar Icons
Main Menu
Configuration and Information tabs
Simulation Window
The ''Simulation Window' is usually the largest area of the screen. This is where user observe
simulation process.
The machine model itself.
A '' Coordinate cross ''. The coordinate cross shows the orientation and direction of X, Y and Z axis.
So user can orient himself by using this.
A '' Ruler '' The ruler can be used for measuring and evaluating different distances. The value which
is displaying on this bar shows the real length of this black bar, and it is updating by each
movement. So anything on the simulation screen with the length of this bar has the dimension of
displaying value.
A "Work piece Center Point". This indicates the zero point of the work piece.
The machining time information panel. It is only visible in case the simulation metric set to time
based mode
Tool Bar Icons

The tool bar icons contain the tools to assist user in manipulating the display and simulation.
The tool bar icons are grouped into sub tool bar groups:
View
Manipulates the view direction of the machine and fits the elements to the screen
Fit: Fits to all elements on the screen
Isometric: Rotates to isometric view
Top: Rotates to top view
Front: Rotates to front view
Right: Rotates to right view
Bottom: Rotates to bottom view
Left: Rotates to left view
Back: Rotates to back view

Visibility
Sets certain elements to visible/invisible
Tool path
Tool
Workpiece
Material
Initial Stock
Machine housing
Simulation
Gives control above the machining process
Step Forward/backwards: Step forward/backward allows steps through the tool path to the
next/previous single tool path segment
Next/Previous Operation: Next /previous operation allows to navigate to the next/previous

operation.
Fast Run: Whenever '' Fast Forward Button '' button is pressed, the simulation starts from the
selected step and goes to the last step without showing the simulation precess on the simulation
window. Note that if any collision is happened during this operation, then this collision will be
reported
Loop: When this button is activated then the machining starts over again once it is finished.
simulation faster/slower or to show simulation with some steps on the display screen. The slider is
divided in two parts since the speed slider is set on the middle by default. The slider has double
functionality:
• 1st: The part from middle to left which controls simulation speed. ( When the slider is in the
middle then simulation speed is maximum )
• 2nd: The part from middle to right which controls steps length of displaying machine simulation
on the screen ( Note:The simulation will run step by step but the display mode will jump from some
steps).
For instance the cursor of simulation speed control bar is on the middle, it means that the maximum
simulation speed is set and the simulation is shown step by step on the display screen. If the slider is
dragged from middle to the left then the simulation speed will decrease and if the slider is dragged
from middle to the right then the simulation speed will not change however the display mode will
jump from 10 to 50 steps depending on how much the slider control is far or close to the middle of
the bar. For example if the slider is dragged to the most right position of the slider, then the
simulation display will jump from 50 steps. Consequently simulation display takes place each 50
steps. If a collision is happened during these eliminated steps, then the collision will be displayed on
screen.
Simulation Metrics
Time based machining: The machining simulation will displayed with real time feed rate
motions. Machine motions a very fluent, machining time is exact.
Nc based machining: The machining simulation only uses the NC code positions from the move
list. Machine motion jump from one position to the next.
Tools
Create Presentation: The resent simulation will be packed in a self running presentation
executable.
Hot Keys: Opens the hot keys dialog.
Settings: Opens the simulation properties dialog.

Simulation Modes
The modes are predefined sets of items to be displayed in the simulation window. The modes should
help the user examine the three main components of the simulation: tool path (with collision check),
material verification (with gouge check) kinematic motions (with collision check).
1. Tool Path Backplot Mode: Tool path visible without material removal at this stage
2. Material Removal Mode: Only material removal is visible, no tool path at this stage
3. Machine Kinematic Mode: No tool path backplot and material removal at this stage.
Focus
Gives user the opportunity to directly zoom and observe elements tool, workpiece and machine in
stationery position at any time.
Tool Focus: Only tool and workpiece visible. Tool is stationary, workpiece moves around tool
Work Piece Focus: Only tool and workpiece visible. Workpiece is stationary, tool moves
around workpice
Machine Focus: Machine and workpice are visible. Machine is stationary, workpiece is mounted
on the table.
Backplot
Gives user the opportunity to directly zoom and observe elements tool, workpiece and machine in
stationery position at any time.
Tool Center: Displays the tool paths on the tool center
Tool Tip: Displays the tool path at the tool tip position
All Operations: Shows all operations
Single Operation: Shows only current operation
Follow: Show only the machined tool path
Trace: Show only the left over tool path
Segment: Shows only certain amount of following and traced segments
Too axis vectors: Shows the tool axis vectors at the tool path points
Tool path point: Indicates tool path segment end and start with points
Leads: Shows/hides the lead in/out
Links: Shows/hides the links motions

Gouge report
The gouge report will internally run the deviation analysis on the part. You will immediately get a
gouge report in the report window.
Hit the red pin icon in the tool bar. The red colour indicates that the deviation has is not yet applied.
When the report is finished the icon turns green. You can find the result of the deviation analysis in
the report window
As you can see in the below there is a small arrow beside each tool bar. Clicking on these arrows
assist user to add or remove buttons from each too bar.
Main Menu
File
Load NC : Loads a NC file from the file system.
Create Presentation : The present simulation will be packed in a self running presentation
executable.
Create Simulation Report : The simulation

View
Full Screen : All windows will be hidden and the simulation window extend to the full screen
Fit: Fits to all elements on the screen
Standard Views:
Isometric: Rotates to isometric view
Top: Rotates to top view
Front: Rotates to front view
Right: Rotates to right view

Bottom: Rotates to bottom view
Left: Rotates to left view
Back: Rotates to back view
Show/Hide: Sets certain elements to visible/invisible
Tool path
Tool
Workpiece
Material
Initial Stock
Machine housing
Focus: Gives user the opportunity to directly zoom and observe elements tool, workpiece and
machine in stationery position at any time.
Tool Focus: Only tool and workpiece visible. Tool is stationary, workpiece moves around
tool
Work Piece Focus: Only tool and workpiece visible. Workpiece is stationary, tool moves
around workpice
Machine Focus: Machine and workpice are visible. Machine is stationary, workpiece is
mounted on the table
Modes:
Tool Path Backplot Mode:
Material Verification Mode:
Machine Kinematic Mode:
Tool Path Rendering
Tool Center: Displays the tool paths on the tool center
Tool Tip: Displays the tool path at the tool tip position
All Operations: Shows all operations
Single Operation: Shows only current operation
Follow: Show only the machined tool path
Trace: Show only the left over tool path
Segment: Shows only certain amount of following and traced segments
Too axis vectors: Shows the tool axis vectors at the tool path points
Tool path point: Indicates tool path segment end and start with points
Leads: Shows/hides the lead in/out
Links: Shows/hides the links motions

Machine
Activate machine editing: Click the right mouse button on an element to

• Add / erase tree elements
• Get into the properties
Save the edited machine

Save the edited machine under a different name in a different folder...
Create a new machine
Load a different existing machine

Control
Step Forward/backwards: Step forward/backward allows steps through the tool path to the
next/previous single tool path segment
Next/Previous Operation: Next /previous operation allows to navigate to the next/previous

operation.
Fast Run: Whenever '' Fast Forward Button '' button is pressed, the simulation starts from the
selected step and goes to the last step without showing the simulation precess on the simulation
window. Note that if any collision is happened during this operation, then this collision will be
reported
Loop: When this button is activated then the machining starts over again once it is finished.
simulation faster/slower or to show simulation with some steps on the display screen. The slider is
divided in two parts since the speed slider is set on the middle by default. The slider has double
functionality:
• 1st: The part from middle to left which controls simulation speed. ( When the slider is in the
middle then simulation speed is maximum )
• 2nd: The part from middle to right which controls steps length of displaying machine simulation
on the screen ( Note:The simulation will run step by step but the display mode will jump from
some steps).
For instance the cursor of simulation speed control bar is on the middle, it means that the maximum
simulation speed is set and the simulation is shown step by step on the display screen. If the slider is
dragged from middle to the left then the simulation speed will decrease and if the slider is dragged
from middle to the right then the simulation speed will not change however the display mode will
jump from 10 to 50 steps depending on how much the slider control is far or close to the middle of
the bar. For example if the slider is dragged to the most right position of the slider, then the
simulation display will jump from 50 steps. Consequently simulation display takes place each 50
steps. If a collision is happened during these eliminated steps, then the collision will be displayed on
screen.
Settings
Hot Keys: Opens the hot keys dialog.
Settings: Opens the simulation properties dialog.
Tool bars: Sets the tool bars visible/invisible

Windows: Sets the window tabs visible/invisible
Layout: Defines the layout of the window

Reset to default: This options resets the window layout to default.
All Components: Show all window tabs
Graphics only: Hides all window tabs
Save to file: Save the current layout to a file
Load from file: Loads a layout from a file
Application Look: The machine simulation can be displayed under different color schemes.
Windows
Tabs
The tabs are free floating windows and can be attached freely on the screen
Stock Analysis
Tool Path Analysis
Move List
Machine
Report
CutSim
Measure
Axis Control
Statistics
Stock Analysis
The stock analysis applies colorization schemes onto the rest material which let the user analyze
after following tool path features
Tool Number
The tool path will be colorized after the different tools being used.
Main benefit:
• Identify the amount of different tools being used
• Identify the area a certain tool is performing a machining (roughing, finishing etc..).
Example:
The following picture shows a machining of a simple bottle. The material is colorized after the
different tools being used. As you can see there are 4 different tools used for the machining.
Operation Number
The tool path will be colorized after the different operations.
Main benefit:
• Identify the amount of different operations.
• Identify the area a certain operations is performing a machining (roughing, finishing etc..).
Example:
The following picture shows a machining of a simple bottle. The material is colorized after the
different operations. As you can see there are 4 different operations.
Deviation
The deviation is a material offset compared to the target geometry. The color of the material will
change the more/less material exists on top of the target geometry
Main benefit:
• Identify the amount of the material left on the target geometry.
• Identify the gouges, when too much material was removed and the target geometry is being
damaged.
• Identify area where a rest machining is necessary
Example:
The following picture shows a machining of a simple bottle. The colorization is from green (min.
material left) to blue (max. material left). You see two significant results:
1. Due to the step over of the machining big cusps are left on the machining surface (left side).
2. The tool being use was to big to get into the area between bottle neck and bottle head. A rest
machining is necessary.
Height Change
The height change indicate whether the tool is diving or being pull into and from that material.
Main benefit:
• Identify if there a plunge motions in the material. In this case the tool must be able to perform
plunging.
• Identify the cutting method, Zig Zag or OneWay
Example:
The following picture shows a machining of a male formed part. The colorization is red (for
plunging) and blue (for retracting). The machining obviously is OneWay, starting from one side
going to the other side.
Orientation Change
The material will be colorized after the orientation change of the machines rotation axis.
Main benefit:
• Identify the rotation speed range being used.
• Identify under which rotation speed a certain area is machined.
• The rotation speed gives feed back where machine speed limits are reached and where you
can expect stability issues of the process which influences the final surface quality.
Example:
The following picture shows a machining of a turbine blade. The colorization is from blue (low
rotation speed) to orange (high rotation speed). You see that especially in the small corner radius the
orientation speed is high. The quality in this area could suffer.
Tool Path Length

The tool path length indicates the length of the tool path segments
Main benefit:
• Identify if the tool path points are equally distributed on the work piece. A constant
distribution generally is better for the machining process and stability.
Example:
The following picture shows a machining of a bottle. You see that the tool path length varies in
certain areay. The tool path points are not equal distributed.
Mark Parts
The part will be colorized into chips which have been separated from the main part.
Main benefit:
• Identify the chips which result after the machining.
Example:
The following picture shows the part after machining. It is divided into 2 parts now.
Tool Path Analysis

The tool path analysis applies colorization schemes onto the rest material which let the user analyze
after following tool path features
Tool Number
The tool path will be colorized after the different tools being used.
Main benefit:
• Identify the amount of different tools being used
• Identify the area a certain tool is performing a machining.
Example:
The following picture shows a machining of a simple bottle. The tool path is colorized after the
different tools being used. As you can see there are 4 different tools being used.
Operation Number
The tool path will be colorized after the different operations being used.
Main benefit:
• Identify the amount of different operations
• Identify the area a certain operation is performing a machining.
Example:
The following picture shows a machining of a simple bottle. The tool path is colorized after the
different operations being used. As you can see there are 4 different operations.
Tool Path sequence

The tool path will be colorized in a 'hot to cold' gradient.
Main benefit:
• Identify start point and the end point of the machining
• Identify the cutting method, eg, if you ZigZag or OneWay.
• Identify the cut order, eg. from inside to outside, from outside to inside.
Example:
The following picture shows a machining of a half sphere. The sequence is form red to blue. You
can read from the colorization the tool path starts outside and ends in the middle of the sphere. Also
it is performed in a one way.
Rotation Axis value
The tool path will be colorized after the tilt angle of the machines rotation axis.
Main benefit:
• Identify the rotation axis angle range being used.
• Identify under which rotation angle a certain area is machined.
• Identify limit overruns.
Example:
The following picture shows a machining of a half sphere. You see that the upper half and the lower
half are machined with a different axis tilting.
Rotation Axis Value Change
The tool path will be colorized after the tilt angle of one (A,B or C) of the machines rotation axis
value changes.
Main benefit:
Example:
The following picture shows a machining of an impeller. The colorization is from green (low
rotation speed) to blue (high rotation speed). You see that especially in the upper segment the speed
is partially very high. At the end and the beginning of the hub the rotation speed is slow.
Rotation Axis Reversal
The tool path will be colorized after rotation axis reversals. So every time a when the rotation axis
changes the direction the tool path segment will change the color.
Main benefit:
• Identify the area where possible contouring errors have negative influence on the machining
result, surface quality
Example:
The following picture shows a machining of a half sphere. You see that in the middle of the
machining the rotation axis performs a reversal.
Linear Axis Reversal
The tool path will be colorized after linear axis reversals. A reversal can be defined by a threshold
angle. Default is 150 deg. So every time a when the linear axis changes the direction > 150 deg. the
tool path segment will be colored red.
Main benefit:
• Identify the area where possible axis reversal have negative influence on the machining
result, surface quality
Example:
The following picture shows a 3 axis machining of a random geometry.

Due to the pattern, in some areas the tool path changes its direction instantly.
Orientation Change
The tool path will be colorized after its orientation change angle between 2 segments.
Main benefit:
• Identify the curvature of the tool path. Find the areas where the tool path is fluent and smooth
or area where it is edgy where errors have negative influence on the machining result, surface
quality.
Example:
The following picture shows a machining of a concave shaped surface. The tool path is a spiral
motion. Accordingly in the middle the radius is small, orientation change is big. The more the tool
path proceeds to the edge the orientation change gets less.
Segment Length
The tool path will be colorized after the length of the segments.
Main benefit:
• Identify the areas where you have long linear motions, usually in roughing tool path or where
the segments become very short, eg for finishing.
Example:
The following picture shows a machining of a concave shaped surface. The tool path is a spiral
motion. Accordingly in the middle the radius is small, orientation change is big. The more the tool
path proceeds to the edge the segments get shorter
Height Change
The tool path will be colorized after its orientation relative to the tool path. The colors indicate
following:
Red: Plunge in tool axis direction
Orange: Lag angle orientation of the tool (pushing)
Grey: Normal orientation
Light green: Lead angle orientation of the tool (pulling)
Green: Retracting along tool axis
Main benefit:
• Identify the if the tool is plunging into the part along its tool axis or with an angle.
• Identify the if the tool is been pulled or pushed
• Identify the if the tool is retracting from the part along its tool axis or with an angle.
Example:
The following animation shows a machining of a convex shaped surface. The tool path is a single
motion. You can see the different orientations of the tool relative to the tool path.
Collisions
The tool path will be colorized after collisions status.

• Grey means that the tool path is not yet checked.
• Green means that the tool path is checked and collision free.
• Red means that the tool is colliding with the geometry.
Example:
The following animation shows a machining of a random surface. You see the tool path changes
from grey (not ckecked) into green (checked and collision free).
Feed Rate
The tool path will be colorized after the feed rate.

• Blue means that the tool path has machining feed rate.
• Yellow means that the feed rate is rapid rate.
Example:
The following animation shows a machining of a cylinder. You see the first entry and the last exit
have travel with rapid feed rate.
Axis Pole
The tool path will be colorized to determine if the 2 rotation axes are colinear. The color scheme
reaches from blue to read. The more the axes get colinear the tool path turns more red.
Example:
The following pictures shows a machining of an impeller part. You see that the axis pole
colorization pointed out the areas where the tool is orientated vertical on the part. At this moment the
2 rotation axes have the same orientation.
Tool axis change
The tool path will be colorized after the tilt angle of both machines rotation axis value change.
Main benefit:
Example:
The following picture shows a machining of an impeller. The colorization is from green (low
rotation speed) to blue (high rotation speed). You see that especially in the upper segment the speed
is partially very high. At the end and the beginning of the hub the rotation speed is slow.
Move List
The move list shows the actual NC code. The values displayed here are the tool tip positions in
absolute machine coordinates X, Y, Z (in case of 3 axis machine) and additionally A, B, C, etc.. (in
case of a 4 axis or 5 axis machine).
Main benefits:
• Identify the current position in the process of the machining
• Get an overview of the amount of NC sentences
Main features:
• Navigate through the machining process by dragging the slider (on the right side)
• Navigate through the machining process by using the up and down arrow (after clicking into
the list with the mouse cursor)
• Click on certain blocks and the tool will jump to that position in the process
• Identify limit overruns by the exclamation mark ( )
• Identify collisions with tool, work piece and machine components by the red cross ( )
Settings:
Right click into the move list window.. and select the amount of decimals shown in the move list
Machine
The machine window contains the machine definition expressed in a tree form diagram. This
kinematics tree shows the hierarchical representation of the machines and how machine parts are
defined. Usually the machine parts are dependent on each other.
As an example '' 5AxHermle C30 '' consists of two main trunks, which are A Axis and Y Axis. Each
of these trunks has some sub trunks, i.e. X Axis , Z Axis, tool path and etc.. As you can see from the
picture below, special geometry objects can be attached to an axis.
List items:
All items in this tree have different icons in front. These icons describe the different axis and parts of
the machine. Generally a machine system consists of
translational axis (Usually X, Y and Z)
rotational axis (A, B, C...)
axis transformations (in case the machine is horizontal in stead of vertical some matrix
transformations are necessary)
geometry objects (the machine model parts like x axis, table etc..)
tool path object (the tool path will be handled as an object. If no tool path object is attached in the
tree, then it won't be visible later)
tool object (the tool is necessary for the machine simulation. Without having this defined the
machine doesn't work. The tool itself consists of Flute, Shaft, Arbor and Holder)
work piece object (the work piece is necessary for the machine simulation. Without having this
defined the machine doesn't work)
stock object (the stock is necessary for the machine simulation. Without having this defined the
machine doesn't work)
initial stock object
collision definition sets (which geometry pair should be collision checked)
Main Features:
• Save the edited machine
• Save the edited machine under a different name in a different folder...
• Create a new machine
• Load a different existing machine
• Show the detailed element information
• Activate machine editing
Here property list appears at the bottom of the machine window. Al necessary settings can be
done here.
Report
The report collects all events which happen during simulation. The items in the report will be listed
in a tree format structure.
Each trunk starts with an operation followed by the tool number with the tool definition. Other event
types can be:
• Value underflows
• Value overflows
• Collision events between axis geometries (eg. Collision between c axis and table)
• Collision events between tool and geometries (eg. Collision between tool and c axis)
• Collision events between tool and work piece (
• Collision events between stock and tool part (eg. Collision between stock and arbor part)
• Collision events between stock and tool for rapid motions
Main Features:
• The depth of the collisions is available if the collision happens with the tool (eg. range: more
than 0.2).
• Use the field chooser to customize the layout of the report window. Right click in the report
window and select the 'Field chooser'
Type - This indicates the event type symbolized by an icon

Tool# - this indicates the tool number used in this event
Op. Id - this indicates the operation number used for the event
Block - This indicates the block number in the move list for the event
Comment . This displays the operation comment used in this event
Note that if you click on a field column, the complete list of events will be sorted under that
field criteria.
• Click on the operation or events and the tool will jump to the position in the tool path.
• The report can be exported into a xml file.
CutSim
The CutSim tab provides parameter for the material removal.
Data Model
The data model can be Automatic, 3 axis or 5 axis.
• The automatic set the right mode suitable for the simulated part.
• The 3 axis model is meant to be used for 3 axis machining in Z without undercuts.
• The 5 axis allows undercut material removal.
Accuracy:
The accuracy is the resolution of the stock model. A low accuracy brings more speed but a less
accurate result. A high accuracy slows the machining process down, therefor the resolution of the
stock model is accurate.
Check
The check option handles the whether a part of a tool should remove the material, should be gouge
checked, do both or does nothing.
Flute
a) Cut: Only material removal, no gouge checking
b) Cut and collision check (rapid moves): Material removal and gouge checking
Shaft, Arbor and Holder

a) None: No material removal, no gouge checking
b) Cut: Only Material removal, no gouge checking
c) Cut and collision check : Material removal and gouge checking
Save Stock
The resulting stock model can be saved to a stl file (during or after the machining).
Advanced parameter
It is possible to save the stock geometry after each operation. When you check the check box the
files will be stored under the user defined directory.
Axis Control
With the axis control you can manually move the linear and rotation axes of the machine.
Main features:
• Identify the machine axis limits
• Identify the current axis position
• Right click on the axis slider to enter a defined position or to set all axis to 0.
Main benefit:
• Check if the machine limits are set up correctly
• Check if the collision check is set up properly
Measure
Measure provides different

features to measure out the stock.
Points
Distance
Zoom Box
Dynamic Zoom
Keep/Delete Parts
Points
The point gives information about the current coordinates x, y and z; the tool being used; block
number and the deviation.
Example
Move the cursor onto the stock.
Then double click with the
middle mouse button. A point
will be shown in a small text box
in the simulation window. The
point will also be added to the
point list.
The information in the text box:

• pnt: are the coordinates x,
y and z
• tool: indicates tool being
used
• blk: indicates the block
number in the move list
In case the point will be set on

the deviation colorization a
fourth element will be added to
the point information:
• dev: is the restmaterial
distance to the target
geometry
In this case the is a 0.9501
mm rest material left
Distance
The distance measures the 3D distance between two points on the stock model.
Example
Move the cursor onto the

stock. Then double click
with the middle mouse
button to select the start
point and an end point. A
distance value will be
shown in a small text box
in the simulation window.
The item will also be added
to the distance list. The
information in the text box
is the 3 D distance between
the 2 selected points.
Zoom Box
Use the zoom box to zoom into a certain area of the stock model. The material around the zoom box
will be removed, but therefor has the new area higher resolution.
Example
Move the cursor onto

the stock. Then
double click with the
middle mouse button
to select the start
point and an end
point of the zoom
box.
Hit the zoom in

button to
activate the zoom.
Note that you can
repeat the zoom onto
the new area as well.
Hit the zoom out

button to get to
the previous zoom
stage.
Dynamic Zoom
Use the dynamic zoom into a certain area of the stock model. The material except the portion which
is visible on the screen will be removed. This area will be calculated then with a higher resolution.
Example
Zoom into an area on

the part (indicated as
red area). Use the
mouse wheel.
Hit the zoom in

button to
activate the zoom.
Note that you can
repeat the zoom onto
the new area as well.
Hit the zoom out

button to get to
the previous zoom
stage.
Keep/Delete Part
With this function you can delete chips which are free floating around the actual part. Simply select
'Keep' or 'Delete' and select the chip segment. In case 'Delete' the selected chip will be removed. In
case of 'Keep' the selected part will be kept and all other will be removed. Note that this only works
if the chips have been identified with the stock analysis 'Mark Parts'.
Hot Keys
In the Hot keys dialog you can define
• the key assignments
• the mouse button assignments
Simulation Properties
Simulation Process
Stop Conditions: The stop conditions can be used to stop the machining at a certain situation in the
process as
- tool change
- a certain height above the workpiece
- a certain operation, at certain number of blocks
Notifications: The notification throws a window notification in case one of following events
happens:
- Geometrical collisions: Collisions defined in the collision check setup
- Axis Limit Overrun: When a linear or rotational axis exceeds it physical limits
- Axis Value Mismatch: This happens for values in the move least which are not supposed to appear.
- Material Collisions: Collisions between tool and stock (during cutsim)
Miscellaneous: The geometrical collision checking can be deactivated when CutSim (material
removal) is active.
Simulation: Indicates current environmental parameters

- Collision control enabled/disabled
- Collision check tolerance
- Collision checking between moves
. Unit system metric/inch
Note:
The machine simulation always supports RTCP kinematics for collision checking.
(Picture 1: RTCP enabled; picture 2: RTCP disabled)
Grafics and Background

Background: Select between a solid background color or define a gradient.
Screen Objects: This defines the position of coordinate system and the ruler in the simulation
window.
Animation speed: Tis defines the speed of the animation when switching eg. between different
views or fit to screen.
Tool Path Backplot

Segment Length: This defines the amount of segments to be shown in case 'Segment' tool path
rendering is selected.
Axis vector length: This defines the length of the tool axis vector. The value of the length can be
defined by the radius of the tool, or any other user defined value.
Tool path points: The points size can be set to a value of 1- 5 pixel.
New Machine Setup

How to create a new Machine
There is a set of different files which are necessary to run a machine properly.
Machine Model Files (STL)
STL files define the geometric components of the machine. The names of the STL files are used in
the xml to assign them to the appropriate axis. Usually you have several STL files since your
machine consists of many axes.
Important here is that the machine geometry is aligned to the absolute center point (0, 0, 0). That
means that the absolute center point is located in the tool fixing holder of the machine. In that point
the tool holder will be put. Usually (but not necessary) that point should correspond with the top face
center point of the table. With other words, the tool fixing holder and top face center point of the
table should touch in the same point, which is the 0,0,0 point of the CAD software from where the
STL files where created. The rest of the machine parts should also refer to this point further on.
So move the machine and the spindle to the right position in your CAD model. After this you can
simple save the single parts to STL files. Then they already have the right position.
The machine which will be used for the tutorial already is aligned in the right way.
Reflection Texture (BMP)
This is used for the texture of the reflections. Note that only the .bmp file format are permitted (no
.jpg, . gif etc.).
The following tutorial describes the necessary steps to create a machine. The necessary machine
model files (STL files) can be found in the new_machine.zip archive.
Creating a new machine
A new machine will be created in the kinematics tree window. So if you have loaded the machine
simulation, switch to the machine window. You usually have already selected a machine to get into
the machine simulation. This machine is listed in the tree.
To create a new machine hit the 'New machine' button from the icon bar.
The existing machine will be deleted and a new, empty unnamed machine appears instead. Now
enable machine editing (if not already selected). This will allow you to modify items in the tree.
Click the 'unnamed machine'. Name option appears in the bottom of window.
Change the name of the machine with 'new_machine'. This name is the name of your new machine.
Remember: the machine ID name and the folder name of the machine data have to be identically. In
this case we call the machine 'new_machine'. Hit the 'Save machine as..' button. Save the
'new_machine.xml' to 'new_machine' folder.
Attaching the housing

The housing is considered as a fixed part of the machine. Fixed means, that the housing doesn't
move and stands still since it is not attached to a linear or rotational axis.
Go to the machine window. There hit the 'Edit machine' button to change to edit mode.
First thing to do is to give a name to your machine.

Right click the 'new_machine' in the kinematics tree and choose 'Add Geometry' from the drop down
window. Select the 'HOUSING.STL' from the 'new_machine'directory.
There is a special setting about the housing. When you are running machine simulation you have the
opportunity to blank out the machine housing by pushing that button.
These blank able parts will be defined when you add to your name the prefix 'mh_'. So, all parts with
the prefix mh_ will be blanked out. In our case the name would be 'mh_housing'.
Properties for new geometry are displayed in bottom of window. Change the ID with "mh_housing"
and also you can set up the color. Pick any colour.
After setting up the housing, you machine tree looks like this:
Save the machine. This time use the 'Save Machine' button. That simply saves the changes without
bringing the file browser.
Attaching the kinematic axes

As like the housing, the axes will be added into the kinematic tree and its subbranches. The structure
of the machine parts is hierarchically. The dependence of an tree item always start from the top item
of a branch. The main branch itself is the machine top item which has the housing attached.
To give an example we look at our 'new_machine'. The 'new_machine' is a so called 'table table'
machine. That means that both rotation axes (A and C) lie in the table of the machine. The A axis
(blue) and C axis (purple) axis are attached to the Y axis (grey). The table is independent from the
linear axes X (green) and Z (orange). Accordingly the Y axis and the X axis build a new branch for
themselves.
To add a kinematic axis you have to do 2 things:

• Add the kinematic description
• Attach the machine model part
Adding the kinematic description
Right click on the 'new_machine', go to 'add Transl. Axis' and select 'Y Axis' . The property window
opens automatically.
The new Y axis is added. When you select it from the tree, the properties menu appears in bottom of
window. The properties for 'ID', 'Direction', 'Limits' are setup by default.
The first thing you can change here is ID name. Due to its definition the kinematic axes ID's can't be
named randomly (like 'Y axis').
The next thing to be changed is the kinematic orientation, which is the direction the linear axis
should move. Here the direction must be expressed by a vector which is described in the coordinates
X Y and Z. To let the linear axis move in Y, setup value 1 for Y.
Last option that can be changed is the limit for that axis. Setup minimum limit -80 and maximum
limit 100.
The Y axis appeared in a new branch underneath the machine.
The next thing to do is to attach the A axis onto the Y axis. Right click on the Y axis, go to 'Add
rotation axis' and select 'A Axis'.
Properties menu from the bottom of window are setup by default.

Center point must be changed from default value. This center point defines the position where this
axis rotates around. Due to its definition you have give that information to the kinematic. The
distance will be measured in X, Y and Z to the absolute center point. The A axis is shifted, so you
have to add the shift distance accordingly. In our case it is -106 mm in Z. Our direction is Y 1, X and
Z 0 (it's turning around Y axis).
The limits now will be expressed by angles since it is a rotation axis. Enter the range from -90 to 90.
Set up the kinematic tree like this:
The other axis settings:
C axis:
Right click on the A axis in the kinematics tree

Select 'Add rot. axis'
Add 'C' axis
Transformation direction is Z 1 (it is turning around Z axis)
Center point is 0 for X, Y and Z

Limits are -9999 and 9999
X axis:
Right click on the 'new_machine'

Add 'X' axis
Transformation is X 1, Y and Z 0
Z axis:
Right click on the 'X Axis'

Add 'Z' axis
Transformation is X0, Y 0 and Z 1
Attaching the machine model part
Right click the desired kinematic axis in the kinematic tree. Then choose 'Add Geometry' from the
drop down window. Enter a random ID to the geometry and select the geometry file. The files can be
found in the 'new_machine.zip', so make sure you take the right geometry. Attach following
geometries:
A axis (tilt axis), 'A_AXIS.STL'.

C axis (rotation axis), 'C_AXIS.STL'.
X axis (linear axis), 'X_AXIS.STL'.
Y axis (linear axis), 'Y_AXIS.STL'.
Z axis (linear axis), 'Z_AXIS.STL'.
Attaching the workpiece set

The workpiece, toolpath, stock and initial stock are so called dynamic elements. That means that
they can be changed during simulation and don't stay static like the axes geometries.
In order to attach the elements onto the table, you have to define a certain coordination
transformation.
Now right click on the C axis, select branch 'Add Dynamic Element' and add workpiece set. This
option added a group of options : workpiece, stock, initial stock and toolpath. Also you can add
those options manually.
Attaching the tool

The tool also is a dynamic element. It changes during simulation and doesn't stay static like the axes
geometries.
In order to attach the spindle, you have to define a certain coordination transformation.
Right click on the Z axis (which in this case is the spindle), select branch 'Add Dynamic Element'
and add 'Tool Set'.
Defining the collision pairs

For the machine simulation it is very important that collisions will be recognized. Therefore you can
set collision control sets for machine parts.
Important here is to find the right dependency between the single parts. Eg. It would make no sense
to make a collision checking between the Y axis and the housing. The Y axis would never harm the
housing because it's moving on top. Important is the collision checking between the translation axes
and rotation axes, between the work piece and the rotation and translation axes and of course the
collision checking between the tool and the work piece
Right click on the 'new_machine' machine and select 'add collcheck'.
When CollisionCheck is selected the properties menu appears in bottom of window.

You define the collision checking by setting two groups . Between the two groups the collision will
be checked.
So in the left group you can add the workpiece with all geometries which they belong and in the
right side group, add tool and also with all geometries
A collision checking set eg. would look like this.
Finshing Setup
In the properties of the geometry elements you can change the colors and then you can define a
reflection in case you want to make an element look metallic.
The finished machine should look like this now:


NC Machine Simulation

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

NC Machine Simulation

Uploaded by

Copyright:

Available Formats

NC Machine Simulation

CimatronE 10.0 User Guide

Standard Machine Simulation

display the tool path corresponding to tool center.

display the tool path corresponding to tool tip.

display the entire tool path.

display only the current operation.

display the tool path in 'follow' mode.

display the tool path in 'trace' mode.

display the tool axis vectors.

display the tool path points.

• Hotkey layout will be saved within the layout file.

1) Tool Path Backplot Mode -->'b'

10) Stop --> 's'

Multi core calculation support for material removal simulation

Simulation without multi core calculation:

Simulation with multi core calculation:

Manual dragging of the tool

Show and hide slider in manual axis control

In case it is set to false the slider will disappear.

Python scripting for non post relevant kinematic axes is available

Saveuistate flag is available inside machsim.ini file

Improved control for 3D devices

Run: Starts the simulation.

Next/Previous Operation: Next /previous operation allows to navigate to the

The machine model itself.

Tool Bar Icons

Fit: Fits to all elements on the screen

Isometric: Rotates to isometric view

Top: Rotates to top view

Front: Rotates to front view

Right: Rotates to right view

Bottom: Rotates to bottom view

Left: Rotates to left view

Back: Rotates to back view

Run: Starts the simulation.

Next/Previous Operation: Next /previous operation allows to navigate to the next/previous

Hot Keys: Opens the hot keys dialog.

Settings: Opens the simulation properties dialog.

Tool Center: Displays the tool paths on the tool center

All Operations: Shows all operations

Single Operation: Shows only current operation

Follow: Show only the machined tool path

Trace: Show only the left over tool path

Segment: Shows only certain amount of following and traced segments

Leads: Shows/hides the lead in/out

Links: Shows/hides the links motions

Load NC : Loads a NC file from the file system.

Create Simulation Report : The simulation

Fit: Fits to all elements on the screen

Isometric: Rotates to isometric view

Top: Rotates to top view

Front: Rotates to front view

Right: Rotates to right view

Bottom: Rotates to bottom view

Left: Rotates to left view

Back: Rotates to back view

Show/Hide: Sets certain elements to visible/invisible

Tool Path Backplot Mode:

Material Verification Mode:

Machine Kinematic Mode:

Tool Path Rendering

Tool Center: Displays the tool paths on the tool center