Simulation is essential in design, engineering, and manufacturing. For example, computer-aided engineering (CAE) software simulates 3D models, helping professionals visualize and improve designs while resolving engineering issues. After final design approval, the next step is manufacturing, often using CNC machining. First, import the 3D models into computer-aided manufacturing (CAM) software, which optimizes the tool path, feed rate, and cutting speed based on your input. The CAM software can also simulate the machining process and verify the tool path. However, you can also use dedicated CNC simulation software to complete these tasks.
If you are inclined to use the embedded simulation and verification feature that comes with a CAM system, it is always advisable to bear in mind that some CAM systems are less reliable and slower than others. Given the consequences of errors—such as tool breakage, material waste, machine downtime, labor costs, and even injury—choosing a better solution is essential. The better solution takes the form of CNC simulation software.
This article explores how CNC simulation software enhances the precision and accuracy of CNC machining. As we detail later, this software identifies errors in G-code (CNC programs) that may lead to collisions. They also create digital twins of CNC machines, displaying an interactive machining environment that improves visualization. You can use such an environment for virtual prove-outs, safeguarding your CNC machine, as well as for training employees. We also cover the top 5 CNC simulation software options, including their features, advantages, and disadvantages.
Table of Contents
Understanding CNC Simulation Software
CNC simulation software is standalone software that creates digital twins of CNC machines and machine tools. The software uses provided data – such as the CNC program, material type and size, and custom tool specifications – to simulate the cutting process. The software uses the digital twin and the CNC positioning data in the NC program to realistically and accurately depict/simulate the actual machine behavior.
This simulation captures machine kinematics, fixture and holder collisions, multiple setups and tool changes, precise multi-axis (3, 4, 5, or more axes) and rapid motion, complex tool shapes, and, depending on the software, complex controller functions. By visually depicting the machine behavior and machining process in a virtual environment, the CNC simulation software acts as a visual check.
In addition to simulating the real machining environment and process, the CNC simulation software verifies and optimizes the toolpath. The verification and optimization processes improve the machining process, save time, and reduce manufacturing costs.
CNC Simulation Software vs. Internal CAM Software Simulation
CAM software does support CNC simulation. However, a study by MLC CAD Systems, a Cimco and Mastercam reseller, found that it is slower than dedicated CNC simulation software. The study established that Mastercam’s simulator tool took 15.22 minutes to complete a complex model simulation. In contrast, Cimco Edit took 4.9 minutes. The study confirms that dedicated CNC simulation software is faster than the built-in simulation feature in CAM software.
CNC simulation software offers additional advantages:
- Dedicated CNC simulation software frees up CAM software to carry out its primary functions, like generating toolpaths and creating CNC programs
- CNC simulation software can verify toolpaths and CNC programs generated by any CAM software, providing flexibility and consistency, while CAM systems primarily verify toolpaths they have generated
- Compared to CAM software, whose developers license simulation algorithms from third-party developers like ModuleWorks and integrate them into their products, CNC simulation software developers use their own simulation kernels and engines. These engines are built from the ground up with the user in mind or based on feedback from users and hence consider the needs of the market
For context, ModuleWorks is not your typical software; it is a software – or, more accurately, a set of algorithms – designed to be integrated into other software. You, therefore, cannot download and use it as you would conventional CNC simulation software. To use it and enjoy its advanced simulation capabilities, you must install software that has integrated the ModuleWorks simulation algorithms.
Software like Mastercam, PTC Creo, and Fusion 360 uses some or all ModuleWorks components, including simulation, multi-axis toolpath generation, and toolpath calculation technologies. Under the Strategic Partner Program, ModuleWorks has worked with PTC Inc. and Autodesk, CNC machine builder DMG Mori, CNC machine tool builder DN Solutions, and CNC control system suppliers Mitsubishi Electric and FANUC.
Benefits of Using CNC Simulation Software
There are plenty of benefits of using CNC simulation software. They include:
- Improved safety: CNC simulation software creates a virtual machining environment that enables programmers, machine operators, and students to verify programs and simulate machining processes without manually interacting with the CNC machines. This reduces the risk of accidents, especially among trainees who are still not yet well-versed with operating machinery.
- Collision detection: These software products simulate the interactions between machining tools and the workpieces, which helps identify collisions. It enables the programmers to change the G-code before exporting it to the CNC machine. This way, CNC simulation software prevents tool breakage.
- Detection of programming errors: CNC simulation software can identify errors in CNC programs. These include syntax and cuspidal/pinch point errors on cutter-compensated machine tools.
- Cost savings: Simulation is one of the technologies you can use to reduce CNC machining costs. Simulation software creates a virtual environment that helps you identify potential collisions early on before you get into production. This prevents real-life collisions between tools and workpieces, which may break expensive machine tools. You, therefore, don’t risk expensive machinery. Additionally, with CNC simulation software, you do not need to take machines out of production to perform prove-outs; you can simply verify the CNC program within this virtual environment. Hexagon, the developer of NCSIMUL, states that its simulation software helps manufacturers and machine shops save up to $25,000 per machine per year. For its part, CGTech, the developer of VERICUT, notes that prove-outs of new NC programs on the machine can cost $24,000 per machine per year.
- Safe and Interactive Training: You can use CNC simulation software to train students, operators, and programmers without risking expensive CNC machines, tools, or accidents. Some software allows users to manipulate the 3D simulation, providing an interactive way of training employees and students. (More on this below.)
- Increased precision: Some CNC simulation software products verify and optimize toolpaths, ensuring precision during actual machining.
- Improved productivity: The simulation software products enable machine operators to test programs and visualize the machining process before embarking on actual machining. This has twofold benefits – it ensures that the programs run seamlessly on the CNC machines and decreases the setup time as the operator has a concrete idea of what to do and expect. Additionally, CNC simulation software improves productivity by freeing up CAM software to generate toolpaths, their intended function.
CNC Simulation Software in Training Programs
It may not always be economically feasible to purchase multiple expensive CNC machines solely for the purpose of training students or new employees. And if the machines are already present, it may also not make financial sense to take them out of production just to train newbies. At the same time, the potential for tool breakage adds to the reasons why CNC machines may not be used for training.
In practice, CNC simulation software is used in training programs. These products simulate the CNC machines and machine controllers, giving trainees a glimpse into real-life machining operations, albeit in a virtual environment. CNC simulation software promotes safety, inclusiveness (as every student can interact with a virtual machine via the software), and cost savings. And by interacting with the software, students and trainees gain hands-on knowledge and experience that they can later use to operate actual machines.
Today, there are numerous CNC simulation software specifically designed for CNC training and employee training:
- Siemens SinuTrain for SINUMERIK
- FANUC CNC Simulation Software
- SwanSoft CNC Simulation software (discussed in greater detail later)
SinuTrain for SINUMERIK
SinuTrain creates the digital twin of the CNC SINUMERIC One machine. It also features the same programming and user interface as the SINUMERIC’s control system. SinuTrain, therefore, is an identical programming station for CNC program creation, production planning, and training. It also enables you to prepare and finish work at home or to verify a CNC program without worrying about breaking something.
FANUC CNC Simulation Software
FANUC’s CNC simulation software products are twofold:
- FANUC CNC Machining Simulation for Workforce Development
- FANUC CNC Simulator’s CNC simulation software
FANUC CNC Machining Simulation for Workforce Development
Powered by ModuleWorks, the FANUC CNC Machining Simulation for Workforce Development is a realistic CNC simulation software that facilitates virtual CNC training. It creates a digital twin of the CNC machine and the tools and uses it to simulate the cutting/machining process. This way, the software enables budding professionals to train on FANUC controls operation and part programming. All this is done without risking expensive machinery or accidents. You also do not have to stop production just to facilitate training. Unfortunately, this product is only available in North America.
FANUC CNC Simulator’s CNC Simulation Software
The second CNC simulation software from FANUC can be found in the FANUC CNC Simulator. Powered by the FANUC Manual Guide I software and based on the actual Fanuc Series 0i-MODEL F Plus CNC controller, the simulator aims to familiarize students with the layout, function, feel, and look of the actual CNC control without the need to connect it to the CNC machine. It ships with all the functions of a typical control system, including the e-stop switch, feed override, manual pulse generator, and much more.
The simulator’s software uses a graphical user interface that allows you to interact with the user-friendly icons. It displays all the relevant information you may need on one CNC screen. The software is designed to enable you to create part programs without needing to know G-code. This is because it uses conversational programming instead. Besides enabling you to create and edit programs, the software lets you import programs and use simulation to check programs.
The built-in CNC simulation software in the FANUC CNC Simulator lets you specify the size of the blank material and the tool you intend to use. It also lets you change the orientation of the workpiece relative to the cutting axis of the CNC machine. This capability enables you to better visualize the machining operation. You can also rewind, stop, pause, or control the speed of the simulation. You can also visualize the toolpath, which the software displays as a wireframe animation.
FANUC CNC Simulator’s Software Interface (source)
Top 5 CNC Simulation Software Products
1. VERICUT
VERICUT User Interface (source)
Developed by CGTech, VERICUT is software that simulates CNC machining. It detects errors, potential collisions, and inefficiencies in the NC programs. This CNC simulation software simulates all types of CNC machine tools from leading vendors like DMG Mori, Okuma, Makino, Mazak, etc. It can also be integrated with leading CAM systems
Features of VERICUT
- Tool path verification and optimization
- Realistic 3D simulation that recreates the exact machining environment and simulates precise multi-axis and rapid motion, collisions, machine kinematics, and more
- VERICUT’s new Heat Map display shows the wear pattern on machine tools and uses a combination of colors and messages to demonstrate how each tool was used
- CNC Machine Connectivity facilitates real-time data transfer by enabling VERICUT to connect directly with a CNC machine
- VERICUT sends email or Teams notifications with a summary of results whenever it completes a simulation (you can configure the software to send these notifications after certain events like collisions, tool changes, errors, etc.)
- Enhanced simulation timeline, which contains error markers that let you click directly on an error marker to review an error in the simulation and investigate the reason it occurred
- Enhanced support for CNC machines and programs that use tools mounted in multi-tool stations (MTS)
Pros of VERICUT
The advantages of VERICUT include:
- VERICUT can be used with all CNC machines and is compatible with all CAD/CAM/PLM systems, including CATIA, Creo, CAMWorks, SurfCAM, GibbsCAM, Esprit, Mastercam, NX, Edgecam, Fusion 360, Cimatron, SolidCAM, and more
- It verifies and optimizes toolpaths, enhancing process efficiency
- CGTech, VERICUT’s developer, provides training across various topics and classes, from simulation and verification, machine and control building to force optimization
- VERICUT offers superior collision-checking
- The software provides realistic 3D simulations of CNC machines, including milling, grinding, EDM, turning, and drilling machines, offering multi-axis support, automatic workpiece transfer, and more
- It enhances operational safety
- The software improves productivity by lessening the time you would take to understand and operationalize new CNC machines
- VERICUT improves presentations and documentation
- Many CNC machinists and operators recommend VERICUT
Cons of VERICUT
The disadvantages of VERICUT include:
- VERICUT is expensive, with users stating that this CNC simulation software can cost anywhere between $20,000and $50,000
- VERICUT training courses can be expensive, with online courses going for $400/day and on-site training costing $1950 per day
2. Cimco Edit
Cimco Edit User Interface (source)
Cimco Edit offers several essential tools for editing NC programs. It is also capable of simulating machining processes. Here, simulation is made possible by a backplot and solid simulation feature on Cimco Edit and the Cimco Machine Simulation add-on (purchased separately).
The built-in simulation feature simulates NC programs in 3D using a multi-axis backplotter, which shows the toolpaths for turning and milling. It can simulate, using solid or wireframe view, material removal, collision detection, and more. The add-on, on the other hand, lets you prove-out your G-code on a digital twin of a CNC machine. This way, you can visualize and see the exact movements of the machine tools. In addition, Cimco Machine Simulation detects collisions and out-of-limit moves.
Features of Cimco Edit
Cimco Edit and the Cimco Machine Simulation add-on have the following features:
- GPU-accelerated high-quality simulation
- Interactive 3D simulation that supports zooming, panning, and rotating, as well as speed adjustments
- The simulation in Cimco lets you jump to the previous or next tool, cutting pass, or move
- Cimco generates a simulation report containing all the errors and collisions and the corresponding line in the G-code responsible for the error. Thus, by selecting an error and jumping to the line of code, you can easily modify the code and, using the subsequent report, verify that the issue has been resolved.
- An extensive library of CNC machines’ digital twins, which can be downloaded to the Machine Simulation add-on
- Cimco automatically pauses/stops the simulation under certain circumstances, including after collisions, when travel limits are exceeded, and during tool changes
- Geometry manager: Cimco features a Machine tree (shown in the table below) that enables you to view machine properties as well as the properties of components like the workpiece, head, base, and table. In addition, the manager enables you to configure the origin, work offsets, and the machine’s geometry.
Geometry Manager in Cimco Edit (source)
- The axis control feature lets you control the machine’s travel limits, ensuring all axes fall within these limits.
- Cimco easily integrates with CAM software like Mastercam, SolidCAM, and more
- Solid mode, which simulates stock material removal
- Machine configuration editor lets you define machine setups
Pros of Cimco Edit
The advantages of Cimco Edit include:
- Cimco supports more than 20 languages
- It enables you to identify inaccuracy by comparing the simulated stock to the design model
- The simulation report enables quick program editing and verification
- Cimco’s online library of digital twins includes pre-configured CNC machines from a number of vendors, including Haas, DMG Mori, DN Solutions (formerly Doosan Machine Tools), Quaser, and more. The local library can be updated by downloading and installing the machines from the online library.
- Cimco offers free online courses
Cons of Cimco Edit
The cons of Cimco Edit include:
- Cimco is only available on Windows OS
- The Cimco Edit software and the Cimco Machine Simulation add-on are priced separately
3. NCSIMUL Machine
NCSIMUL Machine Interface (source)
A product of Hexagon Manufacturing Intelligence, NCSIMUL Machine is an advanced CNC machining verification software. It enables manufacturers to virtually build a real-life machining environment before embarking on production. This CNC simulation software uses the real characteristics of your CNC machine to create a direct digital twin of your machines, tools, workpieces, and material. It then utilizes this information to simulate, verify, and optimize G-code programs. The software is available for complex CNC machining, multi-axis (3 to 5-axis) milling, drilling, and turning.
Features of NCSIMUL Machine
- Error and collision detection: NCSIMUL Machine uses 3D graphics to display CNC collisions in real time
- Realistic CNC machine simulation: NCSIMUL Machine creates digital twins of machines, with the resulting simulations including machine accessories and a macro for probing. In addition, the simulation demonstrates a number of crucial processes, such as tool changes and material cutting.
- Part inspection: NCSIMUL Machine can use user-defined tolerances to quickly and easily compare part gouging or material residual against the design model
- G-code decoding and verification: This involves automatic programming error detection (e.g., syntax errors and inconsistencies in the program) and interactive toolpath tracing.
- Certification of program modifications: NCSIMUL Machine automatically checks program modifications and automatically optimizes them as other production or programming tasks continue.
- Integration with NCSIMUL Player: NCSIMUL Machine integrates with NCSIMUL Player, which provides an immersive channel to view and share simulations. NCSIMUL Player enables colleagues to manipulate the simulation in 3D space and access various functionalities such as dimensioning and measurement.
Pros of NCSIMUL Machine
The advantages of NCSIMUL Machine include:
- It optimizes cutting tool feeds and speeds to reduce cycle times
- NCSIMUL Machine aids collaboration by generating CNC technical documents and 3D simulations that can be shared and reviewed
- Its G-code verification capability delivers accurate machining cycle time
- NCSIMUL Machine integrates with CAD/CAM software, enabling you to seamlessly import CAM data; this way, you do not have to rebuild tool libraries, ultimately saving time
- By detecting collision pre-production, the NCSIMUL Machine software facilitates safe and collision-free machining and avoids downtime that may have otherwise resulted from tool breakage
- This CNC simulation software reduces cycle times by optimizing toolpaths
- NCSIMUL Machine enables manufacturers to reduce the cost of proving out CNC programs by as much as $25,000 per machine per year, according to Hexagon
- The software performs dimensional analysis, enabling you to identify features that are out of tolerance or forgotten tool offsets
- Hexagon claims that NCSIMUL Machine can process more data more quickly than the competition, translating to fast simulation
- NCSIMUL Machine has a short learning curve and is easy to use
Cons of NCSIMUL Machine
The disadvantages of NCSIMUL Machine include:
- NCSIMUL Machine does not simulate the interface of the CNC machine’s control system
- Pricing information is not readily available, making it impossible to compare at first glance its price with that of CNC simulation software solutions
4. SwanSoft CNC Simulation (SSCNC)
SwanSoft CNC Simulation User Interface (source)
Developed by Nanjing SwanSoft Technology Company, SwanSoft CNC Simulation software, or SSCNC, is designed for teachers and students. It helps students simulate the machining operations in real-life CNC machines, allowing them to acquire the requisite knowledge quickly without using real machinery. Using SSCNC, learning institutions do not have to spend a fortune purchasing machines.
Features of SSCNC
SwanSoft CNC simulation software ships with the following features:
- SSCNC’s library includes at least 203 operational panels, 81 CNC controllers, and 22 CNC brands
- It simulates the programming and processing functions of various controllers, including FANUC, SINUMERIC, Mitsubishi Electric, HAAS, GTC, Mazak, Heidenhain, MORI SEIKI, and many more
- 3D simulation based on OpenGL
- Windows MACRO recording and replay
- 2/3 axis milling simulation
- G-code debugging tool
- Automatic tool changes, including various types of turrets
- Simulations for coolant, sound, and iron fragment effect
- Measurement tools, including calipers, micrometers, feeler gauges, and edge finders, among others
- Support for custom tools
- Roughness or surface finish measure based on cutting tool parameters
- Simulations for workpiece setting and mounting
- Support for dynamic interaction with the simulation, including zoom, full screen, switch views, and move
Pros of SSCNC
SwanSoft CNC Simulation software offers the following advantages:
- SSCNC reduces the cost of training, as it helps colleges and training institutions train students without having to invest in expensive machines and controllers
- It trains students on different machine controllers, as it simulates their respective interfaces and all their built-in functionalities
- SSCNC promotes safety by ensuring that students learn about machining operations without directly interacting with CNC machines
- It is ideal for both handwritten NC programs as well as programs generated by CAM software
- SSCNC supports various languages, including Chinese, English, Korean, Turkish, Portuguese, Polish, Hungarian, Russian, and Spanish
Cons of SSCNC
The disadvantages of SwanSoft CNC Simulation software include:
- SSCNC is only available on Windows OS
- Nanjing Swansoft Technology Company does not regularly update the trial version of the SSCNC software
- Multi-axis machining in SSCNC is limited to two and 3 axes
5. CNC Simulator Pro
CNC Simulator Pro Interface (source)
CNC Simulator Pro is a full 3D CNC machine simulation software. It simulates over 40 machines across five categories. It also supports more than 30 different materials. Besides being a CNC machine simulator, CNC Simulator Pro is a modern CAD/CAM system, a 3D model milling software, an advanced CNC programming editor, and a gear creator. It is also ideal for training students and new operators.
Features of CNC Simulator Pro
CNC Simulator Pro has the following features:
- CNC Simulator Pro simulates milling, turning, 3D printing, and cutting (laser, plasma, and water jet cutters) machines, plotters, and more
- Its library contains the digital twins of more than 43 machines in five categories
- It supports over 30 different materials, including aluminum, nylon, steel, wood, titanium, ABS (acrylonitrile butadiene styrene), brass, copper, magnesium, and more.
- CNC Simulator Pro includes the SimCAM integrated CAM system, which adds CAD/CAM capabilities
- It includes a virtual CNC controller inspired by FANUC and others
- Free cloud-based storage
- Macro programming, which enables you to customize or automate processes
- Fast backplotting
Pros of CNC Simulator Pro
The advantages of CNC Simulator Pro include:
- CNC Simulator Pro features digital twins of both industrial machinery as well as hobbyists’ tools and machines
- It is ideal for hobbyists, industrial machine operators, teachers and students
- This CNC simulation software ensures safety by limiting their interaction with CNC machines and preventing accidents that may result from errors in G-code
- CNC Simulator Pro improves the speed of writing and editing CNC programs since its intelligent code editor highlights various types of codes and suggests changes or better code
- The software has plenty of built-in tools, including Gear Maker, Image Maker, and 3D Maker, which help you write your CNC programs faster and more accurately
Cons of CNC Simulator Pro
CNC Simulator Pro has the following drawbacks:
- CNC Simulator Pro is only available on Windows and only runs on 64-bit versions of the software
- Its longer update cycles mean users wait for long periods to receive updates. For instance, CNC Simulator 4 has been in beta since September 2021.
- The long update cycles quickly make the 3D simulation graphics appear outdated, especially as better monitors/displays and GPUs become available.
Implementing CNC Simulation Software
CNC simulation software products are different – with the nuanced differences emanating from the number of CNC machines in their libraries, ease of use, integration with CAM systems, and simulation capabilities, just to mention a few. Cost should also be another aspect that guides the implementation of this CNC simulation software. Additionally, you should check whether the developer regularly updates their software.
Thus, when choosing your preferred CNC simulation software, it is essential to check the following:
- CAD/CAM integration: It is advisable to check whether the software seamlessly integrates with your go-to CAM system. This consideration ensures continuity. It also helps you avoid creating new libraries for tools and machines because you can simply migrate that data from one software to another.
- Cost: Some software products, like VERICUT, are more expensive than others. Additionally, some developers offer free online courses, while others charge their learners. Thus, depending on the number of seats you want to purchase, it may be financially prudent to purchase a cheaper yet formidable solution instead of an expensive one.
- Training for use: All software applications have a learning curve – the difference lies in the steepness of the curve. So, you should understand that you must train your employees on how to use the CNC simulation software should you want to boost productivity and ensure you enjoy the aforementioned benefits of the product. At this stage, you should also factor in the cost of training.
- Regularity of updates: Software updates typically resolve bugs and introduce new features that enhance the software’s functionality. CNC simulation software that is rarely updated will, therefore, have outdated features and vice versa.
Conclusion
CNC simulation software plays a crucial role in enhancing CNC precision, productivity, and safety, facilitating training, and helping companies and learning institutions reduce the cost of machining. To benefit from these advantages, select the CNC simulation software that best meets your needs. This selection hinges on a number of elements, chief among them the ability to simulate CNC machining operations. Besides function, other elements to consider when selecting simulation software include cost, regularity of updates, the learning curve, and compatibility with available CAD/CAM systems. You should also assess their features, pros, and cons, which we have discussed in detail in this article.
If you are looking for a simulator for your commercial operations, there are plenty of operations from which to choose. Our list of top 5 CNC simulation software includes VERICUT, Cimco Edit, NCSIMUL Machine, CNC Simulator Pro, and SSCNC. And if you are searching for a solution solely for training purposes, you can choose from a pool that includes Swan Soft CNC Simulation software, Siemens SinuTrain, and FANUC CNC Simulation Software.
