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hyperMILL end-to-end CAM solution is now even more powerful

31 January 2022

From 4-8 April, OPEN MIND Technologies will once again be returning to the MACH exhibition at the Birmingham NEC, giving its MACH exhibition premiere to the latest version of its hyperMILL CAD/CAM software.

Version 2022.1 will incorporate more features, optimised strategies and a host of major enhancements for more powerful and simplified machine and controller independent NC programming.

On Stand 440 in Hall 17, OPEN MIND experts will demonstrate the optimisations to hyperMILL that include enhancements to the 5-axis strategies in VIRTUAL Machining. This will provide users with better results in terms of surface quality, new options for 2D functionality as well as efficient innovations in electrode manufacturing that deliver more convenient and faster programming.

hyperMILL VIRTUAL Machining is all about generating, optimising and simulating NC code reliably through a collection of targeted solutions. Virtual Machining can be used to map all process steps in CNC manufacturing for perfect process control.

The modular technology now also supports additive machining programs. The 'Optimizer' module, which delivers powerful optimisation algorithms for efficient multi-axis machining, also features the ‘Optimized Table-Table Logic’ function for easy programming and reduced air time between cuts. The user selects a distance value, and the Optimizer automatically calculates the safety distances using the raw part, component and clamps selected in the job list.

The defined distance is maintained for all components and the movement sequences are automatically optimised. This makes the generating of ideal linking movements even easier. Also, the new feature of direct data transmission in the CONNECTED Machining module provides additional safety during tool input. Instead of the traditional manual input, the parameters are transferred directly from hyperMILL to the controller.

Seamlessly merging the virtual and real world

The three hyperMILL VIRTUAL Machining modules for the seamless merging of the virtual and real worlds form the core of the safe simulation solution. The 'Center' module virtually maps real machining situations for the machine and controller and simulates these based on the NC code.

The 'Optimizer' module provides powerful optimisation algorithms that ensure efficient multi-axis machining. It also automatically identifies the best inclination for top machining results. The CONNECTED Machining module enables in-depth networking and synchronisation with the machine.

Intelligent component alignment at the touch of a button

Another tool for ensuring greater efficiency and cost-effectiveness in machining is the intelligent real-time component alignment in CAM using hyperMILL BEST FIT. The unaligned component is probed on the machine using 3D probing, and the probing points are sent back to the CAM system in the form of a measuring log. hyperMILL BEST FIT then precisely adjusts the NC code to the actual component position. The adapted NC code is subsequently simulated in the virtual machine on the actual clamping setup and optimised automatically.

5-axis radial machining

Machining strategies for 2.5D, 3D, HSC, Mill/Turn and 5-axis applications offer the ideal solution for any machining situation. In the area of 5-axis radial machining, new improvements raise the bar in blow mould machining.

The new ‘Flow Equidistant’ infeed strategy is the first of its kind that supports the generation of toolpaths with a constant infeed for vertical and challenging surfaces. This means that these surfaces can be integrated into the overall machining sequence and processed in a single step to provide seamless machining with a very high surface finish quality. New undercut detection automatically identifies undercuts and makes the corresponding machining adjustments, if desired. This means that undercut areas can now be skipped with no manual intervention necessary. As a result, users do not need to generate additional surfaces.

A dedicated 3-axis machine mode greatly simplifies the use of radial machining on these machines, and the ‘Smooth Overlap’ function can be applied to the general milling area without selecting a boundary curve. For instance, the ‘Smooth Overlap’ function blends the transitions between two surfaces that have been milled in different machining directions. This results in perfectly transition-free surfaces.

To find out more, come and talk to OPEN MIND experts at MACH on Stand 440 in Hall 17 on 4-8 April at the Birmingham NEC.

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