M A C H I N E R Y As illustrated here, the collision potential with most five axis machining centres is high, especially with small, complex workpieces. Image courtesy: McClay Tooling CGTech’s VeriCut accurately simulates toolpaths using the actual G-code read by the CNC control, avoiding problems caused by post-processor errors. Image courtesy: McClay Tooling implants, knee replacements, that sort of thing. But we also work on wheelchair controls and packaging lines, die casting molds, high-speed equipment for the film industry...it’s a pretty broad range of stuff.” McClay Tooling has a broad range of CNC machine tools as well. Aside from the usual array of manual mills, lathes, and saws found in any job shop, there are four Haas VF-2SS three-axis vertical machining centres and a DMG Mori NLX 2500 lathe with Y-axis and live tooling. McClay Tooling also has several wire EDM machines, leftovers from the days of tool and die work that are now used extensively for slotting bone saw blades and similar surgical components. And six years ago, McClay Tooling purchased its first 5-axis machining centre—a DMG Mori DMU 60—prompting the McClay team to decide that toolpath simulation was no longer a nice-to-have. VeriCut toolpath simulation and verification works by reading the G-code used by the CNC machine tool. Because of this, there’s never any concern over an error in the CAM system’s postprocessor, and potential collisions between the workpiece, toolholders, and machine are clearly identified in advance. VeriCut also compares the “as machined” part against the “as designed” CAD model, so gouges and excess material can be eliminated. It works with virtually all brands of machine tool and controller, including Swiss-style machines, multitaskers and mill-turn lathes, waterjet, EDM, gear hobbing and more. Feeling Safe in the Dark “We bought VeriCut so we could be confident running lights out,” Mr Fisher says. “Since we do a lot of mold work at night, and five axis implants with long cycle times, we needed to be sure that our tool reaches were correct, and that there wouldn’t be any collisions. But we’ve also found VeriCut helps a lot with our setup times. We know what to expect, and any bugs in the program are worked out well in advance of machining the parts.” Mr Fisher says that back then, the machine models available for the DMU 60 weren’t “super robust,” and they had to do some fine-tuning at first to get everything the way they wanted it. And since VeriCut was new to the Christchurch area back then, he says he mostly figured out how to run the software on his own, using the help files and instructional materials that came with the software. “It was very easy to learn,” says Fisher. He’s had good support along the way from NganBoon Tan, the area representative for CGTech. “Boon is a very switched on guy,” Mr Fisher says. “He’s extremely helpful and knows the software inside and out. We’ve really got the DMU dialed in at this point, and it behaves exactly how VeriCut says it will.” Beyond 5-Axis The Christchurch area now has a VeriCut Users Group as well, from which Mr Fisher and his team pick up tips and techniques for using the software. As a result of its long history with VeriCut, McClay Tooling routinely runs machining jobs unattended. They use in-process probing cycles to check critical part dimensions and call for replacement tools when needed, verifying these routines in advance. And because they can view an accurate simulation of the entire machining program before pressing cycle start, there are never any unpleasant morning surprises. McClay Tooling recently ordered its second five-axis machining centre, a UMC-750 from Haas Automation. Mr Fisher says he looks forward to using VeriCut on the new machine, and because McClay also ordered an expanded user license that includes the shop’s other CNC equipment, he’ll begin using it on the vertical mills and the turn-mill lathe as well. “We use it all the time on our 5-axis DMU, and I can honestly say that we’ve avoided many crashes that our CAM system missed, things like running out of travel, or tools not clearing the workpiece on a repositioning move.” 32 March 2017
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