Moving on from the couple of fixture techniques we just looked at, I wanted to talk about the programming side of it because that’s obviously a key part of the manufacturing process. The thing I want to address here is tool path verification software. This is a good way of simulating and therefore, anticipating a problem before the problem ever occurs. What we’re talking about here is simulating too paths for collision checking. We want to prevent a collision before it ever happens due to programming error. 

What this type of software can do is basically highlight areas of conflict prior to machining and improve that operation. You kind of virtually machine the part with software and it will show you conflicts between the tool and the fixture between the spindle snout and the table. It can be, as you can imagine, very helpful. This can be really applied in high volume or low volume, it’s probably a little bit more advantageous in low volume environments where you're doing a lot of programming and first time set ups. 

The software is available and the way that it’s often provided is that you can build the framework of your specific machine tool that you're applying. Many of these software suppliers that you’ll have files already of different models of machines or work zones of the machine, and you can build up the specifications yourself. 

I have a slide courtesy of CG Tech of their VeriCut Software, which we’re pretty familiar with here at Makino. It’s one of the products available on the market today to accomplish this kind of a simulation. 

Why verify prior to machining? The obvious answer is that we want to eliminate mistakes but, again, NC programs often inherently contain errors. This can happen a number of ways. Your programmers can make mistakes. We all make mistakes; it’s nothing against the programmers. The other area that’s really difficult to catch is some of the Cam systems can introduce errors into the part program. You may have a good post-processor and everything else, but a code comes out wrong, or if something crashes, or you’ve got a problem with tool fixtures or the machine. We want to eliminate that. 

Post-processors can also introduce errors. There are a number of ways that a program can find its way to the machine that might have an error in it that could cause us a problem. We want to eliminate that error before it ever happens. This is a big reason why you want to simulate that process to reduce errors and put an error checking process in before an error would ever occur. 

Using software technology to virtual machine a part before real setting begins can do a number of things.  It can eliminate errors which can eliminate scraps, or mallets getting into your raw parts, inventory, and the cost associated with that and the waste associated with that. Certainly, re-work, if there's a problem in the program, is going to require labor and additional time, and broken tools can be a result. 

The technology can reduce the possibility of machine crashes, down times and delays associated with a crash and that can be a major issue because of delays in production with the cost of repairing a machine.  We can detect spindle and table collisions, and that’s really the primary focus of this simulation software to prevent errors in the programming. With this, you could potential improve process efficiency. There's no question about that.

The statement at the bottom right of my slide is such a fitting and appropriate statement. It certainly goes along with the topic and theme of this Webinar.  That is, “a part program that is 99 percent right is 100 percent wrong.”  Isn’t that a great statement, and isn’t it so true?  If we can eliminate any problems in the programming before it occurs, and save tools, machines, and fixtures, and parts, and everything else, it can have a significant impact on your ability to delivery on time, deliver on time and reduce costs. 

I’m going to show a video simulation of how this particular software works. It’s an example of applying  simulation software so you can eliminate errors in the manufacturing process. This is a particular simulation package is called, “VeriCut,” provided by CG Technologies, and it is designed around the model of our A-51 horizontal machining center. 

The red means that there is a conflict between tip of the tool and the fixture. It may be okay in this particular process, but that’s any conflicts or mistakes or errors in the programming process would be identified by that red color.