Table of Contents

Simulation Step Output

For the complete and up-to-date field reference, see MachiningStep.

To assess the risk of tool breakage, also refer to "Evaluating Process Machinability".

This page summarizes the main output data for each simulation step, covering source line, kinematics, load, force/torque, power, thermal, and wear information to help quickly understand the machining state at each step.

Step data contains information for the time interval between two consecutive steps (i.e., from the previous step to the current step). Many fields are therefore simplified representations over that period. Common prefixes based on the simplification method include Average (Avg), Extremes (Min, Max), Range (Delta), and Maximum Absolute Value (MaxAbs).

Basic Source Information

  • FileNo / LineNo / FilePath / LineText / FlagsText: File/line information and flags of the corresponding source NC command.
  • StepIndex: Step sequence index.
  • ToolId: ID of the currently active tool.

Time and Motion

  • AccumulatedTime: Accumulated simulation time.
  • StepDuration: Duration of this step (default per-revolution mode: one step equals one spindle revolution).
  • BeginSpindleAngle_deg: Spindle angular displacement at the start of this step.
  • Cl (Cutter Location): Cutter location point (including IJK normal).
  • MoveOnProgramCoordinate, MovingLength_mm: Displacement vector and length in the program coordinate system.
  • Feedrate_mmdmin / SpindleSpeed_rpm / CuttingSpeed_mmds: Feed rate, spindle speed, and cutting speed.
  • FeedPerTooth_mm / FeedPerCycle_mm / ToothArcDuration_s / SpindleCyclePeriod_s: Feed per tooth/per cycle, tooth arc duration, and spindle cycle period.

Cutting Engagement and Material Removal Rate

  • IsTouched: Whether cutting engagement occurred.
  • CuttingWidth_mm (ae) / CuttingDepth_mm (ap): Cutting width / cutting depth.
  • Mrr_mm3ds: Material removal rate.
  • ProgramSideCusp_um, SideCuspList_um: Side cusp height and distribution estimated from program feed and radius.

Chip

  • ChipThickness_mm (/um): Chip thickness.
  • ChipVolume_mm3: Chip volume.
  • ChipMass_mg: Chip mass.

Force and Torque (Including Mapping Comparison)

  • Coordinate system note: Most fields in this section indicate their coordinate system (e.g., [W] workpiece, [TR] tool running, [SR] spindle rotation). For coordinate system definitions and diagrams, see "Milling Physics Coordinate Systems".
  • AvgForceToToolOnToolRunningCoordinate_N, MaxAbsForce_N: Average/maximum force.
  • Various average/maximum torques (about tool tip, about sensor point; in tool running / spindle rotation / workpiece program coordinate systems).
  • AvgAbsTorque_Nm: Average absolute torque.
  • Mapping comparison: AvgMomentXyByMapping_Nm, AvgAbsTorqueByMapping_Nm, error ratios, and symbolic error correlation metrics.

Power, Torque, and Energy Consumption

  • SpindleInputPower_W (input power): Energy entering the spindle.
  • SpindleOutputPower_W (output power): Energy acting on the cutting end after spindle energy losses — i.e., the energy causing workpiece and chip deformation and temperature change. Output power is typically proportional to input power, with the ratio being the energy efficiency set in the spindle configuration EnergyEfficiency(API).
  • MaxSpindlePowerRatio (maximum spindle power ratio): Input power / instantaneous maximum power based on spindle capability.
  • ContinueSpindlePowerRatio (continuous spindle power ratio): Input power / unlimited-duration maximum power based on spindle capability.
  • AccumulatedSpindleEnergyConsumption_kWh: Accumulated spindle energy consumption.
  • Max/Continue Spindle Torque Ratio: Instantaneous/continuous spindle torque ratios.

Thermal and Temperature

  • CutterBodyTemperature_C / CutterDermisTemperature_C / WorkpieceDermisTemperature_C / ChipTemperature_C: Cutter body, cutter surface, workpiece surface, and chip temperatures.
  • GetCutterDermisTemperature_C(depth_mm) / GetCutterDermisAvgTemperature_C(depth_mm): Cutter subsurface temperature / average temperature at a given depth.
  • ThermalStress_MPa / ThermalYieldRatio: Thermal stress and thermal yield ratio. For tool breakage risk assessment based on thermal yield ratio, see "Evaluating Process Machinability".

Wear and Deflection

For wear models, evaluation metrics, and applicable scenarios, see "Tool Life and Wear".

  • InstantCraterWear_um / AccumulatedCraterWear_um: Instantaneous/accumulated crater wear.
  • AccumulatedFlankWearDepth_um / AccumulatedFlankWearWidth_um: Accumulated flank wear depth/width.
  • Tip/Edge Deflection (um): Tool tip and bottom edge deflection (including maximum and delta values), as well as ReCutDepth_um (re-cut depth).