Reverse Engineering CNC Introduction

Replacing a Machine Tool doesn't mean throwing the archive programs

With some regularity within the departments of work replacing machine tools, making it useless many times previous work programs. In very well organized companies, the programming is validated by CAM application, and therefore do not suffer from this type of situation as a new Post-Processor is generally sufficient to reestablish the connection between the new and the archive of the machine tool programming. Not always, however, and this happens in most cases, the programs have a CNC history existing separately from CAM source, which makes them the only source certified for the repetition of the processing. In this case and in other similar reverse-engineered CNC technology can be a significant help to make the conversion between the park existing CNC programs for the old machine to the new center.

Why use Reverse-Engineering CNC

Don't dispose precious energy

Despite the relative simplicity of CNC programming, manual conversion program is an activity extremely delicate, implicitly source of errors. From an existing program, tested and optimized for processing, it is expected that functions smoothly when converted to another machine so that even a simple mistake in editing a block of instructions can cause major damage. This activity also requires high-profile staff who might be involved in more important tasks.
In this case, and especially in the presence of a considerable number of existing CNC programs, the solution of reverse engineering CNC stands as an alternative to manual operations. Once transferred to the knowledge of the programming source within the application, the process can be automated and does not require the presence of an operator, so the quality of the conversion remains constant for all the process.

The Methodology

Use the existing Industrial Standard

DueZero chose to produce its solutions for Reverse Engineering CNC according to ISO 4343. This law accurately describes the methodology and rules to produce programming in APT format. This choice allows to operate the conversion of CNC programs using an intermediate language in the industrial field, and which can then be subsequently used as input to one or more post-processor without the need of specific customizations.
The original CNC Part-Program is converted from a first application in APT format without loss of information, and considering the kinematics of the machine tool source, and then be processed by standard tools such as APT source if it came from a normal CAM system.
This method allows you to enter the Reverse Engineering within the existing chain of production of CNC programming company, without creating structures for applications that work in parallel to the production process. In addition, all the tools normally used by the Post-Processor up to the machine tool can be used to process the data coming from the system of Reverse Engineering CNC.

Reverse Engineering CNC Tecnology uses limitations

The importance of the preliminary analysis

ISO 4343 includes the majority of cases typically encountered during the examination of the part program. This allows a very accurate translation in most cases, without any deterioration of the quality of programming during the passage from one machine to another. In addition, the software tools available by DueZero ensure an optimum management of the machine tool inverse kinematics, enabling the translation of very complex cases.
Nevertheless, we must take into account certain situations where it is not possible to apply existing technologies. For example, it is not feasible to port to multi-axis machining machines that don't allow the same degree of freedom of the source, with the exception of rare cases. In addition, in the presence of a very manual programming push, it may be necessary to decode a user specific routines or loops to a series of commands to the lowest level for the target machine which, while allowing the perfect execution of the tool path, not implement the porting of the same programming structures present in the source machine.

Software Solutions

Two products Suite for the Reverse Engineering CNC

Over the past two years DueZero has developed two different solutions to address the issues of Reverse Engineering CNC.
The first solution includes REV-APT and Cam-Post applications and allow full automation of the conversion process without allowing the simualzione graphical tool path input. This solution is well suited to mass conversions of programs that are not particularly complex.
The second solution, ICAM PSE suite based, allows the conversion of the CNC trails using all the diagnostic tools of simulation-emulation useful for discovering errors or inconsistencies when porting. It is excellent for the translation of trails far behind and complex, allowing you to emulate the entry path during the conversion and simulate the ritch CNC output during the post-processing, thus achieving a perfect chain of control and ensuring greater safety upstream end of the toolpath.


Tel: +39 049 8912540
Fax: +39 049 8912544
e-mail: info@duezero.com

Process Graphic


Conversion - Example 3X


Conversion - Example 5X