hyperMILL®, one of the world’s most modern CAM programming systems, is available to all SolidWorks® users in their own familiar software environment. The current version includes many new features and functions to achieve more performance and less programming time. hyperMILL® 2011 is based on automated programming and the clever utilisation of existing manufacturing know-how, by offering various functions that help you gain simple, user-friendly and time-saving workflows. New strategies and optimisation functions are available in 2D machining as well as 5axis simultaneous milling and turning. General functions, such as enhanced stock definition and rest material display, or the job-list-based editing of tool paths, simplify daily work. Highlights like intelligent macros, new 5axis shape offset machining and the hyperMILL® API offer several new ways to program and manufacture more efficiently. Visitors will have the opportunity to learn about the advantages and potential of hyperMILL® for SolidWorks® both at OPEN MIND’s booth, number 412.

5axis machining and optimisations

New functions and optimised strategies further lower the programming burden and help to obtain better milling results. The new shape offset roughing and finishing function offers a strategy for the 5axis machining of surfaces with a uniform offset, with simple programming and while avoiding the formation of ‘stair-steps’ that would be common with Z-level roughing approaches. Improved 5axis swarf cutting results in better surface quality. New contour milling features allow for better control when using large milling tools.

Further time savings with 64-bit support

64-bit support means that users have more memory at their disposal. This means that many calculations can be carried out considerably faster. These features are especially useful when machining large models, which require a large number of job steps and toolpaths. hyperMILL® users thus benefit from further time savings in their day-to-day work.

Seamless integration for continuous processing

Thanks to the seamless integration of hyperMILL® for SolidWorks®, continuous processes can be easily implemented using a unified database. Both the CAD and CAM systems use the same data model. The result is a high degree of transparency and error prevention throughout the entire machining process. This also means that SolidWorks® users always work under the same user interface. The hyperMILL® CAM software can be accessed via the SolidWorks® interface using the hyperMILL® button. hyperMILL® offers CAM strategies for every requirement: All 2D, 3D, HSC and 5axis milling strategies, right through to mill-turning and special applications are available directly within SolidWorks®.

hyperMILL® for SolidWorks®: Certified Gold Product

In designating hyperMILL® as a ‘Certified Gold Product’, SolidWorks® conferred its highest award based on outstanding integration, quality and interoperability in relation to its own CAD environment.

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• HyperMill 2011 is released (0)

OPEN MIND Technologies AG has enhanced the 2011 version of its CAM software, hyperMILL®, adding an expanded and improved feature technology. This enables the definition of company standards for CAM programming.

Even complex machining sequences, once defined, can be programmed easily and with automation support using this technology. The method is based on process-oriented linking of characteristic geometry sequences with freely defined machining steps.

Without limits

“CPFs allow the linking and naming of any number of geometry selections and associated parameters in one element, and you can also add images and documentation”, explains Peter Brambs, head of the Global Engineering Service Group at OPEN MIND. CPFs enable the creation and use of macros. A curve for example can be a machining contour or a boundary curve, and that manufacturing purpose can also be stored in the CPF.

One example is a pocket comprised of a hub surface, a lateral cut-out, an upper edge curve, etc. The user can select these individual surfaces, assign a name to them (e.g., contact surface), add an image if necessary so that another user also knows what it is, and then combine it all into a CPF. Other parts that share the same geometric structure can be described and machined using the same CPF. Filter schemes within the CPF technology allow for automated selection of geometry, especially when consistent rules (colors, layers, etc) are used in the creation of smart designs.

The initial steps are to conceive the structure of the CPF, and define the machining steps. With this stored information, complex geometry with a similar structure can be programmed with a few mouse clicks, and with reduced chance of programming errors. Once tested and stored, the CPF is recalled and consistently applied with knowledge of the end-user manufacturing processes.

The software thereby enables the creation of a truly complex customer-specific element that can be selected as a single CAM entity and automated on this basis.

John Hart provides consultation and training to assist a customer to define their own CPFs.

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• hyperMILL®: 5axis shape offset machining (0)

The programming of this intricate latticework ball required know-how and experience on the part of the INABA employees, as well as a flexible CAM system for efficiently solving the complex programming challenge. The company has hyperMILL®, software that offers a broad range of 2D, 3D, HSC, 5axis and mill/turn strategies for the reliable and flexible programming of complex parts. Innovative technologies that require automated programming enable the exploration of alternative machining approaches. The outstanding 5axis strategies for simultaneous machining came in particularly handy in the creation of the latticework ball. Fully automated collision checking and avoidance ensured exemplary and reliable 5axis machining in which the tool, holder and clamps were included in the collision check. The latticework ball was machined on a DMU 40 monoBLOCK.

The Mori Seiki Cutting Dream Contest took place this year for the eighth time. The jury was again staffed with high-ranking professors from various departments at Japanese universities. The competition enjoys a very high reputation in Japan, and the award is a major honour to the winner. INABA ENGINEER representatives accepted the gold medal for their latticework ball at the Mori Seiki Open House on November 17.

“We congratulate INABA ENGINEER for this victory”, said Akira Sugai, Managing Director at OPEN MIND Technologies in Japan, “and we are very proud that hyperMILL® was able for the third time to help a company bring home the gold in this competition.”

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• Applications (0)

Practically from the beginning, OPEN MIND Technologies AG has developed machining strategies for its hyperMILL® CAM system that are also very helpful for tool and mould making. Following head of development Dr. Josef Koch’s motto, “tools and moulds are our passion,” today’s hyperCAD®/hyperMILL® CAD/CAM system supports the entire process chain in the tool and mould industry, thereby contributing significantly to the competitiveness of companies that use our products.

External CAD models can be used for stock definition

Before actual machining begins, hyperMILL® helps the user with its intelligent and dynamic stock definition. Stock contours can be generated from the surface models and solids of any CAD model. Surface models can now be used for stock definition in the 2011 version in the context of arbitrary stock roughing and material removal simulation.

The new version of the CAM software permits quick and simple collision checks for clamps. Clamps are managed as a separate element within the job list and can be managed and imported independently of the part model. As a result, clamps can be checked for collisions early in the machining calculation process.
hyperMILL®’s pocket feature recognition now also detects grooves in open and closed pockets with bottoms. In practice, this means that parallel walls are recognised as grooves, and their centre contour is displayed.

Even faster roughing

In addition to endmills or bullnose endmills, conical tools can now also be used for arbitrary stock roughing.
Efficient collision avoidance ensures that the tools are checked completely against the model, machine and clamps.

“For all tasks that might include ‘shelling’ roughing, or machining with a tool shank, our new hyperMAXX® can be used”, explains Peter Brambs, head of the Global Engineering Service Group at OPEN MIND. The new model, which is also used from the hyperMILL® interface, generally allows higher cutting speeds while reducing wear and tear on both the tools and the machine.

With this new 5axis shape offset roughing and finishing machining strategies, curved surfaces can be machined with a consistent offset. This strategy enables very easy programming of complex geometries, such as engine housing parts or tyre moulds. “In combination with hyperMAXX®, this strategy enables very fast roughing”, says Peter Brambs.

Powerful for cavities

For typical tool and mould making geometries, such as deep cavities, and high and steep walls, hyperMILL® provides 5axis strategies that enable reliable machining with short tool lengths in these areas. Proven 3D strategies such as Z-level finishing, profile finishing, equidistant finishing or rest machining were updated with 5axis tool positions. Thanks to fully automatic calculation of tool positions, these machining tasks can be programmed in a way familiar to those who have worked with 3D machining.

Complete finishing is another strategy that has been customised for the requirements of tool and mould making. By combining Z-level finishing and profile finishing, this strategy can automatically adapt machining to the requirements of individual areas of a model. In accordance with the angle of slope defined, machining is divided automatically between steep and flat areas, which can both be processed in a spiral pattern.

Automatic rest machining

In the finishing cycle, automatic rest machining detects remaining stock machined areas. After defining the reference tool and the machining area, the requisite rest machining is automatically executed.
The consideration of multiple allowances is a new feature. The multiple allowances defined for specific milling areas are now also available for rest machining.

Last but not least, hyperMILL® 2011 has enhanced its automatic 5axis approach and retract macros. Within the 5axis cycles, the approach and retract paths use 5axis simultaneous motion. This allows all of the axes of the machine to already be moving when the cutter approaches the part, and avoids sudden accelerations when the cutter is in contact with the part. This results in smoother overall machine movement and cleaner transitions at the start and end of each milling movement. These automatic 5axis approach and retract strategies ensure greater quality and less programming time.

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• Applications (0)

Around 90 per cent of all CAM strategies are traditionally based on the assumption of two main orientations: the tool axis (Z axis) and the standard axis perpendicular to it. This is ideal for working in what is primarily a “flat” world.

Many parts, however, such as tyre moulds or engine casing parts, tend to be essentially arched, rather than flat. Previously they too could be machined by way of 5axis machines, but the CAM process consisted of multiple jobs or program steps. Consequently, the programmer was faced to program a large number of individual regions and needed to control boundaries and cutter orientation – which translated to a very high overall programming effort. OPEN MIND is the first CAM manufacturer to develop a strategy specifically for 5axis contour offset machining.

Arched surface becomes standard surface

The new machining strategy in hyperMILL® simply turns the arched surface into the standard surface, allowing the tool to work at any point at an angle of 90 degrees. Taking tyres as an example, one could say that the original plane is replaced by the tread. The strategy then works as if it involved “curved” Z roughing or finishing. The shape-offset techniques work in simple 4-axis cylindrical situations, but also with more complex 5-axis wrapped surfaces and any generalized shaped surfaces.

This allows the NC program to be created very easily and quickly. “With sample parts that I have processed with this strategy, I have seen programming time that was previously at two-three hours shrink down to just a few minutes. In one case five hours turned into a mere five minutes,” explains Peter Brambs, Product Manager at OPEN MIND, “- truly a quantum leap”.

The new approach is ideally suited to the types of cavities frequently encountered in mould and tool engineering, as well as for the machining of turbine housings, structured parts (aerospace), tyre negative moulds and side panels, and furthermore synthetic wood models, roll dies, lenses, watch and jewellery components to name but a few.

Since the tool adjusts itself perpendicularly to the hub surface, there are hardly any undercuts. Each pocket, and each profile, can be machined very cleanly. Any tool shape can be used: endmills, bullnose endmills, ball endmills and conical milling tools.

The tool angle is calculated for machining either from the hub surfaces of the model or from an externally-designed guide surface.

According to Peter Brambs, the machining results are “of extremely high quality”. “The tool paths calculated on the basis of this strategy ensure optimal results, for example, in connection with rounded inner corners and automated approach and retract macros in finishing work. The part doesn’t show any marks or steps.”

Moreover, this strategy can be combined with hyperMAXX® (machining strategy for high-performance roughing). This module, fully integrated with hyperMILL®, combines optimal milling paths and maximum material removal and thus minimises machining times significantly.

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• OPEN MIND Technologies: Now The Best CAM System – It’s Official (0)

With hyperMAXX®, OPEN MIND presents an optimisation strategy for stock roughing, which is based on Celeritive Technologies Inc.’s VoluMill solution.
OPEN MIND has fully integrated this software into hyperMILL®. As a result, there is no need to launch a second system to utilise the new roughing options. Plus: No adjustments are required during postprocessing.

Very special algorithms

Special algorithms help to ensure superb performance levels when generating the milling paths. In addition, they also help to protect machines and tools. The reason for this lies in the ideally distributed milling paths that are managing the material removal and cutter engagement.

This results in a host of advantages:

• Automatic adjustment of the feedrate to the current cutting conditions
• Constant load on the tool and the machine during the entire machining operation
• Reduced machining times based on larger axial depth of cut and better path layout on each cutting level
• The fastest possible safe positioning of the tool
• The plunge macro always creates a complete helix or ramp movement
• No sharp edges or sudden changes in milling direction
• Intelligent automated functions for optimised adjustment of feedrate and infeed for the machining of tight areas with full cutting and long tool paths (soft material), as well as trochoidal tool paths that avoid full cutting (harder materials)
• Up to 100 percent of the tool diameter can be used without leaving material behind

New version with more improvements

The new version of hyperMAXX® facilitates milling with even higher feedrate averages. This is possible thanks to an optimised feedrate control developed by OPEN MIND. Previously, the system calculated the feedrate as a linear value between 0 and 100% of the maximum feedrate. Now, the user can specify a minimum feedrate in addition to the maximum feedrate.

If the user enters a minimum value of 50% of the ideal value, for example, this increases the average feedrate value. In this case, the feedrate will be interpolated between 50% and 100%. Next to improving the working feedrate, the extended feedrate definition also has the advantage that it helps to avoid feedrate speeds that are too slow for the tool to cut properly.

The optimised plane detection provided by hyperMAXX® further shortens machining times. This strategy helps to prevent step formation during roughing with large stepdowns, and also to create a uniform allowance on the stock. The strategy automatically detects the different planes and then starts with the largest stepdown depth (as opposed to constant-Z plane-by-plane machining). Planes with a low stepdown depth are then machined with a reduced stepdown, step by step, from bottom to top.

The “Intermediate Steps” function is available for defining additional steps to enable smoother machining of flat transitions and inclined walls. This not only creates a contour cut but also processes entire planes or pockets that were not included in the primary cutting levels. Such an approach enables machining that is optimised for both paths and for machining times. The tool’s cutting width is used more efficiently and tool life is increased.

Process reliability

For axial infeeds, the process is absolutely reliable up to the maximum cutting length of the cutter. The software is suited for machining soft as well as hard materials that are difficult to cut, such as titanium, nickel-based alloys or stainless steel. Both large machining and micro-machining jobs can be handled quickly and efficiently. The high-performance strategy also includes a collision check that accounts for tool lengths, as well as plane detection in automatic mode.

Process reliability furthermore entails the aforementioned adaptive adjustment of the cutter settings. This simplifies the user’s work greatly. The user can set the optimal values for stepdown, feedrate, spindle RPM and the cutting tool without having to worry about worst-case scenarios. The system automatically adjusts the values in areas where the maximum permitted values are exceeded (e.g., tool engagement in case of excess material in the corners).

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• Cost-efficient manufacturing with hyperMILL® (0)

In the Australian manufacturing industry especially, more machining businesses are making an effort to diversify their customer base and capabilities to increase their opportunities. There are many ways to achieve this outcome, but one of the most effective ways of enhancing the capabilities of existing cnc machines is to utilise CAM software.

Maltec run a large, successful machine shop in Tasmania, where they currently employ a total of 42 staff, running both a morning and afternoon shift. Most of their work comes from within the mining industry for which they complete a variety of work from light fabrication through to CNC machining.

HyperMill CAM software was purchased recently to make underlying improvements to their range of CNC machines, allowing them to utilise their full five-axis and run highly complex machining jobs.
Speaking with Maltec’s Managing Director Lindsay Malley, provides an interesting insight into their capabilities pre-HyperMill. “There were a few jobs we’ve had to knock back over the years because we haven’t had the ability to programme in full five-axis. But now we’ve implemented HyperMill, we are branching out into new areas.”

When asked about his reasoning behind purchasing the software, Lindsay’s reply was straight forward. “We just wanted to improve our capabilities.”

Using CAM software such as HyperMill can bring many benefits, in addition to boosting machine capabilities. Benefits can be compared to purchasing a new multi-tasking CNC machine, after owning a standard machining centre or lathe. HyperMill will reduce the number of machine setups, improve cycle and machine setup time, and also simplify machining of complicated parts.

Lindsay mentions the most noticeable benefit, aside from making creation of the part possible, is accuracy, especially for complicated machining which can suffer from small inaccuracies when the part changes orientation or part holding while operating setups which are incapable of using five-axis machining.

There are numerous industries such as aerospace which require machined parts to be extremely accurate. These parts are often highly complex and require full five-axis to even complete the job. The HyperMill software not only makes this possible but also relatively straightforward as well.

An exhaust manifold was Maltec’s first job produced with HyperMill and was one of the contributing factors in deciding to purchase the software. A successful trial run was initially completed by John Hart Software Engineers to demonstrate the ability to complete the part. John Hart Application Engineers then fine-tuned the part programme in order to decrease the cycle time and a successful prototype was then handed over to the customer and new work has been programmed since.

In total, John Hart Engineer’s spent a week at Maltec providing training and helping staff to upgrade the machines and setup the Manifold job. On mentioning the service provided by John Hart, Lindsay was quick to point out, “We’ve been very happy and recommend the service we’ve received from John Hart. Because we are located in Tassie, we communicate a bit over the phone with them. Being that bit further away, it’s been handy to build that relationship.”

Since the exhaust manifold job, the focus at Maltec is slowly shifting towards full five-axis jobs, “As we look toward the future with other machines to buy, we will be focusing on full multi-tasking machines that can utilise the HyperMill software and make full use of the five-axis capabilities. We are looking at either the i or j series Integrex from Mazak”.

Maltec have also changed the way they approach new jobs given their knowledge of machining using full-five axis. This means they can plan ahead using their newly available options, providing the most efficient and cost effective way to produce the part. They’re also actively pursuing five-axis work from both new and existing customers. As Lindsay put it, “we are trying to branch out into new areas using the new capabilities, so we’re not as reliant on our current customer base.”

HyperMill software can be easily integrated into most modern multi-tasking CNC machines, regardless of brand. The software works seamlessly between CAD programs Solidworks and Autodesk Inventor eliminating the duplication of work and data. Hypermill’s post processor is considered to be of the highest quality allowing the user to get the most out of their machine tool. The software also uses a single interface for all machining, from 2D through to simultaneous five-axis machining, making the program more intuitive and the jobs easier to manage.

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• hyperMILL® : Customised Process Features (0)

The 43-employee company gave engineering team leader Ryan McClure the remit to develop its five-axis machining capability and source the right CAM software. It already had a seat of Open Mind Technologies’ HyperMill and a seat of a competitor’s software, but neither of them was being fully utilised. “When I started working at JW Kane, I was tasked with maximising the company’s five-axis potential. At the time, I had little experience of HyperMill, but its ease of use, intuitive working and time-saving features now see 95% of our parts programmed with this software.”

When machining highly complex components for customers such as Bombardier, Airbus, Thales and other aerospace manufacturers, impeccable component quality, time and price pressures are challenges that the company has to meet. To this end, HyperMill has cut programming times and cycle times by more than 50% on most components. Mr McClure says: “HyperMill has a number of features that are not provided by other CAM suppliers, and these features have made a considerable difference to our productivity levels.”

Useful features

Two HyperMill features that have made a significant contribution to JW Kane’s machining are the Residual Stock Model and Linking Cycle features, which have recently cut the machining time on an airframe structure part for Bombardier by 51%. Using a machine with a Heidenhain three-axis control, the component previously had a stage-one operation time of 10min and a stagetwo time of 42min. The use of HyperMill allowed the 52min combined cycle time to be cut to 28min, with stage one and two taking 8 and 20min respectively. “I attribute this time saving to the ability of the software to calculate the ‘rest’ material during roughing and to only cut exactly where the ‘rest’ material is with consecutive cutters during rest milling and finishing operations.

“The linking of tool-paths within the work area removes the number of rapids that the machine requires during positioning. This reduces air time and keeps the tools doing what they are best at — cutting. It’s the air time that costs us money. The ability of the Linking Cycle feature to move the tool around the workpiece to the next approach position is a bonus. Moreover, this move is collision-checked, and checked against the stock when used in production mode, thereby ensuring the shortest possible tool-path.” When Mr McClure compared HyperMill with the competitor CAM package at JW Kane, he found that the cycle time of one aerospace part fell from 41min to 17min with HyperMill — a saving that he attributes to the Residual Stock Model feature, which eliminates mid-air cutting with efficient tool paths.

Mirroring function

Another major feature that HyperMill offers is the Mirroring feature. This has slashed programming times for JW Kane, as Mr McClure confirms: “Mirroring is a real time saver for us.

Aeroplanes are symmetrical by their very nature, with left-hand and right-hand components. Out of a standard batch of 40 aero parts that we are currently machining, each one has an opposite hand. The standard programming time per part using conventional software is 8hr, plus a further 4hr for the opposite hand, but the Open Mind software allows us to program the same parts in less than 5hr, with the mirrored part then taking between 10 and 30min. This makes a mockery of other software that can not mirror tool-paths, especially when it comes to multi-axis parts that can be mirrored automatically and the tool-paths then edited independently of the parent geometry.”

The workload at JW Kane is extremely diverse, with the company producing anything from prototypes to batches of 50; jobs range from 50mm-square parts up to 4.5m-long structures in aluminium, titanium and stainless steel. Machining times range from 5min to 30hr per part, so making major savings on programming times is of significant benefit to the company.

The success of HyperMill at JW Kane resulted in the company buying a second seat in May; since this purchase, the company has continued to improve its production times. In addition to the 50% programming-time savings achieved with Mirroring, and the cycle time savings from the Residual Stock Model and Linking Cycle features, JW Kane is continually looking for further savings. To this end, the company is currently trialling Open Mind’s HyperMaxx roughing module, which is an optional addition to HyperMill.

In conclusion, Mr McClure says: “In the aerospace industry, we say that the final part is the most important, and we must rough economically to achieve good cycle times, keep making a profit and make good quality. I tend to look at it from another perspective: we are really in the business of making swarf at the most economical rate that we can. Aerospace parts are generally machined from solid billets, with up to 75% of the billet being machined away, so we must make the swarf as fast as we can and then finish the part to the highest levels of quality. We are testing the HyperMaxx module with different components to see what the results are. We are finding that we require a new mentality — one that says: ‘Yes, you can take that much off’.

With one 6 by 4in part that we have machined with HyperMaxx, we cut the cycle time from 6min 37sec to just 4min. This saving of over 30% is creating real excitement about the potential when machining large parts that are currently taking more than 20hr to complete.”

Learn more about HyperMill and HyperMaxx.
Contact a John Hart Software Sales Representative to speak about HyperMill.

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• hyperMILL® 2011 allows for automation on different levels (0)

Automation is possible not only in production on the shop floor, but also in connection with CAM programming. OPEN MIND Technologies AG, the CAM software manufacturer from Wessling/Bavaria, provides additional programming tools for this purpose in its new hyperMILL® version.

The renowned feature and macro technology included with hyperMILL® uses geometrical information from the CAD system – so-called features, such as holes and pockets – for further processing in CAM. The recurring machining strategies typical of a feature are combined with tools and technology data, defined as technology macros and that are stored in the macro database.

This way, machining sequences can be prepared quickly and connected easily to the appropriate geometries, and programming steps can be calculated efficiently with a minimum of mouse clicks. Thanks to the new intelligent macros and the generic hole feature, OPEN MIND Technologies is now taking automated programming one step further.

Generic hole feature

The generic hole feature, a newly-developed type of feature, represents a building block in the optimal use of intelligent macros. Holes no longer have to be defined by way of individual features; instead, all holes can now be mapped using just this one feature type. This means the distinction between standard, sink or free holes is not necessary anymore. Nor are settings based on different steps, countersinks or slots necessary. For each step, special properties such as threads or fits can be specified. Since all holes can be defined with one single feature type, more efficient automation for program creation is possible in the second step.

Intelligent macros

By using generic features, different holes can be programmed with a single macro that contains all the possible machining steps using simple IF-THEN queries. When the machining steps are assigned to the various features, the rules are applied to automatically choose between countersinks, threads or fits.

The same rules can also be used for any other feature or machining step. Parameters such as surface, depth, pocket radii, minimum radii, etc., permit unmatched flexibility during the creation and deployment of machining macros for all machining jobs and geometry elements. hyperMILL® automatically adjusts job steps on the basis of these rules and in reference to the geometry information. Holger Max, Service Engineer at OPEN MIND, provides the following example: “Let’s take a hole with a diameter of 8 mm that may have various depths of 6 mm, 14 mm, 30 mm and 120 mm. Depending on how deep the hole is, very different machining approaches may be required. These can now be stored entirely within one macro.”

Application Programming Interfaces (APIs)

In its new version, hyperMILL® comes with its own programming interface. The interface can be used with all .NET programming languages, including C# and Visual Basic.
This facilitates a wide range of programs with add-on functions, as well as an even larger degree of automation. It is possible to create programs that, similar to configurations, control the entire CAM programming process via algorithms and rules. Without having to open a CAD/CAM system, the user just answers a few questions and programming proceeds automatically.

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Editing tool paths

Users are now able to edit the calculated milling paths quickly and easily thanks to a graphical interface. The milling paths can be trimmed to any type of 2D contour, meaning that sections of previously calculated milling paths can be removed without requiring a recalculation. This way, users can quickly and easily respond to special machining requirements, for example, when specific areas are to be excluded from milling with a special clamping system. The fast travel movements required for interconnecting the remaining milling paths are checked against the milling area and then calculated for
collision-free machining. Because the editing job always references the original job step, any recalculations or changes to this job step automatically also take into account any subsequent edits.

Tool path optimisation

With the Z-level finishing and complete finishing machining strategies, hyperMILL® is offering a new optimisation function for users to trim tool paths to the milling area. The ‘Trimming to milling area’ function avoids tool paths on surfaces where the tool does not touch the model, as is the case with undercuts. Only those milling paths are output where the workpiece will actually be machined. Empty cuts are thus avoided. This function is available for ballmills and bullnose endmills.

Working with multiple allowances

The multiple allowances defined in the milling area are now also available for rest machining. This means that when the rest material is calculated, the same model parameters apply as for the arbitrary stock roughing machining strategy and the finishing strategies; these strategies also include different allowances for the different surfaces and model areas.

Using external CAD models for stock definition

CAD tool for programming cylinders and curved surfaces hyperMILL® 2011 includes a CAD tool for programming cylinders and curved surfaces. This allows users to transform cylindrical surfaces. In other words, users can program the machining job as if they were dealing with a flat surface. Afterwards, the tool paths are projected onto the cylindrical or curved surface. Here, hyperMILL® automatically aligns the tool position to match the surface. Undercuts and other particularities are fully accounted for. This feature is designed for four-axis machining.

Fast and simple collision checking

Within the job list, clamps are managed as a separate element. Any clamps can therefore be assigned to any job list. The frame system that can be defined for clamps can be used to position both the model and the clamping system on the machine. As a result, clamps can be checked for collisions as early as during the calculation of the machining strategy.

Automatic chamfering

Automatic chamfering is calculated with a permanent collision check of the entire tool against the model. This ensures that only those areas will be touched where the tool can approach and cut without any danger of collision. The chamfers to be created can be part of the model design. In addition, this strategy is suitable for chamfering and deburring parts with sharp edges.

Easy, time-saving modification of tool data

Tool data that do not cause any changes to the tool paths – such as feedrate or RPM – can be modified without the job step needing to be recalculated. In contrast to when such values are modified during postprocessing, they are directly changed for each corresponding job step here. The changes are therefore permanently retained, even after there are recalculations.

Linking job*

The linking job function can now also be applied to turning jobs. With a linking job, all operations that are executed with the same tool can be linked into a single machining job. Infeed and retract movements and the connection paths between the individual jobs are additionally checked for collisions. The linking job function minimises fast travel and redundant movements, thereby optimising machining times.

Stock transformation

Every stock manually created or calculated in hyperMILL® can be freely positioned in the workspace thanks to transformations. By shifting, turning or mirroring assembled stocks, the user can position the individual elements just like they are clamped on the machine.

Using conical milling tools

Conical tools are now also available for arbitrary stock roughing. Collision control and collision avoidance check the entire tool for collisions with the model and stock, ensuring superb process reliability.
Arbitrary start points can be defi ned to better control the stepdown points during roughing. During the calculation, the machining strategy automatically detects the best start point. Priority is given to start points that permit stepdown outside of the material, and to pre-drilled start holes.

Improved display with more information

hyperMILL® includes an option for automatically creating a removal model for each job and for displaying the different rest material areas in different colours. With such a colour scheme, users can quickly get an overview of how much rest material there is in the different areas. The removal model also indicates how many job steps are still required for rest machining to be completed.

Intelligent macros

Intelligent macros are designed as a tool for automatic programming. Previous hyperMILL® macros collate machining strategies, tools and technology data for the purpose of machining specific features. The new intelligent macros complement this concept with a set of rules that specify when a machining strategy is executed in reference to the geometry data.

The use of intelligent macros relies on generic features. Because the generic hole feature, for example, can be used to program all diff erent types of holes, only one macro needs to be programmed for it. With a sequence of simple IF-THEN queries, all the machining steps can be defined within this one macro. When the machining steps are assigned, the macro’s rules are applied to automatically decide whether to create countersinks, threads or fits. Because all the different stages and parameters can be queried this way, one single macro is usually sufficient to cover machining of all the different hole types.

An intelligent macro’s rules can also be used for any other feature or machining step. Parameters such as surface, depth, pocket radii, minimum radii, etc., permit utmost flexibility during the creation and deployment of machining macros for all machining jobs and geometry elements.

NC event

In hyperMILL®, the NC event is a browser element. NC events let users adapt programs to specific situations by adding commands – it is independent from jobs and job lists. With this browser element, entering commands and restructuring programs becomes fast and easy.

Automation of processes and workflows

As we know from Microsoft Office products, applications can be controlled via APIs (Application Programming Interface). hyperMILL® now also includes this versatile tool. The API is used to create applications that can control hyperMILL® automatically. These applications can be easily integrated into existing IT environments. For instance, this might involve the development of applications that control the entire NC program creation process based on standardised workfl ows.

For example, a parameter set could be imported, which in turn might result in automatically opening a component. A selection script allows surfaces and contours to be allocated to the machining strategies, and any required parameters are handed over. Calculation and postprocessor runs are also started automatically, taking the programming burden away from the user. In effect, milling programs can be generated in the background without the need to open the CAD/CAM system.

The hyperMILL® API is a powerful tool for companies that wish to intensively automate their processes. The applications in question can be written in any .NET-supported programming language, including VBA .NET, C#, or C++.

Chamfering holes

Long approach paths and large clearance distances make operations like the chamfering of holes very time-consuming. This new function enables the approach movement to be calculated in rapid traverse up to just above the hole for deeper holes and sinks. This means that only the actual machining job is fed in, which signifi cantly reduces overall machining time. All approach and retract movements are of course checked for collisions.

hyperMAXX®

The new version of hyperMAXX® facilitates milling with even higher feedrate averages. This is possible thanks to an optimised feedrate control developed by OPEN MIND. Previously, the system calculated the feedrate as a linear value between 0 and 100% of the maximum feedrate. Now, the user can specify a minimum feedrate in addition to the maximum feedrate. If the user enters a minimum value of 50% of the ideal value, for example, this increases the average feedrate value. In this case, the feedrate will be interpolated between 50% and 100%. Next to improving the working feedrate, the extended feedrate defi nition also has the advantage that it helps avoid feedrates that are too slow for the tool to cut properly. The user can thus optimise machining jobs even more fl exibly to match requirements and past experiences.

The optimised plane detection provided by hyperMAXX® further shortens machining times. This strategy helps to prevent step formation during roughing with large stepdowns, and also to create a smooth off set on the stock. The strategy automatically detects the different planes and then starts with the largest stepdown depth (as opposed to constant-Z planeby-plane machining).

Planes between two stepdowns are machined from bottom to top with a decreased stepdown depth. The ‘Intermediate Steps’ function is available for defi ning additional steps to enable smoother machining of flat transitions and inclined walls. This not only creates a contour cut but also processes entire planes or pockets that were not included in the main cut division. Such an approach enables machining that is optimised for both paths and for machining times. The tool’s cutting width is optimally used and tool life is increased.

64-bit support

hyperMILL®’s 64-bit architecture increases the amount of available memory. This improves performance, especially when creating programs for large parts. Calculations in particular are run with additional stability. 64-bit support furthermore provides full use of multi-core processors.

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