Trendsetting Technologies and Novel Functionality
New paradigm in manufacturing
hyperMILL? 2009.1 o?ers innovative functions and a
new multidimensional, process-oriented CAM platform.
This is a unique platform which, with comprehensive features for planning, organising and implementing machining processes, allows users to organise these processes with a view to the future. Users can aggregate manufacturing expertise and thus safely and ?exibly implement complex tasks and reduce production times.
This is made possible through the following features: – Associative linking of geometries, tools and technology macros – Automatic inclusion of modi?ed external data – De?nition of processing standards using customized process features – Automated programming associated with the above – Ability to de?ne individual di?erences between similar geometries by simply editing/deleting individual constraints – Process-oriented work?ow with signi?cant reduction in auxiliary processing times
Here, hyperMILL? 2009.1 is building on past experience. As a bene?t, users need not relearn how to program. Since users can continue to work in the same manner as previously, they can gradually learn this new comprehensive method of programming.
Customized Process Features: CPF allows users to de?ne various characteristic geometry sequences using freely de?nable machining processes.
Transformations: Transformations allow users to move and/or copy a program across spatial coordinates.
Mirroring: This function mirrors input data across a plane and calculates an independent toolpath on the basis of the mirrored geometry.
Production mode: This feature automatically optimises all transition moves to minimize processing times for standard parts.
Job linking: This feature merges machining operations using a common tool into a single machining job.
Management functions and tools
System requirements: Windows XP, Windows Vista. hyperCAD? 2008.1, thinkdesign 2008.1 Software languages: D, E, I, F, ESP, J, NL, PL, CZ, RU, CHIN
? Parts veri?cation for e?cient job planning and CAM programming
The new modelling and surface analysis tools allow users to quickly and easily determine which element properties in a component are relevant for machining tasks. By simply clicking on a surface, users receive important information on the surface type (radius, plane, free-form surface), minimum and maximum radius, position and angle as well as picking point coordinates for the selected frame system. When selecting two elements, the minimum distance between the two surfaces is displayed. In addition to analysing individual surfaces, hyperMILL? can automatically search for all planes and radii on a component and also mark their positions and sizes accordingly. Various machining data, such as machining type or tolerances, are often compiled into standardised colour tables. These can be stored in hyperMILL? so that users have easy access to tolerance and ?t data for holes or other geometries to be machined in a component. Manual positioning of any tool allows users to quickly and easily check whether areas that are di?cult to access can be machined and, if so, at which angle. To do this, any tool de?ned in hyperMILL? can be moved to any position and freely rotated around all axes.
Integration of standardised colour tables
Analysis of existing radii on component
? For well-structured job lists
Compound jobs help users to improve their project organisation and management. A job list consists of several compound jobs. Users can structure these jobs according to aspects such as machining process, geometry, 3D position or tool orientation. Thus, it is possible to create structured lists containing many hundreds of jobs. Furthermore, the various jobs can be shown or hidden as a group. A compound job can be assigned to a transformation that is then valid for all corresponding job steps.
Clear structuring according to job group
Associative job copies
? For associative copying
Associative jobs permanently link all parameters with the original. Changes to the job template are automatically copied to the associated jobs. Any individually de?nable parameter for a job step can be disassociated from the template by a simple mouse click so that it can be de?ned di?erently for this job step. This new functionality allows users to work more ?exibly and quickly edit common machining strategies where only few parameters di?er across several steps in a job. All parameters that have been disassociated from the job template are displayed in a separate window of the job step where they can be edited.
Management functions and tools
? Fast and easy editing
The redesigned user interface allows additional options to edit several steps in a job. Next to central parameters such as surface, depth, allowance or infeed, various other geometry selections such as milling or milling surfaces and even macros can be changed globally across multiple jobs.
? Improved management of data and ?les used in hyperMILL?
This function simpli?es the handling, entry and con?guration of directories containing essential hyperMILL? data such as postprocessor information, machine de?nitions and NC ?les. When saving a CAD model, a backup copy can be created automatically. The storage location and number of backup copies are freely de?nable.
? Extended tool de?nition and collision checks
In addition to a holder, thicker shaft and head, tools can now also be de?ned with extensions. For optimum processing, the required length of a tool is calculated during the entire collision check. Here, the software calculates the required length. After the calculation, hyperMILL? returns the length by which the de?ned tool should be extended or shortened in order to perform the step without colliding.
Tool length calculation
? Extensive de?nitions of tools using technology data
By entering the technology data for tool extensions, copying tools into a job list automatically changes the corresponding technology values. In addition to the material-speci?c cutting data, users can also create various pro?les for each tool de?ned in the database. Thus, di?erent applications can be prede?ned and selected in the job steps – even for the same workpiece and cutting materials.
Freely de?nable tool holders
Freely de?nable tool extensions …
... Corresponding coupling systems
Management functions and tools
hyperMILL? 2009.1 comes equipped with a fully redesigned high-performance tool database. Tools can now be de?ned with greater versatility and much more realistically. To fully assemble a tool, freely de?nable tool extensions are now available with corresponding coupling systems.
CPF – Customized Process Features (optional)
? Automation of CAM programming and de?nition of companyspeci?c machining standards
Extended feature technology allows users to de?ne any type of complex machining sequence and store it as a technology macro so that it can be quickly and easily applied to various similar machining tasks. This is based on process-oriented links between characteristic geometries with freely de?nable sequences of various machining strategies – from 2D, 3D and 5AXIS milling to turning. The same elements can be used in various work steps for di?erent tasks. For instance, a surface selection can be used as a stop surface in one step and a milling surface in the next step. The various geometry elements can be selected manually in the model or selected automatically by de?ning selection rules. Thus similarly structured external data can be used to quickly program similar components or for making design changes later on.
Operating screen for Customized Process Features
? For reproducing machining jobs on identical or similar geometries
Using transformations, it is possible to reproduce programs for machining identical or similar geometries within a component or several identical components that are clamped together. By freely transforming machining steps across spatial coordinates, users can simplify their programming workload and reduce costs. In other words, multiple copies of machining steps can be placed along the X and Y axes or rotated around a freely de?nable axis. With transformations, users can easily and conveniently create programs for multiple components clamped within a single plane or in a tombstone ?xture, for example. Since the “copies” are associated with the job template, modi?cations to a program or geometry can be implemented quickly and easily. Any changes to the job template are copied automatically by hyperMILL? to the associated jobs. Furthermore, each parameter can be modi?ed individually. Since users can make local changes or even delete parameters and dependencies, work?ows remain highly ?exible (see also “Associative job copies”, page 5). Another powerful feature is that users can perform collision checks relative to the ?nished part for programs that have been o?set or rotated. This means that jobs involving tombstones or multiple setups can be programmed e?ciently and reliably. Transformations can be applied to all job steps.
Spatial copies of programs
Copies of program sections for components with identical elements
? Creates symmetrical geometries or geometrical planes in components and determines entire machining programs for mirrored components
In contrast to simple mirroring actions performed by machine controllers, hyperMILL? does not merely mirror the NC paths but also the entire step. This requires recalculating an independent toolpath for the mirrored geometry. Here, hyperMILL? automatically adapts the required technologies so that climb milling movements remain intact. Automatic approach and retract strategies, curve orientations and optimised infeed movements are taken into consideration in mirrored jobs. Mirroring automatically creates an associated element in a browser. Any changes to the original are automatically applied to the mirrored versions. Again, every parameter can also be modi?ed individually if required. Mirroring can be applied to all job steps as well as to the entire job list.
Geometry and boundaries are mirrored
? For intelligent links between jobs and e?ective reduction of transition moves
Multiple job steps to be machined with the same tool can be combined into a single step using job linking. Here, each of the job steps remains unchanged. hyperMILL? calculates the NC toolpaths between these steps with respect to the workpiece and performs a collision check. Each job link is established independently of the type of machining (2D, 3D and 5AXIS machining) and machining direction. Even undercut areas can be approached safely with job linking. This new unique function allows users to combine multiple strategies into a single processing cycle. The bene?t is that there are no transition moves to safety planes between these jobs, saving much non-cutting time. And the job linking moves are collision controlled.
With and without job linking
? Automatic optimisation of transition moves for shortest possible machining times of standard parts
Production mode is a new function that lets you minimise all transition moves within a job. hyperMILL? automatically optimises fast travel movements according to the path length by stepping over or sideways around the geometry to the starting point of the next path. Lateral movements prevent unnecessary plunging movements. By including the stock in the collision calculation, hyperMILL? ensures that transition moves remain reliable.
Machining with production mode
Machining without production mode
Extended collision checks
? Better process reliability, improved surface quality
The safety allowances for tool collision checks can now be de?ned in even higher detail. Each of the various tool components (spindles, holders, extensions) can be de?ned with separate allowances for checks against the model. Next to collision checks, the required length can also be calculated. Depending on the entry, the tool is not only extended but the shortest possible tool is also calculated (see also “Tool de?nition”).
De?nition with safety allowance
Advanced stock de?nition
? Convenient and easy de?nition of turning stock
hyperMILL? provides users with various options for de?ning stock for turning processes: 1) The user chooses the stock contour as a 2D sketch. 2) Relative to a rotational axis, the software automatically calculates a rotationally symmetrical stock that contains the entire CAD model. 3) The user generates the turning stock on the basis of 3D milling stock or STL model. Here, the new function for de?ning the bounding geometry makes the work?ow very easy and user-friendly. The corresponding surfaces are simply selected by clicking them with the mouse. Next, users can enter a stock allowance applicable to all contours or de?ne separate allowances for each contour. hyperMILL? automatically creates the corresponding geometry. Furthermore, a parallel stock allowance can also be de?ned as an o?set to the contour – as required for cast components, for instance hyperMILL? automatically suggests a minimum size for the stock. Based on these values, users can de?ne global or separate stock allowances or even de?ne the ?nal dimensions.
De?ning the bounding geometry
? For optimised cutting conditions during ?nishing
These new functions are speci?cally intended so that users can machine ?at and steep regions. To de?ne the areas to be machined, the user ?rst selects the entire contour. Next, the user de?nes the areas that are to be machined and the maximum slope angle to be used in the single-step process.
Slope-dependent turning deactivated
Feature recognition for pockets
? Detection of breakthroughs
Pocket feature recognition has been extended to include breakthroughs. In addition to closed pockets, pockets with islands and pockets with open sides, hyperMILL? now also detects breakthroughs. In automatic mode, any closed breakthroughs within the model are detected in the frame direction. In manual mode, users can specify the start and end points to also detect open areas or separate breakthroughs.
Pockets without a bottom surface
Open pockets without ?ooring
? Simple creation of toolpaths
Toolpaths can be generated manually by moving the tool across the model with the mouse. Once de?ned, hyperMILL? performs a collision check for the tool against the model. If a collision is detected, the software modi?es the tool paths to place them at collision free points on the model.
Easy generation of NC toolpaths
With collision checks
Reliable programming of machining processes
2D contour milling
? Unique potential for optimisation with reductions in programming and machining times
hyperMILL? 2009.1 provides new functions for optimised 2D machining of contours. The “Automatic orientation”, “Fast travel optimisation” and “Contour sorting” functions mainly assist users while programming models with multiple contour areas or for machining automatically detected pocket features. The automatic search feature for starting points can be used together with new intelligent approach and retract macros to ensure the transition moves are always performed in the most suitable areas for the technology in use. Other functions such as automatic step-down levels, multiple infeeds in the vertical and horizontal machining directions, and de?nition of additional ?nishing allowances allow users to make e?ective and reliable use of their tools. As an added bene?t, the surface quality also improves. The new production mode allows the created milling paths to be checked against the current stock material. Any traversing or other redundant movements that are detected are reduced to a minimum. Using a collision check, fast travel movements can be performed directly within a model or in its vicinity. This eliminates the need for repeated, time-consuming positioning movements along the clearance plane. As a result, machining times are reduced and the process becomes more reliable.
Automatic cut division
Trimming against the model Fillet outside edges…
... with extended edges
Optimised peck drilling
? Drilling deep holes
Complex deep holes with various steps and cross-holes can be programmed separately using hyperMILL?. The infeeds, drilling speeds and coolant can be controlled separately for di?erent areas and geometry elements such as guide bushings, pilot holes or cross-holes. Here, the strategy automatically detects cross-holes in the speci?ed stock.
Automatic detection of cross-holes
F1, S1, M9
F2, S2, M8
F3, S3, M9 Cross-hole/breakthrough F4, S4, M9 F5, S5, M9
F2, S2, M8
Input screen for optimising process
? Optimised and reliable stock roughing with high milling quality and precision
To improve milling paths and prevent empty cuts and/or very short movements, “minimum material removal” can be de?ned to optimise NC toolpaths. Here, hyperMILL? ?lters out small areas of material. Using the new parameter “Force contour cutting”, stock roughing can also be used for machining rest materials as well as for preliminary ?nishing. As early as during the roughing phase, an allowance is applied equally across the entire component. After entering the new tool parameter, “core diameter” and “core height”, hyperMILL? provides the best possible plunge movement. Here, the infeed is calculated automatically and adapted to the tool.
With minimum material removal
Without minimum material removal
Use for preliminary ?nishing
3D radius compensation
? Precise machining
3D radius compensation reduces programming workloads for users and makes it possible to achieve high machining tolerances – for instance, when a tool is used for milling multiple electrodes.
For higher precision
Automatic 3D rest material
? For e?cient machining and milling ribs and grooves
A bullnose endmill can be used to detect rest material areas as well as for actual machining. A rest material area that has not been machined due to potential collisions can be used as a reference for a subsequent machining step with modi?ed tools (e.g., longer tool lengths). This ensures that only the areas that could not be completed during the ?rst step are machined in this next one. With the new machining strategies for cavities, it is now possible to create grooves, ribs or deep, narrow grooves in a single machining step. Deep areas containing large amounts of material can be cleared completely and e?ectively using a constant infeed.
Previous job as reference
Visualisation of non-machined area
Bullnose endmill as reference tool
Drill point optimisation
? More e?ective machining with minimised tool path lengths
Drill hole optimisation is now also available for 5AXIS drilling. In addition to the shortest paths between the drill holes, the preferred axis of rotation still has to be de?ned. This combines the drill holes so that depending on the settings, ?rst the C-axis or the A/B-axis is moved. Furthermore, users also have the option of using the Z-height as a sorting criterion.
Optimised drilling for B-axis
Optimised drilling for C-axis
Optimised drilling for Z-level
? More possibilities for de?ning tool positions according to your speci?c needs
The 5AXIS machining strategies of pro?le ?nishing, Z-level ?nishing and reworking now include automatic indexing functions. The tilt strategy automatically subdivides the component into separate areas that can be machined at a constant tilt angle. By de?ning boundaries and segment limits, areas can be de?ned wherein a speci?c tilt angle is to be used. Optionally, the entire machining procedure can be merely indexed or even de?ned with a vertical tool position. The remaining areas to be machined either vertically or at a tilt can be optionally calculated as NC toolpaths for simultaneous machining.
Areas with constant tilt angle
Automatic 5AXIS rest material
? Optimised machining and straightforward programming according to your speci?c needs
Automatic 5x Rest Machining allows users to freely combine various approach strategies with each other. Depending on the given requirements, users decide whether only to approach or to machine the various rest material areas using a vertically aligned tool. For areas that can be machined using a vertical or angled tool, the area not yet processed can also be milled simultaneously.
With automatic search feature for constant tilt angles
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? All rights reserved, OPEN MIND Technologies AG, Wessling, Germany. Published august 2009. All information subject to change. No reproduction allowed without the consent of the publisher.
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