True 5-Axis Simulation with FANUC's Smart Digital Twin

True 5-axis simulation is critical to manufacturers using advanced machining processes. Digitalization solutions provide value throughout a production facility by increasing efficiency and flexibility as well as reducing costs. FANUC’s Smart Digital Twin tools, including true 5-axis simulation powered by CNC GUIDE2, will become critical for advanced manufacturing operations, such as those in the aerospace and the medical industries.

Differences Between True 5-axis Simulation and Estimated Solutions

There are vast differences between FANUC’s true 5-axis simulation powered by CNC GUIDE2 and other solutions. Many simulation verification packages simply plot programmed points. These existing packages have no ability to understand the actual algorithms in the CNC. As a result, the simulation provided is a simple dot-to-dot drawing of the programmed points.

With advanced algorithms and compensations, such as FANUC’s TCP, Smooth Tolerance Control+ and AiCC II, a simple plot of points is not adequate for true process verification or process analysis/optimization since the critical information is not the points, but how the CNC generates a path through or near the programmed points. If the servo model is included in the simulation, as it is in CNC GUIDE2, the real dynamic response of the machine tool can be observed.

The parts that typically benefit most from accurate simulation often include probing for accuracy. With true 5-axis simulation powered by CNC GUIDE2, it’s possible to see the accurate impact of different kinematic calibration and dynamic offsets on the motion. A fraction of a degree skew in 5-axis can result in significantly different rotary axis motion.

Benefits of True 5-axis Simulation Powered by CNC GUIDE2

True 5-axis offline simulation powered by CNC GUIDE2 can provide enormous value to manufacturers via the following examples:

1) Accurate part/program verification

True 5-axis simulation is critical in proving out programs for parts with extremely long cycle times or that are very expensive. If an error occurs in the generated path, the product might have to be scrapped, wasting valuable time and risking the loss of millions of dollars. Due to the expense involved, many facilities still produce several test parts before attempting to cut an actual production part.

The ability to accurately simulate this process offline not only reduces the potential of scrapping parts but also eliminates the need for extensive prototyping currently performed.

2) Production process optimization

Most production facilities have high spindle utilization – especially for the large 5-axis machines. A spindle not making production parts is not making money for the facility. Programmers do not have time to experiment with modern programming features and as a result are not implementing many of the features that can improve cycle time and part accuracy.

If the programmer can execute and analyze the program performance offline via CNC GUIDE2, they will experiment with and take advantage of the new FANUC features improving overall performance of the machine. This results in better quality parts with the potential to drastically improve cycle time and accuracy.

3) Technical support diagnostics

Diagnosing any machining issue can consume a lot of time and resources. Virtual simulation tools can simplify troubleshooting, especially in determining if the problem is a programming issue, a CNC issue and/or caused by a simple parameter/feature missing. The tools also eliminate experience bias that often leads to incorrect guesses and lengthy delays resolving issues.

Using FANUC’s Smart Digital Twin tools along with a copy of the real machine parameters and the real part program, support staff can verify most of the common tool path issues without lengthy travel delays or associated costs. Moreover, the Smart Digital Twin tools can illuminate if other simple optimizations and/or corrections could be made. All this can be done quickly, effectively and virtually reducing costs and downtime.

4) Training

Effective training can accurately teach a programmer or operator how to make the machine and CNC combination run optimally. By producing accurate path results virtually, features can be easily described and the benefits proven to manufacturers; all without any risk of damage to the actual machine.

5) Feature development

FANUC engineers and manufacturers can collaborate to develop and quickly test new macros and parameter settings. This results in faster implementation and better machining processes at a reduced developmental cost due to the ability to accurately test functionality without hardware.

True 5-axis Simulation Advancing Manufacturing

The ability to use virtual controls that match real-world controls can dramatically help machine shops streamline their processes and truly harness all the benefits of digital machine simulation.

FANUC’s Smart Digital Twin products offer manufacturers a great way to prove out equipment and processes – all without tying up the actual machine tool. Unlike a lot of digital tools for the CNC machining industry, FANUC’s Smart Digital Twin software uses the same FANUC technology, powered by CNC GUIDE2, to reproduce the highest fidelity representation of real-world equipment. Whether simulating the G-code part program or the machining process, the Smart Digital Twin products are designed to help test, verify and optimize the process.