any machine tool that is verified and optimized without an external post-processor. It takes into account the kinemat- ics of the machine tool, machine controller, cutting tools and conditions. This efficiency results in lead-time reduc- tion from prototype to production and in repurposing legacy programs to new machines. Another development in NC simulation/verification is the use of physics-based technology for analysis, verifica- tion and optimization of NC cutting processes. At IMTS 2014, Manufacturing Automation Labs Inc. previewed its new NPro advanced physics-based process simulation and toolpath optimization software developed as a plug-in module for Siemens PLM Software’s NX CAM software. In contrast to geometry-based solutions, which adjust purely

existing manufacturing facilities. With simulation software in the 3DEXPERIENCE platform from Dassault Systèmes, manufacturers can easily view and share product designs and simulations for collaboration among global locations. The latest Dassault 3DEXPERIENCE Release 2016x gives

users a stronger bond between 3D simulations and their con- nection with the shop floor. “We have been a big promoter of 3D work instructions on the shop floor. It started in aero- space and defense,” said Patrick Michel, vice president DEL- MIA Digital Manufacturing, Dassault Systèmes. “Additionally you can connect a virtual simulation to the shop floor in near real time, that is, getting information into the simulation that reflects what actually took place less than 15 minutes ago on the shop floor anywhere in the world.”

The Process Simula- tion Reviewer in Das- sault’s 3DExperience digital manufacturing platform offers us- ers realistic reviews of shop-floor processes.

on the volume of material removed, the Npro software considers the geometry of the chip being removed, work- piece material properties, tool geometry and tool motion (kinematics), and machine-tool limitations and dynamics. The NC simulation in Siemens NX CAM is an internally de-

veloped system that does full G-code simulation, said Aaron Frankel, Siemens PLM Software’s director of product market- ing. “We can also use the actual Sinumerik 840 D control- ler software VNCK, which gives the best fidelity simulation possible. We’re partnering with different companies like MAL, using a physics-based approach. We’re looking at the routing of the cutting tools and forces, and we’ve optimized the path for speed and quality. It’s relatively new.”

Moving toward the digital factory Digital tools can help manufacturers prove out process- es in advance of finalizing plant-floor layouts in new and


With globalization, simulation has made an even greater impact on manufacturers that have more globalized opera- tions than ever before, Michel noted. “One thing we see in digital manufacturing is the virtualization of things: Almost all companies are integrating their work with global teams. Some of the Japanese companies are making decisions now in the US, and that was unheard of before,” Michel said. While automotive manufacturers have heavily adopted

simulation for robotics and material flow, the technologies offered by digital manufacturing solutions like Siemens’ Tecnomatix line are spreading to many other industry segments, noted Ulrich Rossgoderer, director, product management, Siemens PLM Software. “Consumer goods companies want to shorten the cycle between design and production,” he said. “In aerospace, what we see is the need for automation and simulation is growing on the factory floor for the amount of engines and aircrafts that

Summer 2016

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