Right the first time. Every time.

CNC Machine NC Program Cutting Speed Composite Drilling &

Simulation Verification Optimization Applications Fastening

VERICUT is a non-biased checking mechanism of the post-processed

code from both of our CAM systems. Our policy is that no program
can go to the floor unless it has gone through VERICUT.
Frank Dorsey, Engineering Manager
Ellanef Manufacturing Corporation
A Subsidiary of Magellan Aerospace USA, Inc.
 Go ahead...

CRASH Your
Machine! ...as long as it’s in VERICUT

A crash on a VERICUT “virtual machine” can save your real machine!

VERICUT CNC simulation software enables you to VERICUT also optimizes the cutting process to make your
machine parts on the computer before actual cutting occurs programs fast and efficient. And, VERICUT offers the best
so you can eliminate errors that could ruin the part, damage tools available for analyzing, inspecting, and using the in-
the fixture, break the cutting tool, or crash the machine. process, “as-cut” model.

CRASH! A Little About CGTech

When you invest in VERICUT, you’re not just buying a software
program, you’re teaming up with the largest group of CNC
machining experts in the world. Features and benefits or work-
ing with us include:

POur products, including VERICUT simulation

technology, are developed in-house by CGTech
engineers. This allows for quick changes and specific
customization by the original developers.

PCGTech enjoys very high retention of its sales,

customer support engineers, and resellers. This
provides consistent and experienced contacts for a
long-term business relationship with your company.

PYour CGTech contacts work closely with VERICUT

developers to best support your needs.

PCGTech has been a stable and consistently profitable

business, owned and managed by the original founders
The sound is since 1988.
devastating... PCGTech is privately held and 100% self-financed,
allowing us to plan long-term without concern of
investors, stock price, or parent company pressure.

PA large pool of trained VERICUT users exists in virtually

every industrialized country (tens of thousands of seats
A simple mistake can ruin your part, tool, machine, or sold).
even your machinist! And it can throw your production PWe have seen most of the challenges manufacturers
schedule into disarray. face. We are continually exposed to new manufacturing
methods and technologies worldwide, and can quickly
react to ever-changing industry needs.
If you use a CNC machine seriously, you should seriously
consider VERICUT simulation! PAs an approved vendor/product at most major
companies around the world, CGTech is a reliable
partner for your NC manufacturing operations.
2
 CAD/CAM, Tooling, & Model Interfaces
Composite Applications
PROGRAMMING SIMULATION
Verification VERICUT Drilling
& Fastening (VDAF) VCPe
Machine Multi-Axis VDAF
Simulation Programming VCPsp VCSsp
CNC Machine Knife Trimming CNC Machine
Probing Paths Probing
OptiPath ® AUTO-DIFF TM
Laser ATL Layup
Projection Paths
CNC Machine Model
Probing Export

VCPmp VCSmp
Workpiece Verification and Reviewer. . . . . . . Page 4
Reduce scrap and rework by detecting program
mistakes BEFORE machining occurs.

Reports, Multi-Axis, and AUTO-DIFF. . . . . . . . . . . . . 5 VERICUT’s modular format provides flexibility – you
Generate in-process inspection instructions and other purchase only the capabilities you need. It’s easy to add
documentation from in-process machined features.
Compare the cut stock to the design model. modules; just let us know and we provide a license that
gives you immediate access. VERICUT runs on Windows
CNC Machine Simulation. . . . . . . . . . . . . . . . . . . . . . 6 platforms. VERICUT is delivered as both a 32 bit and
Simulate your CNC machine, exactly as it behaves
on the shop floor, to detect potential problems 64 bit application. G-codes and CAM center-line (CL)
before the program goes to the shop floor. formats are supported.
CNC Program Optimization. . . . . . . . . . . . . . . . . . . . 8 “VERICUT paid for itself
Automatically modify feed rates to make your
programs more efficient. the first time we used it.”
Dave Watson, Manufacturing Eng.
CNC Probe Programs. . . . . . . . . . . . . . . . . . . . . . . . 10 Lockheed Martin
Create and simulate CNC probe programs. Aeronautical Systems

CAD Model Export. . . . . . . . . . . . . . . . . . . . . . . . . . 11

Create a CAD model from an existing NC
program, at any stage of machining.

Interfaces to VERICUT. . . . . . . . . . . . . . . . . . . . . . . 12
Seamlessly integrate VERICUT with your
CAM system or tool management software.

Implementation Advice. . . . . . . . . . . . . . . . . . . . . . 13
Get the most from your VERICUT purchase.

Training & Services . . . . . . . . . . . . . . . . . . . . . . . . . 14

Team up with CGTech manufacturing experts
committed to helping you succeed.

Drilling & Fastening. . . . . . . . . . . . . . . . . . . . . . . . . 16

Program and simulate your automated
drilling & fastening machines.

Composite Applications. . . . . . . . . . . . . . . . . . . . . . 18
Program and simulate your automated
fiber-placement and tape-laying CNC machines.

Photo courtesy of Mazak. 3

 Workpiece
CAD/CAM, Tooling, & Model Interfaces

Verification

Verification
Machine Multi-Axis
Simulation

OptiPath ® AUTO-DIFF TM

CNC Machine Model

Probing Export
Control Support:
Easily detect program mistakes Verification supports most common Included Analysis Tools
and verify part accuracy with control functions, and controls are The base Verification module en-
the VERICUT base module: easily modified. ables you to view and analyze the
n Rotary axis pivot points geometry of the cut part. Models
Verification.
n Look-ahead cutter compensa- can be cross-sectioned multiple
Superior Performance: tion times at any orientation, so you
VERICUT’s unique algorithm pro- n Supports several different tool can check areas that would be
vides fast, accurate results. Per- length compensation methods
impossible to see in a solid model
formance does not degrade with n Control cycles; fixture offsets
(such as the intersection of drilled
increased cuts, so VERICUT can n Variables, subroutines, macros,
holes).
process programs with millions of looping, branching logic
cuts and virtually any type of material The X-Caliper™ tool measures
removal technique. Inspection and Measurement: thickness, volume, depth, gaps,
n Zoom, reverse, rotate, cross- distances, angles, hole diameters,
Machining Support: section the cut stock tapping features, corner radii,
n 3-axis milling; 2-axis turning n Measure thickness, volume,
scallop height, edges, and more.
n Rotary 5-axis positioning. Add depth, gaps, distances, angles,
Delta X, Y, Z component distance
our Multi-Axis module to detect hole diameters, corner radii,
measurements are included.
collisions during positioning scallop heights, etc.
X-Caliper also allows you to op-
and to remove material during
Other Capabilities: tionally highlight features, such
continuous four and 5-axis mill-
ing, drilling, turning, and combi- n Video and image capture as all planes on the same level.
nation mill/turn operations. n Create a custom user interface You can view and measure all
n EDM Die Sinking for specific applications tool collisions, even after subse-
n Multiple simultaneous n Add previously removed mate- quent machining operations have
cutting tools rial back to the cut stock when removed them from the screen.
n Multiple stepping back in Review Mode
setups or
operations VERICUT Reviewer
With VERICUT Reviewer shop
floor personnel, suppliers, cus-
The Project Tree
tomers, and other production
allows you to view
and configure all engineers can view animations
setups for a job. of the CNC machining process.
Each setup has its VERICUT Reviewer incorporates
own CNC machine, all the functionality of NC Review
fixtures, tools, NC
programs, and Mode in a stand-alone viewer that just like normal VERICUT, and the
simulation settings. does not use a license. Reviewer cut stock can be measured using
The cut stock auto- can play forward and backward all the standard X-Caliper tools. The
matically orients as while removing and replacing mate- “Reviewer” file can be saved at any
it moves from setup
rial. You can rotate, pan and zoom point in a VERICUT session.
to setup.
4
Inspection Reports & Setup Plans report will display. Creating the report
Save time and improve accuracy by is quick and easy because you use
generating in-process inspection the in-process model to graphically
instructions and other documenta- select features.
tion from VERICUT’s simulated in-
For inspection reports, VERICUT
process machined features! identifies the feature, extracts feature
With VERICUT, you can establish sizes, and applies a standard toler-
a formal, but simple and efficient ance for the measurement. You can
method to create and document in- then add any additional instructions
spection and setup procedures. and select the measuring instrument
All VERICUT reports are customiz- from a list. The setup plan feature
able using a simple template. When allows you to add simple dimen- VERICUT report. All VERICUT re-
modifying a template, a preview win- sions and notes to a VERICUT im- ports can be saved in standard HTML
dow shows exactly how the finished age that can then be added to a or PDF formats.

Multi-Axis
As complexity of the part and the machining operation increases, so does the
CAD/CAM, Tooling, & Model Interfaces

chance for error. Don’t leave the accuracy of the NC program, the quality of the Verification
part, or the safety of the operator to chance! The Multi-Axis module verifies and Machine
Simulation
Multi-Axis

simulates material removal during:

n Multi-axis milling (i.e. cutting with a changing tool axis) OptiPath ® AUTO-DIFF TM

n Synchronized motion of multiple independent cutting heads or CNC Machine Model

Probing Export
attachments such as 4-axis lathes/mill-turns or multiple-head machines

AUTO-DIFF
CAD/CAM, Tooling, & Model Interfaces

Verification
Machine
Simulation
Multi-Axis
Detect gouges and excess Different colors can be assigned to the design
OptiPath ®
AUTO-DIFF TM
material by comparing the model, rough stock, errors, gouges, collisions,
design model to the “as- or excess material for easy identification.
CNC Machine Model
The Surface Range tables include
machined” model.
Probing Export

a value to represent surface

By the time a part design is ready to be machined, it may
cuts exactly matching
have passed through several engineers/programmers,
the design model.
departments, companies, and CAD/CAM systems. In
the end, it can be difficult to tell whether the tool path
accurately represents the intended design. With AUTO-
DIFF, you can be sure.
The design model can be a solid, surface, skin, or
points. You can “embed” the design model inside
the rough material for interactive gouge-checking.
If the tool contacts the design, VERICUT highlights
the gouge and records the error. The design model Zoomed
AUTO-DIFF
even moves with the cut stock as it transitions be- results show
tween setups. a gouge
5
 Machine Simulation
CAD/CAM, Tooling, & Model Interfaces
No more expensive surprises!
Verification Simulate your CNC machines, exactly
Machine
Simulation
Multi-Axis as they behave on the shop floor, so
you can detect errors and potential
OptiPath ® AUTO-DIFF TM
problems before the program goes
CNC Machine
Probing
Model
Export out to the shop!

A machine crash can be very expen- miss zones” around the components Machine Simulation Supports:
sive, potentially ruin the machine, to check for close calls, and detect n Multi-axis milling, drilling, turning,
and delay your entire manufacturing over-travel errors. Machine movements mill-turn, EDM
schedule! But with VERICUT, you can even be simulated while stepping n Simultaneous mill/turn on differ-
can dramatically reduce the chance or playing backwards in VERICUT’s ent spindles and workpieces
for error and avoid wasting valuable Review Mode. n Machines with multiple synchro-
production time proving-out new pro- nized CNC controls
grams on the machine. A selection of customizable machine
models are included. Or, you can n Auxiliary attachments: tail stock,
Machine Simulation detects collisions build models from scratch. Machine steady rests, part catchers, bar
and near-misses between all machine components can be designed in a pullers, pallet changers, etc
tool components such as axis slides, CAD system or defined in VERICUT. n Automatic workpiece transfer to
heads, turrets, rotary tables, spindles, A “Component Tree” feature makes it pick-off or sub-spindles
tool changers, fixtures, work pieces, easy to connect the machine’s pieces n STEP, STL, IGES, and others.
cutting tools, and other user-defined and manage the kinematics of the Many sample machines and control
objects. You can also set up “near- machine. configurations are included.

VERICUT’s MDI includes axis Prevent CNC machine crashes Improve process efficiency
jog buttons and allows tool and near-misses Increase shop safety
positioning by graphical
Reduce the time it takes to
picks. Using the simple MDI Train programmers and
implement new CNC machines
controls, you can make sure machinists without using
your machine can reach all the Show machinists what to production time...
necessary features of the part. expect from new NC programs or risking a crash

Cutter/Grinder Verification & Machine Simulation

Before you risk crashing the machine or
destroying the grinding wheel, verify
grinding operations in VERICUT
and perform detailed analysis to
make sure the part is correct
before machining. Featuring
an interface designed espe-
cially for grinding, verification
and machine simulation can
be launched from a grinder programming system
(i.e. NUMROTOplus® or Schütte) to verify multi-axis
grinding.
6
Superior Collision Checking Point-check methods
VERICUT features the most accurate
VERICUT
detects the can miss collisions!
collision-checking available. Rather
collision!
than just checking points along a
path, VERICUT checks along the
entire path of travel by sweeping
through space. You don’t have to
specify a “step size” tolerance that
can slow the simulation if too small or
miss the collision if too large!
Today’s NC machine tools process
complex NC programs. VERICUT
was designed by NC programmers
and professionals in NC simulation
and verification software. Because
of this expertise, VERICUT is an
excellent tool when using multi-axis
machines, complex NC code, and/or
advanced programming techniques.
VERICUT is designed to support
advanced control functions including:
n Look-ahead or 3D cutter
compensation
n Tool tip programming & tool
length compensation
n Gage length reference point
programming
n Canned cycles and fixture
offsets
n Rotary axis pivot points
n Variables, subprograms, and
macros
n Subroutines, looping, and
branching logic

Tools to Simulate More Complex Applications...

VERICUT also supports: n Turning operations which are
n Automatic part transfer not symmetric about the lathe
between fixtures spindle
n Facing head (or n Machines that use Parallel
“programmable boring bar”) kinematics, such as the SMT
n Mill/turn machining center’s Tricept head
multi-channel programming/ n Multi-axis waterjet cutting
synchronization operations
n CNC controls which allow n Material removal for gear
programming of the tool axis hobbing (synchronize
using IJK tool axis vectors spindles)
7
 OptiPath Feed Rate Optimization
CAD/CAM, Tooling, & Model Interfaces
Cut parts faster, improve
Verification
Machine Multi-Axis
surface finish, & reduce tool
Simulation

OptiPath ® AUTO-DIFF TM
wear without altering the
CNC Machine
Probing
Model
Export
path trajectory
VERICUT’s optimization module, encountered. It then outputs a new
OptiPath,® automatically modifies tool path, identical to the original but OptiPath supports multi-axis machining!
feed rates based on the current with improved feed rates. It does not
cutting conditions to make your alter the route of the tool path. its maximum safe rate-of-advance into
programs more efficient, while also material for the varying cutting con-
extending tool life and improving Simplified Setup and Use ditions. For example, during planar
surface finish! A setup wizard prompts you for cutter roughing of an aluminum aerospace
settings as you machine the part. Es- structural component, material may
Knowledge-Based Machining sentially, you add intelligence to the be removed at a constant axial depth,
VE R ICUT is a true knowledge- cutter. All the settings for that cutter but the radial width of cut could dif-
based machining system. Through are stored in an optimization library. fer greatly from cut to cut. OptiPath
the simulation process, it learns the You define the settings once. Every modifies the feed rates to maintain a
exact depth, width, and angle of each time you use that cutter the results constant volume removal rate.
cut. And it knows exactly how much can be instantly optimized!
material is removed by each cut seg- Optimization for Finishing
ment. With that knowledge, OptiPath OptiPath also features a “learn mode”
for creating the optimization library Chip loads typically vary widely as the
divides the motion into smaller seg- tool profiles through the material left
ments. Where necessary, based on with no setup required. For each tool,
OptiPath finds the maximum volume behind during roughing cuts. OptiPath
the amount of material removed in adjusts the feed rates to maintain a
each segment, it assigns the best removal rate and chip thickness and
uses them to determine the optimiza- constant chip load. (Constant chip
feed rate for each cutting condition loads are recommended by cutting
tion settings for the tool.
tool makers to reduce “chip thinning.”)
Adjust, test, and fine-tune your op- The results are improved tool life and
timization settings as many times better surface finish. This is especially
as you want without re-running the critical when tip cutting with a ball
simulation. After running the simula- end mill or contouring a surface with
tion once, VERICUT stores all the a small step-over, such as semi-
cut information. You can interactively finishing or finishing in a tool steel
navigate, evaluate, and change the mold cavity.
optimization settings individually on
a cut-by-cut level. The results are
displayed immediately. “4½ hours of programmer time
spent on optimization saved us
Optimization for Roughing $75,000!”
Brian Carlson
OptiPath features a “learn mode” for easy During roughing, the goal is to re- Programming Manager
creation of optimized NC programs with no move as much material as quickly as Aerospace Dynamics,
8 setup required. possible. OptiPath keeps the cutter at International
 “...the result of using the
Photo courtesy of Iscar.

Typical NC Program: Point of greatest

one feed rate material removal
(450mm/min) optimization feature is a savings
of more than 81 hours on one
job alone.”
Ben Miller
Tool & Die Programmer,
TOOL STEEL Parker Hannifin Corporation
How it Original NC program feed rate does not change

Works... 450mm/min

As the cutting tool Machine More Efficiently...

encounters more ma- Optimized NC Program: Point of greatest
Cut more parts in the same amount
additional feed rates
terial, feed rates decrease. ...same trajectory
material removal
(450mm/min) of time – it’s like getting a free CNC
As less material is removed,
the feed rates speed up accord-
machine! Reducing cycle time in-
ingly. Based on the amount of material creases productivity and gets parts
removed by each cut segment, OptiPath to market faster.
automatically calculates and inserts im-
proved feed rates where necessary. Without TOOL STEEL

changing the trajectory, OptiPath writes the

Optimized NC program adjusts feed rates automatically
Save Money...
800 700 450mm/min 700 800
updated feed rates to a new NC program. Increased productivity by reducing
the time it takes to cut parts can
Could You Benefit from OptiPath? add up to significant annual savings.
Do any of the following sound familiar? If so, OptiPath can help!
n Removing a lot of material n Optimizing programs “by ear” Improve Part Quality...
n Long machining times n Reworking programs for feeds/speeds... Constant cutting pressure causes
n Large NC programs Howor nooptimization
software time to doAsso
works: the cutting tool encounters more material, feed rates
decrease; as less material is removed, the feed rates speed up accordingly. Based on the little or no variation in cutter deflec-
amount of material removed by each cut segment, the optimization software automatically calcu-
n Interrupted cuts (multiple entry/exit) latesCAM
n and insertssystem
improved feedand/or programmers
rates where necessary don’t
and a new NC program is written–with-
tion. Finishes on corners, edges, and
out changing the trajectory.
n Cutting at variable depths/widths have necessary knowledge blend areas are better so less bench
n High speed machining n “Resident expert” retiring/leaving work is required.
n Thin wall machining n Poor surface finish
n Delicate tooling and materials n Excessive bench time
Make Cutters Last Longer...
n Expensive tooling and materials n Chip thinning problems
Optimum cutting conditions pro-
n Hard materials, soft materials n Cutter deflection problems
n Older equipment n Chatter in corners
long tool life. Shorter machining
n Multiple parts n Air cuts or light cuts at slow or pro- times mean less cutter wear, so
n Premature cutter wear/failure grammed feed rates you change tools or inserts less
frequently.
Feed Rate=MAX High Speed vs. High Efficiency Machining
The traditional method of high-speed machining, cutting Reduce Machine Wear...
at high feed rates with very shallow cuts and small step- A more constant cutting pressure
over, can actually defeat the goal of reducing machining between the machine tool and the
time! Cutting at greater depths removes material more workpiece reduces variable forces
efficiently. But, the cutter may encounter an overloaded on the axis motors for smoother
condition causing it to break or exceed the machine’s
machine operation.
horsepower. Since OptiPath knows the amount of material
removed, it adjusts feed rates accordingly and maintains
Make Better Use of Time...
a consistent chip thickness. This provides more efficient
Machinists don’t have to be glued to
machining while protecting the machine and cutter.
the feed rate override! They can run
8mm CUT DEPTH multiple machines, set up the next
job, or attend to other duties.
TOOL STEEL Excess material that could break cutter
9
 CNC Machine Probing 1. The part is cut
CAD/CAM, Tooling, & Model Interfaces

5. Probe motions are

Verification simulated prior to
Machine Multi-Axis being sent to CNC
Simulation
machine
OptiPath ® AUTO-DIFF TM

CNC Machine Model

Probing Export

Create & Simulate CNC Probe

Programs with VERICUT! 4. G-code
output 2. Features
VERICUT is an ideal place to cre- are selected
ate probing sequences in a CNC
program because of its ‘in-process’
model. This in-process feature geom-
etry is not available anywhere else
in the CNC manufacturing process.
3. Parameters are set (post processor,
Any number of errors can occur that cycle types, tolerances, etc.)
will likely result in a broken inspection
probe when using a CNC machine or break the probe tip. gathered during probing), VERICUT
to perform probing operations. The With VERICUT simulation, there is no helps protect probes and probe tips
probe tip/stem could contact another reason creating your probing opera- that could be damaged or broken by
object while not in probe mode. The tions should ever cause a headache. programming errors.
probe body or other machine com- VERICUT notifies you when the VERICUT simulates probe cycle
ponent could hit something when probe tip contacts an object while subroutines or sub-programs, includ-
moving. Or, an error in the probe not in ‘probe mode,’ and detects any ing complex logic and Type II formats
cycle logic could cause unexpected collisions. By emulating the probe used to set offsets and make deci-
machine motion — which could crash cycle’s logic (which may alter ma- sions based on probe results. CNC
the machine, destroy the probe body, chine motion based on information Machine Probing will help ensure that
you will not destroy the probe or crash
the machine during tasks such as:
n Locating the stock and/or fixture
and adjusting offsets
n Measuring and adjusting for
stock variations
n Identifying stock and/or fixture
configuration or part number
n Measuring and adjusting tool or
fixture offsets
n Simulating tool check cycles
n Inspecting machined features

Contact CGTech to learn how VERICUT

can create and simulate your custom
VERICUT simulates probe cycle subroutines or sub-programs used to set offsets and make
10 probe cycles!
decisions based on probe results.
 Model Export
CAD/CAM, Tooling, & Model Interfaces

Verification
Machine Multi-Axis
Simulation
With Model Export, you can create
CAD models of the cut part from OptiPath ® AUTO-DIFF TM

your NC data at any stage of the CNC Machine Model

Probing Export
machining process, complete with
machined features.
VERICUT can be used to create
a CAD model from an existing NC
program. The model includes features
such as holes, fillets, corner radii,
pocket floors and walls – just as it’s
cut on the machine.
n Export a CAD model at any
stage in the machining process
n IGES and STL output
n CATIA V5, CATIA V4, STEP and In-process,
ACIS output with an optional “as-machined” model
Model Interface (not included you can use in your CAD program!
with Model Export.)

Make Legacy Data Useful: Improve Process Planning: Improve Reverse Engineering:
n Create CAD models from old n Plan for multiple setups or n Take the “as-machined” model
G-code or APT programs staged machining back into your CAD system

Perfect Offset Surfaces Create Fillets Automatically In-process stock model

Offset surfaces can be created us- VERICUT’s cut stock exactly match- Large or complex models may require
ing a CAD program, but this creates es the finished part, including any several setups. Model Export can be
undesirable gaps and overlaps that fillets. The size of the ball nose end used to export a CAD model after
require extensive model clean-up. mill determines the fillet radius. Model each setup, providing programmers
Model Export can be used to gener- Export will export a CAD model that with a starting point for subsequent
ate a CAD model without gaps or includes all fillets. operations.
overlaps!
10mm
Radius

20mm Ball
Nose End
Mill

10mm
Radius

Running the original NC program with a

smaller ball nose end mill automatically Exported CAD model includes all fillets. Fillet An exported in-process model provides a start-
creates an offset surface. size is determined by the end mill radius. ing point for subsequent operations.
11
 CAD/CAM & Other Interfaces
Integrate VERICUT and your CAM system(s) to easily create the most accurate and efficient NC programs possible!
CAD/CAM, Tooling, & Model Interfaces The interfaces make verify- All stock, fixture, and design independently, so you can
ing and optimizing NC pro- geometry is automatically continue working in your
Verification grams, and simulating CNC transferred to VERICUT in CAM system while simulating
Machine
Simulation
Multi-Axis machines, a much easier the correct orientation, along your NC programs. You can
and more efficient process. with your NC program, tool- also import NC programs
OptiPath ® AUTO-DIFF TM
With most interfaces you can ing, machine and control from other CAM systems in
CNC Machine
Probing
Model
Export
verify individual operations, data, and other simulation CL or post-processed G-
or a series of operations. parameters. VERICUT runs code format.

The following CAD/CAM interfaces are available directly from CGTech:

NX

Other interfaces available:

(from Open Mind) (from Delcam) (from Missler) (from Delcam)

(from COSCOM) (from SolidCAM) (from SolidCAM) (from Cimatron)

(from CGS)
(from Schütte) (from Geometric) (from NCG Cam Solutions)

Tool Management Interfaces extract tool lists from assemblies. It is an on-the-fly live connection to your tool
your tool manager system and creates VERICUT tool manager.

Model Interfaces enable VERICUT to read the desig- the ability to use several industry-standard model file
nated model file formats and use them as stock, fixture, formats: STL, IGES, VDA-FS, DXF, and NX (with NX
design, tool holder, and machine models. When com- Interface). Optional model interface modules allow
bined with Model Export, VERICUT’s cut stock may be VERICUT to use these additional formats: STEP, ACIS,
12 written out in these formats as well. VERICUT includes CATIA V4, and CATIA V5.
 Make VERICUT Work For You
It’s Easy to Implement
VERICUT Quickly to
Capitalize On Your
Investment
V E R I C UT

tio n
Obtain the full

VE
value of your Ma IC

R
chine onfigu ra
UT T ning
VERICUT invest- rai
C Jiri Machacek, NC Programmer at AERO
ment by integrat- Vodochody, uses VERICUT to improve
ing it into your machining efficiency and ensure machine
existing manufacturing tool safety.
process. CGTech’s sales,
technical, and development staff
have significant NC machining Three Steps to Run VERICUT:
expertise. We know how to help
m 1. Define your stock model
io
n
I

you get the most from VERICUT in ple

your manufacturing environment. m e n t at n Import from your CAD
system or create it in
We will meet with your management
to establish clearly defined goals. VERICUT
Then we will help determine how 2. Set up your tooling
you can get up and running with tailored to your specific requirements. n Tool setup wizards for
VERICUT as quickly as possible us- For a new customer purchasing one milling tools and turrets
ing: VERICUT training, Customized VMC, we may recommend two days
n Create any cutter shape
VERICUT Machine Configurations of on-site training and one day of
(VMCs), and an implementation plan implementation. n Read cutter descriptions
from the tool path file
n Import CAD solid models
“Just wanted to let you know I verified and optimized my first n Import via CAD/CAM or
part Monday afternoon. The interface worked great and was tool management interface
a huge time savings. I was able to optimize the NC file for a
38.98% improvement in cycle time. The boss is very happy and 3. Import your NC program
we are looking forward to using this new tool on everything. I n G-code
have to say this was the best training course I’ve ever taken… n CAM files (APT)
very good job showing us a lot in short time.”
Then press cut. It’s that simple!
Jon Matthews, Gibbs Machine Corp

Do you know how much prove-outs are costing you? x 12 Number of machines
In today’s competitive manufacturing environment, software verification x 10 Hours per day
is essential to your ability to produce on-time, high quality goods at a x 20 Days per month
reasonable cost. In the conservative example to the right, prove-outs x 0.10 % of time proving programs
cost $24,000 a month. This does not factor in additional costs such = 240 Hours spent
x $100 Hourly machine cost
as scrapped or damaged parts, broken tooling, damaged fixtures, and
= $ 24,000 Monthly, or
extra machine tool maintenance. What are prove-outs costing you?
$ 288,000 annual prove-out cost
13
 Services & Training
CGTech, and its global network of resellers, offer a host of consulting and training services

VERICUT training is offered regularly at numer- Implementation Services:

ous locations. Following are descriptions of Implementation & Automation Consulting
Get help integrating VERICUT into your manufacturing
training courses, implementation services, and
engineering and NC programming processes: both up-
consultancy that are available. For more infor- stream CAD/CAM systems and downstream shop-floor
mation contact your CGTech representative or systems. Ensure that VERICUT fits into your electronic
reseller. workflow as smoothly and efficiently as possible! On-site
advice from a VERICUT expert while working on your
Standard VERICUT Training initial VERICUT projects, eliminates false starts and
CGTech’s hands-on training gives you the knowledge & confusion, and can be the key to accelerating your ROI.
skills to maximize VERICUT’s potential. These courses
are suited to NC programmers and CNC machine op- VERICUT Audit
erators. After completing a course, you will be a better Are you using VERICUT to its full potential? Here’s how
VERICUT user! to tell! A VERICUT expert comes to your site and evalu-
ates your VERICUT use and provides you with a written
Machine & Control Building Training report covering potential risks in your current operation
VERICUT Machine & Control Building training is intended and areas where you can achieve better results. We check
for experienced VERICUT users with a good working your VERICUT installation and assess whether your staff
knowledge of VERICUT. The class builds on your exist- is sufficiently trained.
ing knowledge as you learn techniques for configuring
VERICUT Machine Configurations (VMCs) that can be OptiPath Mentoring
utilized by all users at your company. Make sure you take full advantage of VERICUT’s opti-
mization capabilities. We teach you how to optimize NC
On-site or web-based VERICUT Training programs – using your parts, on your
Can’t make it to a CGTech facility? Need customized machines. We work with you to set up
training? We’ll come to you! On-site or online training can optimization libraries and fine-tune the
raise your VERICUT skills to the next level and is a perfect results, including runs on your ma-
complement to implement newly purchased VERICUT chines, so your operators can
Machine Configurations (see “Contract Services” on see for themselves how
the next page). efficient the optimized
programs are.
New Release Update Training
Improve your productivity
When you invest in
with new VERICUT VERICUT, you’re team-
features quickly i n g u p w i t h ex p e r t s
as a CGTech ex- committed to helping
pert helps you you succeed with our
technology. Our dedicat-
learn how to ap- ed staff of trainers, sup-
ply them to your port engineers, & developers
manufacturing pro- are available to help you reach
cesses. your NC manufacturing goals.

14
Contract Services: CAD Model Export
VERICUT Machine Configuration Need an accurate CAD representation of your machined
Hire CGTech to create VERICUT Machine Configura- part, mid-process, or at the end of the final operation?
tions (VMCs) of your exact equipment and make running We convert your NC programs (G-code or APT) into an
simulations a “push-button” operation! “as-machined” CAD model.

NC Program Optimization Custom Tool Libraries &

Want to improve the quality and production rates of your Custom Software Development
NC machining? Send us your NC programs (G-code or We build VERICUT tool libraries from scratch or from
APT), and we return faster, more efficient programs. This your existing spreadsheets and databases. Do you need
is an ideal solution for shops with limited time, manpower, special capabilities not currently found in the software?
or optimization expertise. We tailor the software to suit your specific needs!

Configuring VERICUT to Simulate your CNC Machines

VERICUT Machine Configuration (VMC) Your CGTech representative or reseller can work with you
CGTech has an extensive collection of VMCs developed to provide a quotation for VMCs. They will discuss your
over several years for customers and with our machine requirements in detail in order to accurately determine the
tool partners. We maintain this collection, updating it for project scope. They will need to know the make and model
new VERICUT versions, features, and added machine and of your machine(s), control type, special machine features
control functionality. beyond basic motion axes (tool changers, tailstocks, etc.)
CAD models are only part of a working VMC. VERICUT also and control features. They will also make sure that the VMCs
needs the control emulation logic and machine kinematics are delivered to your satisfaction.
contained in the VMC. The VMC is configured to exactly
match the Machine Tool options to ensure that your virtual Our Machine Tool Partners
machine and real machine behave identically. CGTech has many years of experience creating and editing
VMCs to meet the needs of its users. We are able to pro-
Supplying VMCs vide VMCs for machines from many of the leading Machine
Each VMC requires some configuration to ensure it meets Tool Builders, often using CAD data supplied through our
your exact machine specifications and options. This configu- partnerships with these companies.
ration is usually done by CGTech (or a VERICUT reseller). Our Machine Tool partners include DMG, Mazak, Mori-Seiki,
However, training can be provided to allow an experienced Matsuura, Makino, Chiron, Hermle, Doosan, and many more.
user to create and configure VMCs. Machine Tool brands we have built VMCs for, include:

Zim mermann

dörries scharmann
Starrag Group

Starrag Group

®
CMS
Industries
15
 VERICUT Drilling & Fastening
VERICUT Drilling & Fastening (VDAF) is a software application for simulating and programming auto-
drilling & fastening machines. VDAF is independent of both the machine and CAD system.
CAD/CAM, Tooling, & Model Interfaces

VERICUT Drilling
& Fastening (VDAF)
VDAF
Programming

When working with expensive

airframe assemblies, the cost of
drilling or fastening mistakes is
high! How much time do you spend
avoiding them?
Visualize and simulate CNC drilling
and fastening machines using the
same NC program code that will be
run on the machine. Simulation is
independent from programming, and VDAF’s programming option adds a user-friendly interface for creating CNC auto-drilling and
VDAF can simulate NC programs fastening NC programs.
from any programming system for any
CNC-automated drilling and fastening The VDAF Programming Add-on VERICUT Drilling & Fastening
machine. module to VDAF gives you the abil- (VDAF) can help you avoid
ity to create NC programs for CNC problems such as:
auto-drilling and fastening ma-
chines. Fasteners n Drilled hole or fastener in
are displayed in a wrong position
tree dialog that al- n Missed hole or fastener
lows you to group
fastener types un- n Wrong hole size or
der tree branches fastener in right position
and order them as
n Hole not drilled through
needed.
the stack
n Hole double-drilled or
double-filled
n Wrong fastener for
material stack
n Collision with structure
n Collision with tooling
n Collision with added
fasteners
16
VERICUT Drilling & Fas- cal and global reference
tening is based on industry locations. Designating
Virtual Fastener
leading VE R ICUT Soft- CAD Assembly and activating reference
Machine Library
ware. VDAF is designed & holes create commands
/Control
to create and simulate NC Fixture Models in the NC program to
programs for automatic drill- align the operation to
ing and fastening machines, the physical part.
also called “layer drilling” or VERICUT Drilling &
“riveting” machines. The VDAF Program-
Post - Fastening (VDAF) ming Add-on Option
processor
requires a VDAF Simu-
Product Descriptions lation base license.

VDAF Simulation Error Checks, Post-processor

NC Statistics &
The base simulation soft- The post-processor for-
Programs Reports
ware is used to visualize and mats the auto-drilling /
simulate drilling and fasten- fastening paths created
ing from NC program code. in VERICUT for a spe-
VDAF simulation is a univer- cific machine. The post-
sal software application capable of single license can program multiple processor contains the definition of
simulating multiple CNC auto-drilling different machines using a post-pro- all drilling, fastening, utility cycles, and
or auto-fastening machines. A single cessor configured for each machine. functions used in the NC program.
license can simulate multiple different
machines using a VERICUT Machine The assembly to be programmed
Configuration (VMC) configured for within VDAF contains an individual Other Options
each machine. Every VDAF imple- part model for each member of the
mentation requires at least one VMC. CAD assembly, located in its proper CATIA V5 Model Interface
assembled position. Each part’s Reads CATIA V5 native assembly files
VDAF simulates machine motion di- material is identified, as well as the (.CATProduct) into VDAF Simulation
rectly from NC program files to check clamp surface and any fixturing. and Programming.
for collisions and other potential VDAF’s fastener locations are cre-
process problems. VDAF simulation ated from the CAD model’s fastener Custom Fastener Object Reader
also checks specific auto-driller/fas- locations and attributes, as read by
tener actions, such as: proper drilling A custom script running inside the
the custom-tailored fastener reader
and fastening through the stack, ap- CAD system that reads user-defined
utility. Fastener locations contain the
propriate tool selection for specified fastener information and converts it
attributes of a fastener and its loca-
hole or fastener parameters, properly into a VERICUT fastener file, in prep-
tion in the assembly. The set of fas-
inserted fastener for given hole and aration for programming and simula-
teners and their attributes define the
stack call-out, and collisions with tion. This script is custom-written for
drill and fastener cycles to be used.
inserted fasteners. each end-user implementation.
One or more reference locations
VDAF Programming Add-on Option may be selected, typically at Drilled Vistagy SyncroFIT Interface
This add-on module to VDAF Simu- at Assembly (DA) holes or temporary A standard interface for reading the
lation creates NC programs for fastener locations. These selections assembly, fastener definition, and
automatic drilling and fastening. This invoke machine reference operations, process information from SyncroFIT’s
is a universal software application but typically do not affect nominal Airframe Design Environment, and
capable of programming many CNC locations in the NC program. Hole or prepares files for programming and
auto-driller/fastener machines. A fastener locations are grouped by lo- simulation in VDAF.
17
 Composite
CAD/CAM, Tooling, & Model Interfaces
Composite Applicaons
PROGRAMMING SIMULATION

VCPe

Applications
VCPsp VCSsp
CNC Machine Knife Trimming CNC Machine
Probing Paths Probing

Laser ATL Layup

Projection Paths

VCPmp VCSmp
Programming & Simulation Software for Automated
Fiber-Placement (AFP) and Tape-Laying Machines (ATL)

VERICUT Composite Paths for Engineering (VCPe) on a composite part’s design intent. By producing actual
VCPe gives a composite part designer, mechanical AFP tape courses that could be used to program AFP
engineer or process engineer access to the same soft- fabrication equipment in the workshop, the user can
ware tools NC programmers use to create Automated measure and evaluate the effects of AFP path trajectory,
Fiber Placement (AFP) NC program paths that are sub- material steering, surface curvature, course convergence
sequently used in the workshop to lay-up a composite and other process constraints as they would be applied
part. Using these tools the part designer or engineer in manufacturing. Tape course geometry can be written to
can easily create and experiment with various AFP path various CAD formats for further evaluation by the user’s
options and evaluate the effects AFP manufacturing has existing analysis methods and tools.
VERICUT Composite Programming (VCP) & Simulation (VCS)
VCP reads CAD surfaces and ply boundary information and adds
material to fill the plies according to user-specified manufacturing
standards and requirements. Layup paths are then linked together to
form specific layup sequences and are output as NC programs for the
automated layup machine. VCP can be used to program any number
of machines, and includes support for probing, knife trimming paths,
laser projection, and automated tape laying machines (ATL). VCP
is also offered for a single platform (VCPsp) with optional modules.

VCS reads CAD models and NC programs, either from VCP or

other composite layup path-generation applications, and simulates
the sequence of NC programs on a virtual machine. Material is ap-
plied to the layup form via NC program instructions in a virtual CNC
simulation environment. The simulated material applied to the form
can be measured and inspected to ensure the NC program
follows manufacturing standards and requirements. A re-
port showing simulation results and statistical information
can be created automatically. VCS can be used to simulate
any number of machines, and includes support for prob-
ing. VCS is also offered for a single platform (VCSsp) with
probing optional.

18
VCP Process Features:
Reads CATIA V5, NX, STEP, or ACIS surface models Links paths to create form layup sequences
n Other model formats available upon request n Automatic and manual linkage of paths based on
shortest distance and form’s topology
Reads Fibersim, CATIA V5, or other external ply geom- n Insert machine-specific commands and actions
etry and information n Insert safe start and restart events
n Boundary geometry
n Ply direction Post-processes linked paths
n Start points n Output per machine requirements
n Configure machine-specific events
Generates layup paths based on manufacturing n Output safe start and restart sequences
engineering rules
n Rosette projection at specified angles
n Parallel to guiding curve
n Follows the natural path of the form’s surface

Add thickness to form for subsequent sequences

VCS Analysis Features:

Reads CAD geometry of the layup form Checks the process for compaction roller/form
n Used for collision detection and material application conformance and direction
n Verify roller orientation to path
Uses VERICUT virtual machine and control emulation n Verify path correctness to the form and previously
to simulate the layup machinery applied sequences/layers of material
n Can be configured for virtually any CNC syntax and n Check roller conformance for bridging or excessive
machine kinematics configuration compaction

Reads the NC program and simulates the layup Added material is

process based on NC program commands measurable and
n Validate the actual NC program that will run on the can be inspected
layup equipment for manufacturing
n Add material to the form based on NC program requirements
commands n Measure lap, gap,
n Material is added in discrete layers/sequences, and thickness
constructing the workpiece exactly like the physical n Detect steering
process radius violations 19
United States — Corporate Headquarters
9000 Research Drive Irvine, California 92618
TEL +1 (949) 753-1050 • FAX +1 (949) 753-1053
info@cgtech.com

United Kingdom Germany Japan

CGTech, Ltd. CGTech Deutschland GmbH CGTech Japan
Curtis House, 34 Third Avenue Neusser Landstr. 384 3F ERG Bldg. 1-5-3,
Hove, East Sussex, BN3 2PD D-50769 Cologne Nishi-Ikebukuro, Toshima-ku
TEL +44 (0) 1273-773538 TEL +49 (0) 221-97996-0 Tokyo 171-0021
FAX +44 (0) 1273-721688 FAX +49 (0) 221-97996-28 TEL +81 (3) 5911-4688
info.uk@cgtech.com info.de@cgtech.com FAX +81 (3) 5911-4689
info.japan@cgtech.com

France Italy China

CGTech S.A.R.L. CGTech s.r.l. CGTech China
Les Passerelles Viale Verdi, 1 Room 905, Raise Plaza,
104 avenue Albert 1er 31100 Treviso No.126 Jianguo Road,
92500 Rueil-Malmaison TEL +39 (0422) 583915 Chaoyang District, Beijing, 100022
TEL +33 (0)1 41-96-88-50 FAX +39 (0422) 543464 TEL (086) 10-6566 9919
FAX +33 (0)1 41-96-88-51 info.italia@cgtech.com FAX (086) 10-6566 1538
info.france@cgtech.com info.china@cgtech.com

Brazil India Singapore

CGTech Brazil CGTech India CGTech Singapore
Rua Serra de Botucatu, 22 Altos # 38, 1st Main, 3rd Cross PO Box 074
03317-000 Tatuapé Malagala, Krishnananda Nagar Singapore 914003
São Paulo SP New Outer Ring Road TEL +65 6638 6455
TEL +55 11 4119-0907 Bengaluru, 560091 info.ap@cgtech.com
info.brazil@cgtech.com TEL +91 080 23 18 69 81
info.india@cgtech.com

CGTech® is the leader in CNC machine simu- CGTech software is used by companies of all
lation, verification, and optimization software sizes, universities, trade schools, and govern-
technology. Since 1988, our products have ment agencies.
been the standard in manufacturing industry
sectors including aerospace, automotive and CGTech maintains an active Technology Partner-
ground transportation, mold and die, consumer ship program. VERICUT users in this program
products, power generation, and heavy indus- include many of the world’s leading machine
try. With subsidiary offices throughout Europe builders, CAD/CAM developers, and manu-
and Asia, and a global network of resellers, facturing software companies.
When you invest in VERICUT, you’re not just buying a software program, you’re
teaming up with a manufacturing partner with the best reputation in the business!

System requirements are subject to change. See the CGTech web site for the most up-to-date product information and system requirements.

© CGTech 2014. All rights reserved.

CGTech, OptiPath, and VERICUT are registered trademarks of CGTech. AUTO-DIFF, X-Caliper, and CATV are trademarks of CGTech. All other trademarks are property of their respective owners. 1/2014