HyperMill 2011 is released
October 5, 2011
Openmind has released the latest verion of their increasingly popular hyperMILL® software. The software has been upgraded boasting an impressive list of new and modified features. Below is a summary of the changes.
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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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