Introduction
On-tool and off-tool programming are two different strategies for operating waterjet cutting machines. IGEMS supports both technologies, but they differ in what functionality they offer and what you can do from IGEMS. In this document I will explain these differences and their impact on you as a user.
Key Differences
In summary, the difference between on-tool and off-tool programming lies in where the logic for speeds, feeds, and material settings is determined.
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On-Tool Programming: The NC file generated by IGEMS CAD/CAM contains only geometry. Material type, thickness, piercing types, and other parameters are defined at the machine by the operator.
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Off-Tool Programming: Material, thickness, and cutting parameters are selected within IGEMS CAD/CAM. IGEMS automatically calculates speeds and feeds, embedding them in the NC file. The machine operator only needs to load and run the file.
Why Off-Tool Programming is Preferred for Waterjet Cutting
Both on-tool and off-tool programming have their use cases, but off-tool programming offers significant advantages in automation, optimization, and efficiency. IGEMS supports both approaches, allowing users to choose the best method based on their workflow and machine capabilities.
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CAD/CAM software like IGEMS can optimize cutting paths, nesting, and material usage more effectively than manual programming on the machine.
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Automated parameter calculation improves accuracy, efficiency, and cost estimation.
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It allows better simulation of cutting processes, reducing the risk of errors and collisions.
Limitations for On-Tool Programming
Some features cannot be controlled by IGEMS in an on-tool system because key parameters are determined later by the operator at the machine. These limitations include:
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Unknown Feed Rate: IGEMS cannot predict the actual feed rate used by the machine, making accurate reports and cost estimates impossible.
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Piercing Types: IGEMS allows different piercing types in a job, but on-tool machines override these settings, as piercings are determined on the controller.
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Pre-Piercing Control: Decisions regarding whether to activate pre-piercing and if it is done part-wise or sheet-wise are made at the machine, not in IGEMS.
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3D Simulation Accuracy: IGEMS simulations may not accurately reflect the actual machine kinematics, as motor angles and movements are controlled by the machine’s controller. However, off-tool programming enables IGEMS to detect and avoid potential collisions with work fixtures and materials.
In an on-tool machine, programming decisions occur at the machine, this can tie up the machine and reduce overall production time giving you Reduced Production Efficiency.
Advantages of On-Tool Programming
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Reusability of NC Files: Since NC files only contain geometry, they can be reused for different material thicknesses without needing to regenerate them in IGEMS.
Conclusion
I hope you found this article useful and now have a better understanding of the difference between on tool programming and off tool programming.