hyperMILL® is a powerful CAM solution that enables tasks to be programmed significantly faster – even NC programs for the most complex geometries can be created easily. Working from an intuitive user interface, users can program all machining strategies for 2D, 3D, HSC, 5axis and mill/turn machining. hyperMILL® offers several options for automated programming, from sophisticated feature and macro technology to intelligent macros and functions such as transformation and mirroring. Innovative technologies and machining strategies avoid air cutting movements, reduce machine running times, and improve processes.
“Russian metalworking companies are being asked more and more often to produce high-quality products and tools under tremendous time pressure. There is a lot of optimisation potential in this area, above all in machining,” says Slava Botsvine, OPEN MIND Sales Director for Russia and the CIS region. “With hyperMILL®, OPEN MIND offers users pioneering software to make programming and production more cost-effective and efficient.”

Machine-specific NC programs

OPEN MIND develops its own postprocessors, thereby ensuring that its machining programs work perfectly on each machine. OPEN MIND’s postprocessors generate NC programs from neutral CAM data that are optimised to meet the customer’s requirements and are matched to the machines and controllers being used. Using a Centre of Excellence concept, worldwide postprocessor experiences are combined to improve performance and functions.

hyperMILL® offers alternative manufacturing methods by exploiting the options for 5axis machining with innovative technologies and reducing processing times with complete machining in a single step. As of the current version, hyperMILL® also offers 64-bit support. This means that users have more memory at their disposal, and that many calculations can be carried out considerably faster. These features are especially useful when machining large models, which require a greater number of job steps and toolpaths. hyperMILL® users thus benefit from further time savings in their day-to-day work.

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• hyperMILL® in tool and mould making (0)

Companies benefit from the high manufacturing quality offered by hyperMILL®. Particularly with implants, optimal surface quality is crucial for ensuring compatibility in the human body. High-precision machining in medical applications using materials that are difficult to chip – such as titanium or hard metal – require optimal toolpaths and tool tilt angles. hyperMILL® offers a comprehensive concept for 5axis machining. Intelligent solutions, such as 5axis shape offset roughing and finishing, 5axis top milling or 5axis swarf cutting simplify the programming of demanding geometries, ensure high surface quality and reduce machine running times. The use of shorter and therefore more stable tools enables high-quality machining of high steep walls. Improved cutting conditions plus the reduced risk of chatter and tool breakage ensure the best results.

Faster programming

OPEN MIND relies on process automation and automated programming. The use of existing production expertise reduces programming times significantly. For example, hyperMILL® includes intelligent macros, which represent the next level in feature and macro technology. Thanks to intelligent macros, users can save predefined rules and conditions for every stage of the machining process. Job steps are automatically assigned and adjusted to the corresponding geometry in accordance with these rules and geometry information such as diameter, depth, open or closed pockets. hyperMILL® also demonstrates its time-saving potential in the programming of recurring geometries and identical elements. Transformation techniques facilitate the arrangement and copying of programs across the workspace. A mirroring function facilitates the programming of symmetrical parts.

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• Manufacturing moulds quickly and in one setup (0)

Mould manufacturers realize a decisive competitive advantage by being able to quickly react to customer requirements and design changes. Companies aiming to optimise their CNC manufacturing process have to focus on the CAM implementation of CAD data. To reduce programming time and make machining more efficient, OPEN MIND’s latest hyperMILL® 2011 release continues to rely on automated programming and the smart utilisation of existing manufacturing expertise. Proven feature and macro technology for intelligent macros was further developed for this purpose along with other enhancements. This means users can now define and save rules and conditions for every stage of the machining process in the CAM software. Job steps are automatically assigned and adjusted to the corresponding geometry in accordance with these rules and geometry information such as open or closed pockets, diameter and depth.

5axis machining in one setup

Innovative CAM technologies exploit the options for 5axis machining to reduce processing times through complete machining in a single setup. The further optimisation of machining strategies not only reduces the programming time but also accelerates and refines the manufacturing steps. For example, the new shape offset roughing and finishing function offers a strategy for 5axis machining of curved surfaces with a uniform offset while avoiding the formation of z-level ‘steps’. hyperMILL®’s automatic 5axis approach and retract strategies further improve machining safety and quality, while advanced 5axis swarf cutting results in better surface quality.

Individual postprocessors

OPEN MIND produces almost all of their postprocessors for their customers in order to reliably bring the tool paths in hyperMILL® to the machines. Every user has specific ideas about the NC programming format based on their respective company’s parts portfolio and experience. OPEN MIND offers to make these ideas a reality – without losing sight of reliable performance.

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• SolidWorks® users show strong interest in hyperMILL® (0)

SolidWorks World 2012 attracted more than 5,900 visitors to southern California. There they learned that hyperMILL® for SolidWorks® makes the hyperMILL® CAM software available as an integrated component of the SolidWorks® solution that is controlled using the familiar CAD user interface. This feature of the CAM software, which has been awarded Certified Gold Product status in recognition of its perfect integration, quality and interoperability, further adds to the appeal for SolidWorks® users.

Helmet acts as eye-catcher

Automation options for 2.5D machining and new 3D strategies such as rest machining and new roughing extensions elicited particularly positive reactions from visitors. Other popular features included the new shape-offset roughing and finish for efficient 4axis or 5axis machining of curved surfaces. These machining strategies help to improve manufacturing of engine casings, structural components and tyre moulds, to name but a few examples.

The motorbike helmet presented at the OPEN MIND booth was a true visitor magnet. This part, milled from solid stock, demonstrated the milling skills of the Japanese Daishin Seiki corporation and the possibilities of 5axis machining with hyperMILL®. Alan Levine, Managing Director of OPEN MIND Technologies USA, Inc. was very satisfied with the event: “SolidWorks World provides a fantastic opportunity to interact with the SolidWorks® community and discuss our gold partner CAM solution, which enables them to work seamlessly and without the need to convert any data. The customers enjoy the benefits of working in their existing software environment.”

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• Workpiece programmed with hyperMILL® wins gold medal (0)

OPEN MIND will be participating in the special ‘Metal meets Medical’ exhibition. The entire process chain from design to manufacturing will be displayed using several medical engineering products under the tagline ‘From one-off pieces to mass production’. The range of medical engineering products is immense, ranging from surgical instruments and implants to other medical parts. The respective geometries of these products differ accordingly and hyperMILL® offers the necessary flexibility when it comes to CAM programming. Companies benefit from the high manufacturing quality offered by hyperMILL®. Particularly with implants, high surface quality is crucial for ensuring compatibility in the human body. This requires high-precision machining of materials that are difficult to machine, such as titanium or hard metal. A medical product programmed with hyperMILL® will be milled live on a Mikron machine from AgieCharmillies at the special exhibition.

Reduced programming effort

hyperMILL® offers new functions that help you achieve simple, user-friendly and time-saving workflows. OPEN MIND has extended a proven technology for intelligent macros in its current version for this purpose. This means users can now save predefined rules and conditions for every stage of the machining process in the CAM software. Job steps are automatically assigned and adjusted to the corresponding geometry in accordance with these rules and geometry information such as diameter, depth, open or closed pockets. There are even more possibilities for customised automation: Customised process features, or CPFs, allow companies to define individual corporate standards for automated programming. The method is based on process-oriented linking of characteristic geometry sequences with freely defined machining steps. A CPF like this is provided with a name, documented with images, if necessary, and can then be selected as a CAM element.

High-performance postprocessors

hyperMILL® offers alternative manufacturing methods by exploiting the options for 5axis machining with innovative technologies and reducing processing times in complete machining in a single setup. CAM specialists developed the interfaces to tool machines and maintain them as an integral component of the CAM software in order to reliably bring the optimised tool paths in hyperMILL® to the CNC machines and guarantee maximum performance. OPEN MIND saves the user from having to customise the otherwise usually generalised postprocessors.

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• Openmind hyperMILL® (0)

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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• Manufacturing moulds quickly and in one setup (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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• SolidWorks® users show strong interest in hyperMILL® (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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• OPEN MIND Technologies at SolidWorks World 2012 (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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