{"id":2652,"date":"2020-03-02T19:18:09","date_gmt":"2020-03-03T00:18:09","guid":{"rendered":"https:\/\/blogs.sw.siemens.com\/nx-manufacturing\/?p=2652"},"modified":"2026-03-26T09:21:39","modified_gmt":"2026-03-26T13:21:39","slug":"how-nx-cam-simulation-capabilities-validate-machines-and-processes","status":"publish","type":"post","link":"https:\/\/blogs.sw.siemens.com\/nx-manufacturing\/how-nx-cam-simulation-capabilities-validate-machines-and-processes\/","title":{"rendered":"How NX CAM simulation capabilities validate machines and processes"},"content":{"rendered":"\n

A recent article in SME.org, \u201cSimulation Software for Error-free Metalcutting<\/a>,\u201d describes how the latest simulation packages offer CAD\/CAM and NC-level code-checking to ensure fast, error-free machining processes to prevent costly programming mistakes. <\/p>\n\n\n\n

Siemens\u2019 Sashko Kurciski, Sr. Product Marketing Manager, NX for manufacturing solutions, offered insight about the need for accurate NC code simulation not only for toolpath validation, but also for machining process planning to avoid possible collisions and to optimize cutting time.\u00a0 Read what Sashko has to say in the following excerpts from the story.<\/p>\n\n\n\n

Validating machines and processes<\/h2>\n\n\n\n

Modern machine tools can have complex kinematics, such as multiple channels with two or more multiple tools cutting the same part simultaneously, or multiple parts mounted at multiple spindles, noted Sashko Kurciski, senior product marketing manager, NX for manufacturing solutions, Siemens Digital Industries Software Inc., Plano, Texas. For example, five-axis machine tools typically have three linear and two rotary axes, which support unlimited tool positions and orientations within the workspace of the machine tool.<\/em><\/p>\n\n\n\n

\u201cFor simultaneous five-axis motions, it is extremely important\nto understand how the actual controller executes the NC code, i.e., which\nkinematics solution is picked in order to avoid collisions or gouges,\u201d Kurciski\nsaid. \u201cThese sophisticated machine tools only amplify the need for accurate NC\ncode simulation not only for toolpath validation, but also for machining\nprocess planning to avoid possible collisions and to optimize cutting times.\nUsing a highly-accurate simulation is critical to be able to stay competitive.\u201d\nIt requires using a comprehensive digital twin of the machine, controller, and\nthe entire process, he added.<\/em><\/p>\n\n\n\n

Manufacturers need the digital model of the machine model to be\naccurate, Kurciski added. \u201cPossible issues might include incomplete definition\nof the kinematics of the machine tool and missing information about the\ncontroller and the underlying software. Typically, the in-CAM simulation is\nbased on the internal representation of the toolpath, which is different from\nthe G-code [NC program] that controls the machine,\u201d he said.<\/em><\/p>\n\n\n\n

To stay competitive, manufacturers need to deliver increasingly complex parts faster with better quality, while reducing production costs (due to shrinking profit margins), Kurciski said. This requires maximizing machine uptime, minimizing errors in production and shorter machining cycles. Digital validation of the machining process is the critical component in achieving these goals.<\/em><\/p>\n\n\n\n

\u201cSome form of machining simulation is available in many CAM\nsystems. While in most cases the CAM systems can simulate the internal\nrepresentation of the toolpath, this can differ from the G-code that runs the\nmachine,\u201d he said. \u201cThis causes a disconnect between the virtual and physical\nwords of manufacturing that can result in costly errors on the shop floor.\u201d<\/em><\/p>\n\n\n\n

To address limitations of in-CAM simulation modules, Kurciski\nnoted that some machine shops use third-party simulation software in addition\nto their CAM systems. \u201cIntroducing a stand-alone system in the process\nintroduces more inefficiencies and possibilities to use incorrect data due to\nmultiple data transfers between systems,\u201d he said. \u201cAdditionally, this\ndisjointed process relies on multiple systems and can make the process\ninflexible and slow.\u201d He thinks it prevents manufacturers from quickly reacting\nto design or process changes that require automated toolpath recalculations and\nvalidation of the updated machining sequence.<\/em><\/p>\n\n\n\n

Systems such as NX CAM include integrated G-code-based\nsimulation, which enables programmers to ensure that the same NC program that\nruns the machine tool is used to simulate and verify in the same NC programming\nsystem, Kurciski said.<\/em><\/p>\n\n\n\n

\u201cYou can achieve high-fidelity simulation only if the NC\nsimulation module considers all the machine kinematics data and all the moves,\nwhich will finally be executed on the physical machine tool,\u201d he said. \u201cWithout\nusing G-code in simulation, you cannot accurately simulate the machining\nprocess. For example, using the actual G-code for simulation enables companies\nto get accurate machining time estimates, including cutting motions, position\nand transfer moves, and tool changes.\u201d<\/em><\/p>\n\n\n\n

NX offers one more level of simulation using Virtual NC Controller Kernel (VNCK) from Siemens\u2019 Sinumerik controllers, Kurciski said, enabling a new level of accuracy when using 3D simulations to validate machining operations. \u201cThe integrated Virtual NC Controller Kernel solution is driven by an accurate and complete software model that is provided by the controller manufacturer and calibrated for your machine tool,\u201d he said. \u201cThe resulting simulation responds exactly like a real machine with the same toolpath and setup. The integrated solution facilitates the closest possible digital representation of actual machine tool motion with highly accurate swept paths, speeds and accelerations, and tool changes. The solution\u2019s software is calibrated for specific machine tools with the hundreds of unique performance parameters taken from the real machine and controller.\u201d<\/em><\/p>\n\n\n\n

Read the complete story\nin SME.org<\/a><\/p>\n\n\n\n

Learn about the newest capabilities in NX for manufacturing.<\/a><\/p>\n\n\n\n

Try NX CAM free for 30 days! Register now!<\/a> <\/p>\n\n\n\n

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