What are the potential risks associated with running a CNC program that has not been thoroughly simulated?

Running a CNC program that has not been thoroughly simulated poses several potential risks, primarily relating to machine damage, workpiece damage, tool damage, and operator safety. First, it risks machine collisions. The most significant risk is a collision between the cutting tool, the tool holder, the workpiece, the fixture, or other machine components. A collision can damage the machine, the tool, the workpiece, and can even cause serious injury to the operator. Simulation helps detect these collisions before they occur. Second, it risks workpiece damage. Incorrect toolpaths or cutting parameters can cause damage to the workpiece, resulting in scrapped parts and material waste. Third, it risks tool breakage. Excessive cutting forces or incorrect toolpaths can cause the cutting tool to break, resulting in downtime and potential damage to the machine. Tool breakage can also lead to projectile shards, posing a safety hazard. Fourth, it risks incorrect part dimensions. Programming errors can lead to parts that are out of tolerance, requiring rework or scrapping. Fifth, it risks inefficient machining. Suboptimal toolpaths or cutting parameters can result in longer machining times and increased tooling costs. Sixth, there's a risk of unexpected machine behavior. Simulation allows the programmer to foresee how all aspects of the program come together. Finally, operator safety is paramount. Unexpected machine movements or tool breakage can create hazardous situations for the operator. For example, a rapid traverse move in the wrong direction can cause a collision that could injure the operator.