NCSIMUL Product History

Listed below are the previous releases of NCSIMUL, to view what features where introduced in each of the releases click the buttons below.

NCSIMUL Version 2021.1

NCSIMUL 2021.1

Learn what’s new in the latest release of NCSIMUL

Automatic intermediate stock management

Because NCSIMUL enables data to be sent from the CAM system to the simulation without adjustment before the verification begins, the NC-programmer can start debugging the G-code file during programming and switch between the CAM system and simulation as required. With the new automatic intermediate stock management function, the simulation will always start from the last updated intermediate stock.

When loading a new version of the G-code file, NCSIMUL 2021.1 saves a recording of the previous file and compares the two versions after decoding it compares the two records. This comparison is based on the analysis of tool sequences, coordinates and cutting conditions. As soon as a difference is detected, the intermediate stock of the sequence as well as the following ones are deleted. The user can also choose to manually delete an intermediate stock to allow the restart of the simulation at a specific desired location.

The intermediate stock management function enables users to start verification early in the programming process and to see their modifications in real time. For programs containing a lot of tool changes, verification times can be reduced by up to 50%.

5-axis setup performance analysis

NCSIMUL 2021.1 enhances the analysis functions supporting simulation and collision detection by offering a function to analyse the behaviour of the machine in continuous 5-axis mode, helping users predict and mitigate against machining problems. The tool axis passing close to the point of singularity can generate significant motion in the rotary axes. Small movements of the tool tip with a large variation in inclination can also cause larger motion in the machine axes. These phenomena can cause cutting problems because the tool spends more time chasing the part than removing material.

The 5-axis setup performance analysis function makes it possible to identify all sections of the trajectory that are close to the point of singularity, as well as the orientations that will cause large amplitude motion in the rotary axes. It also compares the actual recalculated cutting feed rate of the tool tip, accounting for the maximum axis speeds with the programmed feed rate. In the analysis report, the 5-axis quality factor of each trajectory appears. With the help of this report, users can define the best position and orientation of the part on the machine table for successful machining.

Automation: Creation of customized templates

NCSIMUL 2021.1’s AUTOMATION module, which is the user's assistant to perform simulation, cut analysis and optimization tasks, is equipped with a command template editor. This new feature provides complete autonomy for the software administrator, where previously customized templates were only available as a service. Now, templates can be created in minutes via a simple user interface, removing the time needed to request and deploy custom reports. Users simply describe the sequence of actions to be carried out in the project; they have access to all parameters of each command and can combine tasks such as updating external data, simulation, cutting analysis calculation and air-cut optimization, as well as execution report export.

CAM interfaces: NX multi-processes, CATIA V5 mill-turn tooling management

The NX interface allows users to export all the processes contained in the manufacturing file at one time. Users can also configure the intermediate stock recovery at the start of the following processes, which allows the verification to be started without any adjustment. Improved CATIA V5 interface allows turning tools to be exported. Interfaces are compatible for Hexagon 2021.0, CATIA V5 R30, MasterCam V2021, NX Continuous (V 1899).

User experience improvements

NCDOC reporting module: Users can now enrich documentation by integrating images from outside. The selected files are stored in the NCSIMUL project. Automatic image capture of intermediate stock can be configured with a choice of rendering type displaying previous machining operations in color or in initial blank, as well as the option to make the tool invisible.

OPTIPOWER and OPTITOOL optimization modules: OPTIPOWER now calculates the cutting force applied to the external contact point of the tool. The maximum torque and the maximum cutting force for each machining sequence are integrated in the analysis report, and it is possible to check the evolution of these parameters with the ‘graphs’ function. In OPTITOOL, it is now possible to define a minimum feed per tooth to avoid being below the minimum chip thickness value (in case of toolpath optimization based on chip flow or cutting power).


NCSIMUL Version 2021.0


Comparison Module

The 2021 release features a new comparison mode which detects excessive material, during a fast and hidden simulation. It shows a solid comparison between the CAD/CAM models or previous cut stock and the NCSIMUL simulated model.

This new item of functionality is the only way to detect unwanted rest stock on a large part. It shows a list of the excess material that’s left, and can also be displayed in a 3D window linked to the list.

Amongst its numerous benefits:

  • Finding small, missing drill holes on large aerospace components
  • Finding missing holes which need to be connected on mold bodies and hydraulic parts.


Integrated to NCDoc, dimensioning is a new function which creates control instructions for operators during the CNC process. It defines a dimension check-list with user-defined tolerances; automatically defines the minimum measurement needed for each cut; generates a comprehensive view for the programmer and operator on the 3D simulation; and works with the NCDoc documentation template.

Tools Evaluation Options

A new set of options quickly evaluate tools that can benefit from air-cutting optimization, with the ‘out of material working time’ in the sequence list. This works with the NCDoc documentation template, and customizes stock nearness values for each sequence, and the optimization is automatically stored for future strategies. Enhancements to editing Setup reduce simulation time by merging fixtures, parts and rough stock elements from one, or multiple, CAD files read in NCSIMUL. It creates simple geometric rough stock – either cylinder or cubes – an automatic part envelope; and all setup elements can move up or down.

Mill-Turn Tooling Management

Improvements to mill-turn tooling management for ESPRIT CAM and TopSolid CAM interface: With a new ‘Configuration interface file’ associated to each digital twin, it is now possible to define the mapping of tool assembly positioning – station number, turret and orientation –between the CAM system and NCSIMUL. This means the interfaces can crate NCSIMUL projects, ready to run the simulation.

Turning Parts 2D Display

A simplified 2D display for turning parts improves the analysis of dynamic rough stock. It quickly displays the tool and toolpath next to the cut model and reference part profiles.

Online Document Center

The document center is now available online, and includes additional descriptions of the released versions, including more details under the ‘case studies,’ and ‘focus on’ tabs.

Cutting Tool Wear Simulation

For cutting tool wear simulation as defined in the tool magazine, a button now runs the simulation for tools either ‘fresh out of the box,’ or ‘worn down.’ User-defined values apply for each cutting tool, and the system can check if a worn tool will generate alarms or collisions with unwanted rest stock material. This defines the sharpening rules, and decreases tool consumption.

The enhanced functionality in NCSIMUL 2021 further increases shopfloor productivity and reduces manufacturing costs.