THE CHALLENGES

It is extremely important for every  manufacturing company to guarantee the quality and to keep the agreed lead times for the manufactured products. An important prerequisite for this is the optimal organization of the internal business processes, effective planning and the availability of modern machinery in the enterprise. In the same time it is of great importancethe use of modern software systems to leverage the level of digitalization of the Research  and Development and of the processes in the manufacturing.

Modern systems for manufacturing planning and CNC programmings are entering the enterprises today. This allows the simulation of the manufacturing technology  and their easier programming. Today, computer simulations of the technological process make it possible to simulate, predict and evaluate possible technological strategies, to select the most optimal of them and to achieve the highest quality at the lowest cost. One of the leading solutions for the simulation and programming of CNC machines is DELMIA 3DEXPERIENCE Machining.

DELMIA 3DEXPERIENCE Machining is a CAM software used for the simulation and generation of NC programs for CNC machines. It is part of the business platform 3DEXPERIENCE and has full integration with the the CAD system CATIA. The architecture of DELMIA 3DEXPERIENCE Machining has  following features:

1. The designer and the technologist shall use an unified working environment for three-dimensional design, strength and kinematic analysis and generation of control programs. This allows you to easily update the processing programs when changing the geometry of the product.

2. DELMIA 3DEXPERIENCE Machining is end-to-end solution for the planning of manufacturing operations- from the programming of processing strategies, through the tools used to the necessary technological equipment. Moreover, DELMIA 3DEXPERIENCE Machining allows the simulation of the work not only of the cutting tools, but also of the whole machine. This is possible by uniform presentation of the geometric information of the processed product, the technological equipment for its fastening, the technological map of the processing operations and the necessary cutting tools.

3. DELMIA 3DEXPERIENCE Machining has a completely new interface enabling technologists to work efficiently and easily with the system. It is easy to use for young engineers and the working methodologies are adapted to the qualification programs of universities and technical high schools.

Each project in DELMIA 3DEXPERIENCE Machining follows an systematic approach to generate the NC program. The work methods set out in DELMIA 3DEXPERIENCE Machining have been optimized over the years based on the experience of tens of thousands of successful projects developed by machining technologists around the world. Dassault Systemes' software engineers use this experience and continuously improve the system, adapting it to new work strategies, types of materials and innovative processing tools, taking into account the latest scientific discoveries in the field.

The main steps of work in DELMIA 3DEXPERIENCE Machining are the following:

1. Import of the 3D model

After importing the 3D model of the processed product, it is corrected if necessary (in case a CAD system other than CATIA is used).

2. Setting the fixation and machined areas of the workpiece

The next step is to set the base of the product and select the machined areas of the model.

3. Choice of technological process

The selection of the technological process of processing follows as a s next step. DELMIA 3DEXPERIENCE Machining provides guidelines for selecting the most optimal work strategies based on the world's best practices, but the technologist can change and adapt the technology at any time according to his specific needs. After choosing the strategy, the technological sequence can be changed by the technologist.

4. Performing initial simulation

In the next step the simulation of the work of the cutting tool, the way of work, the withdrawal of work is carried out and depending on the needs a simulation of the work of the whole metal-cutting machine can be carried out taking into account its kinematics (typical for 5-axis machining). Through the various possibilities for visualization of the machining process at each stage it is possible to trace which machining tool from the store works, to determine the amount of material taken, the depth of cut in a given operation, the wall thickness of the part after a given operation or to identify possible collisions. The simulation takes into account the actual spatial location of the part, the gripping devices, the machining tool and the machining head, as well as the overall dimensions of the machine table. When a collision is detected between the machining tool, the spindle, the workpiece and the machine, the simulation can be stopped.

5. Optimization of the technological sequence

The technologist can set a new machining trajectory, change the machining approach from 3- to 5-axis milling. The metal-cutting machine is simulated not only by its geometric shape and kinematic capabilities, but also by the permissible feed limits. For example, in case the submission limits are exceeded, this is reported by the program.

6. Output of the final NC program and project documentation

The last step is the output of the control program and its documentation.

DELMIA 3DEXPERIENCE Machining has the typical modular architecture for all products in the 3DEXPERIENCE platform. All products are devided in Roles and applications (Apps), which can be upgraded at any time depending on your needs. Roles contain applications that are segregated in each role to cover the typical needs of individual roles.

DELMIA 3DEXPERIENCE Machining hasfollowing roles:

- Cutting Tool Technologist (NTT)

- NC Prismatic Programmer (NPM)

- NC Milling Machining Programmer (NMG)

- NC Prismatic and Turning Programmer (NPT)

- NC Multi-axis Milling Programmer (NMX)

- NC Multi-axis Milling and Turning Programmer (NMT)

- NC Machine Code Validation Specialist (NMV)

- Drill & Fill Engineer (GDR)

Allows the creation of company libraries of machining tools according to the ISO13399 standard. Libraries can preserve tool geometries and specific processing modes so that they can be used by engineers across the enterprise and can lead to a higher level of standardization.

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Simulation and programming of 2.5-coordinate milling and drilling. Additional hardening steel processing strategies (Spiral Morphing, Adaptive Concentric Milling) further expand the capabilities of the module.

NC Prismatic Programmer (NPM) can be extended with following roles:

- NC Prismatic & Turning Programmer (NPT)

- NC Milling Machining Programmer (NMG)

- NC Multi-Axis Milling Programmer (NMX)

- NC Multi-Axis Milling & Turning Programmer (NMT)

- 3D Design for Manufacturing Engineer (DME)

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NC Milling Machining Programmer (NMG)
Simulation and programming of 2.5 and 3-coordinate milling of free surfaces. Additional hardened steel processing strategies (Spiral Morphing, Adaptive Concentric Milling) further expand the capabilities of the module. It is possible to program an additional 5-axis via a 3 + 2 axis converter in order to avoid collisions.

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NC Prismatic and Turning Programmer (NPT)
Simulation and programming of lathe and machining centers with lathe-milling functions. Allows programming of prismatic details and drilling operations.

NC Prismatic and Turning Programmer (NPT) can be extended with the following roles:
- NC Machine Code Validation Specialist (NMV)
- Shop Floor Equipment Engineer (EQE)
- 3D Design for Manufacturing Engineer (DME)
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NC Multi-Axis Milling Programmer (NMX)
NC Multi-Axis Milling Programmer (NMX) allows simulation and programming of parallel 5-axis milling of free surfaces. This includes programming of drilling operations, specialized strategies for processing hardened steels (Spiral Morphing, Adaptive Concentric Milling), which further expand the capabilities of the module.

NC Multi-Axis Milling Programmer (NMX) can be extended with the following roles:
- NC Machine Code Validation Specialist (NMV)
- Shop Floor Equipment Engineer (EQE)
-3D Design for Manufacturing Engineer (DME)
For more information, visit the Dassault Systemes page: click here
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 NC Multi-Axis Milling & Turning Programmer (NMT)
The NC Multi-Axis Milling & Turning Programmer (NMT) allows the simulation and programming of turning and drilling operations with several turrets, typical of machining centers with turning and milling functions. Allows 5-axis machining for products of great complexity. It is possible to program synchronized operations with several turrets.

NC Multi-Axis Milling & Turning Programmer (NMT) ) can be extended with following roles:
- NC Machine Code Validation Specialist (NMV)
- Shop Floor Equipment Engineer (EQE)
- 3D Design for Manufacturing Engineer (DME)
For more information, visit the Dassault Systemes page:klick here
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NC Machine Code Validation Specialist (NMV)
NC Machine Code Validation Specialist (NMV) provides additional capabilities to control and verify the generated control programs through 3D simulation of the CNC machine and the processing tool based on ISO code (G code or machine code). The validation of the simulation at the ISO code level is extremely close to the real conditions, because the ISO code corresponds to the commands that the controller sends to the control of the machine. NMV allows simulation of the seized material, as well as the ability to simulate the movement of the machine (complete kinematics of the machine), allowing the diagnosis of possible collisions between the machining tool, the part and the process equipment.

For more information, visit the Dassault Systemes page: klick here
For a detailed brochure klick hereDrill & Fill Engineer (GDR)
Drill & Fill Engineer (NDR) is used for simulation and programming of drilling and riveting operations typical in the production of aircraft fuselages.

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Automation of complete technological processes - from control of a separate machine to control of production lines
The final phase after determining the optimal machining strategy is to conduct a complete machining simulation with a completely realistic reproduction of the actual production parameters of the available metal cutting machines. In DELMIA 3DEXPERIENCE Machining, it is additionally possible to completely close the process of planning and simulation of an entire production site with full synchronization of the operation of multiple CNC machines, their operators and conveyors between them.

TECHNICAL ADVANTAGES
With DELMIA 3DEXPERIENCE Machining, all needs for simulation, control generation and CNC machine programs can be covered. The exceptional technological capabilities of the system make it extremely suitable for companies for which compromises with the quality of the manufactured products are unacceptable and the economic compliance of the projects is of leading importance.
Some of the main technological capabilities of DELMIA 3DEXPERIENCE Machining are:
- a wide range of processing strategies that are constantly evolving and increasing;
- different options for feeding and removing the machining tool from the workpiece;
- large selection of machining tools and possibility for their adaptation;
- support for high speed milling (HSM - High Speed ​​Machining);
automatic collision control between workpiece, machine tool, equipment and machine;
- visualization of the control program;
- possibilities for editing the programs;
a wide range of postprocessors and the ability to create them;
- support for APT and ISO formats;
- facilitated ability to work with any type of CAD systems supporting the formats STEP, IGES, STL;

ECONOMIC ADVANTAGES
1. Selection of optimal processing in order to achieve the highest quality at the lowest cost.
2. Optimal use of the resource of expensive CNC machines
3. Quick and easy entry into the simulation and programming of CNC machines and for non-specialists
4. By using the collaborative platform for engineering design 3DEXPERIENCE it is possible to manage the whole process of design and production planning in a single information base. This can be:
- geometric information about the part
- the devices for its fastening
- the technological map of the processing operations and the cutting tools necessary for them
- Specialized modes of operation