“ All core machines in our main production lines are CAM-programmed . This keeps downtime to a minimum ,” says Gotzmann . Schunk employs a total of 68 CAM programmers — nine of whom focus on custom clamping technology for smaller batches and order-specific production . “ In this department alone , we create around 3,000 NC programs annually for approximately 2,000 custom-developed , designed , and produced products ,” Gülgönül explains .
Process Reliability is Key
For both department heads , maximum process reliability is critical for a cost-effective production process , as waste is something Schunk cannot afford . Alongside CAM programming and automation , the simulation of production tasks before actual machining plays a significant role .
“ Machine simulation is a key element for a safe machining process . The simulation integrated into the CAM system is not enough for us . It ’ s crucial that the simulation we run in the office perfectly matches the real processes on the machines , including the kinematics of the equipment . Only then can we ensure that what we ’ ve programmed will be executed exactly as intended ,” Gülgönül explains why Schunk uses the Vericut simulation and optimisation software .
“ Vericut provided the complete package : the software delivers exactly what we need for efficient and safe production , and the Vericut team offers reliable support with their expertise ,” explains Steffen Gotzmann . CAM administrator Juri Buling adds : “ When machines are idle , it costs a lot of money , and we want to avoid that .
That ’ s why investing in Vericut was the logical step .” With Vericut , the entire clamping situation — including the blank , clamping tools , machining tools , and the machine itself — can be simulated . According to Buling , this virtual machining process has significantly increased process reliability in Schunk ’ s production .
An Integral Part of the Process Chain A key feature of Vericut , according to Hans Erkelenz , Managing Director of CGTech Germany , who led the project , is the fully independently developed software : “ Since 1988 , Vericut has been considered a benchmark in machining production , leading the field in machine simulation , verification , and optimisation for all types of CNC machining , as well as additive and hybrid manufacturing processes . The software operates independently and integrates with all common CAM systems .” Moreover , its core simulation engine is the fastest and most accurate in the NC simulation field .
We can also simulate features like engraving or transferring parts from main to counter-spindle — so Vericut is an essential part of our process chain ,” says Buling . Erkelenz adds : “ Vericut simulates the real machine environment with precise multi-axis and high-speed movements , multiple setups , and complex tool shapes , providing insights into potential collisions with holders or fixtures .”
Minimised Setup and Downtime
Due to the wide variety of customer-specific solutions at Schunk , frequent setups are necessary . “ Thanks to CAM programming and Vericut simulation , we manage to keep these setup and downtime as low as possible .
The NC program is already prepared on the machine , and we know it works because we ’ ve verified it with Vericut ,” Gotzmann explains . This allows Schunk to use available resources as efficiently as possible .
According to the production manager , having a verified NC program also gives machine operators more confidence , allowing them to run new parts faster and more effectively .
“ Not to mention that we can optimise programs through Vericut without having to test them directly on the hardware — a significant advantage in times when continuous productivity increases are essential to remain competitive .” Optimising NC programs is especially crucial for series parts .
Project Timelines Met
Since implementing Vericut , collisions have been eliminated at Schunk , and unnecessary costs due to downtime are avoided .
“ The project was challenging , so it ’ s all the more remarkable that Vericut fully met the timeline ,” emphasises Fatih Gülgönül . “ Schunk is undoubtedly a special client for Vericut due to its scale and tight schedule ,” notes Erkelenz . “ Thanks to excellent support from Schunk , we were able to integrate the first 30 machines into the simulation within a year — this was challenging for our entire team ! I ’ m proud we were able to meet all expectations 100 %.” The next steps for Schunk are already clear , as Buling concludes : “ Our goal is to increasingly digitise all production sites and equip them with Vericut — ultimately securing our competitiveness .”
Currently , Schunk simulates 34 machine tools with Vericut in Lauffen : “ We can simulate and optimise all our machines , including automated multi-channel turn-mill centres — with 100 % accurate kinematics .
For more information , please visit www . vericut . com
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