Today highly complex components are manufactured on NC-controlled machine tools. The NC programs, controlling these machines, are usually automatically generated by CAM software. This automatic processing is often erroneous. The VR-based realistic machine simulation, presented in this paper, extends the usual content of a machine simulation, like material removal and collision detection, by various new aspects. The coupling of a real NC unit allows the recognition and elimination of all process- as well as controller-caused errors. The integration of the multi-body simulation enables the consideration of inertia, machine rigidity and milling cutter deflection.

Today highly complex components are manufactured on NC-controlled machine tools. The NC programs, controlling these machines, are usually automatically generated by CAM software. This automatic processing is often erroneous. The VR-based realistic machine simulation, presented in this paper, extends the usual content of a machine simulation, like material removal and collision detection, by various new aspects. The coupling of a real NC unit allows the recognition and elimination of all process- as well as controller-caused errors. The integration of the multi-body simulation enables the consideration of inertia, machine rigidity and milling cutter deflection.