OPEN MIND closes the gap between CAM systems and physical machine environments with its hyperMILL VIRTUAL Machining solution is an integrated all-in-one system that eliminates the need for various software solutions. It maps all steps virtually, thus giving manufacturers absolute control over the machining process. This includes programming, NC code generation and optimization, simulation of the NC code, and networking with the machine.

At OPEN MIND, the development of a safe simulation solution starts long before the NC code. The CAD/CAM developer relies on in-house innovative solutions to build an integrated system where NC code generation and simulation are closely interlinked. The generated NC code is tested extensively, taking into account machine limitations. It is guaranteed to run on the respective machines. All process-relevant data is available in the NC code simulation, delivering an unsurpassed level of accuracy and safety.

Three modules for merging the virtual and real world
OPEN MIND has equipped hyperMILL VIRTUAL Machining with three modules for merging the virtual and real worlds. In the Center module, real machining situations are virtually mapped for the machine and controller. They are then simulated based on the NC code. The CONNECTED Machining module enables in-depth networking and synchronization with the machine. For example, the simulation software can detect deviations in the origin or tool positions.

The Optimizer module provides powerful optimization algorithms that ensure efficient multi-axis machining. It also automatically identifies the best solution for top machining results. Moreover, users can write the CAM programs for portal milling machines in the same way as for 5-axis milling centers. The Optimizer automatically adds the rewinds necessitated by rotary and linear axis limits and by collision control based on the machine’s digital twin. This eliminates unnecessary retract movements to safety positions between two machining steps with the same tool. When combining jobs with the same tool (linking), 2D and 3D machining steps are transformed into smooth movements. The Optimizer can also distinguish between roughing and finishing operations.

Intelligent part alignment at the push of a button
Another tool for ensuring greater efficiency and cost-effectiveness in machining is the intelligent component alignment in CAM in real-time using hyperMILL BEST FIT. The unaligned part is probed on the machine using 3D probing, and the probing points are sent back to the CAM system as a measurement log. hyperMILL BEST FIT then precisely adjusts the NC code to the actual part position. The adapted NC code is subsequently simulated in the virtual machine on the actual clamping setup and optimized automatically. To ensure safe and accurate machining, the machine operator performs a final verification measurement. After that, he can start machining without having to align the part on the machine beforehand. The advantages include immense time savings, safe machining, and well planned processes.

More features, optimized strategies, major enhancements: OPEN MIND has upgraded its hyperMILL® CAM software for machine- and controller-independent NC programming. These include optimizations for hyperMILL® VIRTUAL Machining, enhancements to the 5-axis strategies for better results in terms of surface quality, new options for 2D functionalities, as well as efficient innovations in the area of electrode manufacturing that deliver even more convenient and faster programming.

hyperMILL® VIRTUAL Machining is all about generating, optimizing, 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 optimization 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 from all components and the movement sequences are automatically optimized. Generating ideal linking movements is even easier as a result. 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 optimization 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 synchronization 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 component alignment in CAM in real time 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 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 optimized 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, the new improvements in the CAM software raise the bar in blow mold 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 these surfaces can be integrated into the overall machining sequence and processed in a single step. Seamless machining with a very high surface quality is guaranteed.

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.

Programming turning processes even faster and easier
The two new feature types make programming turning processes much easier and faster. Component areas for turning or plunging are reliably recognized, structured, and displayed. During this process, hyperMILL® automatically divides the recognized features into several areas that can be turned, faced, groove machined, or machined with a combination of these technologies. This saves users a lot of time in contour selection and programming, while giving them full access to all recognized contours. With macro technology, components can thus be programmed automatically with just a few mouse clicks.

hyperMILL® now offers convenient programming for two-sided machining on machines with a main and counter spindle. The machining jobs are simply programmed under the “Main Spindle” and “Counter Spindle” containers, which assigns them to the respective machining side. The component or bar material, with or without parting, is transferred with the new transfer job. NC output from the main side, opposite side, and component transfer are realized in one end-to-end NC program with a machine model and a post-processor. DMG MORI CTX machines with Siemens control are supported starting in release 2022.1. More manufacturers and machine types will follow.

Time-saving erosion path changes with hyperCAD®-S Electrode
Thanks to the simple creation and subsequent modification of traverse paths during the EDM process with hyperCAD®-S Electrode, users no longer need to program on the controller.

OPEN MIND’s hyperMILL® BEST FIT is a new function that is revolutionizing planning in machining operations. Instead of having to align the unmachined part in the clamping to the NC program manually, the hyperMILL® CAM system aligns the NC program automatically to the component position. This method saves time and increases process reliability, especially with cast, forged, welded, and additively manufactured stocks with small or irregular allowances, when reworking heat-treated parts, and during machine changeovers. Each of these processes requires a delicate touch to calibrate it with the CAD model of the end product.

hyperMILL® BEST FIT takes full advantage of the options offered by the virtual machine in the CAM program and communication with a 5-axis machining center capable of 3D measurements to eliminate the uncertainty that comes with manual alignment.

Real-time alignment for reliable, plannable processes
Up to now, it has been standard practice to adapt the stock and the clamping in the machine to the conditions of the NC program. The component is aligned manually, using a dial gauge, control cycles, plus a great deal of sensitivity. The actual clamping operation is adapted to conform to the virtual programming. This process was time-intensive, often needed to be repeated multiple times, and involved a number of uncertainties. One way to solve this issue is to align the component in CAM in real time. The unaligned stock is probed on the machine by way of a 3D measurement, the measurement log is sent to the CAM system, and hyperMILL® BEST FIT adjusts the NC code to the actual position of the component. The virtual world (programming) is adapted to the real world (clamping), not the other way around! The adjusted NC code is then simulated in the virtual machine on the actual clamping setup, and automatically optimized.

A real game changer in many application areas
“Thanks to hyperMILL® BEST FIT, time-consuming and unsafe component alignment on the machine is a thing of the past. hyperMILL® detects the situation on the machine and aligns the component virtually,” explains Manfred Guggemos, Product Manager at OPEN MIND Technologies. “Component alignment at the touch of a button is a real game changer in many application areas. This could include reworking refurbished parts and imperfect forged parts, machining parts that are too heavy to be aligned by hand, eliminating the need for high-precision equipment, and more. What makes this unique is that unlike previous solutions available on the market, hyperMILL® BEST FIT does not change the origin on the controller and generates completely collision-checked toolpaths.”

 SoftInWay Inc. and OPEN MIND Technologies AG announce a cooperation agreement to provide a complete solution for the design, development and manufacturing of gas turbine components and other types of turbomachinery. Both companies are known for their best-in-class software platforms that provide component developers the needed productivity tools to accelerate the product development and production process while maintaining a high level of accuracy.

The AxSTREAM^® Software Platform provides an integrated and streamlined approach to turbomachinery design. The software consists of a number of different modules to perform preliminary design, meanline and streamline analysis, CFD and FEA, blade profiling, and rotor dynamics, bearings analysis, and rotor design for compressors, pumps and turbines. These tools are used to produce optimal components, considering speed, power, range, and life. The interactive and user-friendly design process enables these conditions to be achieved efficiently and reliably.

hyperMILL is a modular complete CAM solution for 2.5D, 3D, 5-axis, HSC/HPC, and mill-turning processes as well as its special applications and highly efficient automation solutions. The CAM software provides technology-leading geometry analysis and tool path calculations. There are specialized routines designed for efficient programming and machining of these components on 5-axis milling or mill-turn machines. The multi-blade and single-blade turbomachinery solutions are embedded within hyperMILL that is applied to more broad-based milling, drilling and turning applications, allowing an all-in-one CAM system for turbomachinery developers. Robust CNC postprocessors are also provided to assure strong communication to machine tool controllers.

This partnership between SoftInWay and OPEN MIND brings product, services, sales and technical teams together for a complete software solution. Customers can work with each company to obtain tools, training and services from these industry experts. Both companies are well represented with direct employees and authorized resellers in America, Europe and Asia and look forward to collaborating together to contribute towards the advancement of the turbomachinery industry.

OPEN MIND Technologies AG, one of the leading CAD/CAM software developers, draws a positive conclusion from this year’s Tire Technology Expo in Hanover. The numerous lively discussions taking place at the OPEN MIND booth revolved around the powerful tire module of the hyperMILL^® CAM suite. In addition the software developer presented the hyperMILL^® MAXX Machining performance package for roughing, finishing and drilling operations.

The tire module of the hyperMILL^® CAM suite offers a range of special functions for the NC programming of tire molds. At its heart is the Tire Clock, where the tire’s design is defined with all segments, tracks, pitch sequences and pitches.

Automated functions support creating and managing the elements and geometries required for programming. The user can display the suitable geometry for each operation in order to avoid errors. This means that each pitch only has to be programmed once. The new Multiple Track Support function allows a separate pitch sequence to be defined for each track.

MAXXimum Performance
The hyperMILL^® MAXX Machining performance package features three special optional modules for highly efficient rouging, finishing and drilling. The numerous CAM strategies help companies realise significant optimisation potential.

The roughing module in the performance package offers solutions for high-performance cutting (HPC) with spiral and trochoidal tool movements on prismatic and curved component surfaces. Innovative algorithms ensure that a constant chip volume is always removed by each tooth of the milling tool. This delivers high utilisation rates without exposing the tool to undue stresses, resulting in roughing speeds that are 20 to 70 per cent higher than before. OPEN MIND has made this fast roughing method available for all types of machining from 2,5D to 5axis simultaneous.

With ‘5axis tangent plane machining’, OPEN MIND has developed a special CAM innovation for plane machining. Time savings of up to 90 per cent can be achieved together with the conical barrel cutter. Path distances of six and eight mm are possible with the large radii of the conical barrel cutters. This results in optimal surfaces and longer tool life.

‘5axis helical drilling’ is another performance strategy. Holes can be machined easily and efficiently with this solution.

OPEN MIND Technologies AG has now released the latest version of its CAM system, hyperMILL 2017.1. Users now benefit from many new functions and optimisation tools that make programming faster while reducing auxiliary processing times when carrying out machining jobs. The software developer has also made crucial additions to hyperCAD^®-S, its proprietary CAD for CAM solution. The software is available from November 2016.

Manufacturing companies heavily rely on multi-functional mill/turning centres to optimise their machining processes. OPEN MIND supports this trend and has added many new mill/turning functions to hyperMILL 2017.1.

The extended chip break function for turning operations now allows the customer to machine hard and soft materials with more flexibility than ever before. New functions make it possible to remove chips safely for non-falling contours. The machining length can now be defined in combination with a short stop to break swarf. This ensures the workpiece is not damaged by swarf getting wrapped around the spindle. It’s also possible to maintain high surface quality with the machining length defined in combination with a short pause. The user can select from two methods to specify the stop, define the dwell time or even the number of spindle rotations. Greater control of the chip break is now possible where the area to be machined is divided into multiple sections that are then machined in a specified order.

2.5D and 3D machining
The new release offers a number of new functions and expansions for 2.5D and 3D machining. hyperMILL 2017.1 supports cutter radius compensation when using 2D thread milling and 2D helical drilling strategies. If the tool radius changes, hyperMILL automatically adjusts the programmed path. The user has two options for how this adjustment is made: the compensated path option or the compensated centre path option.

The new 3D cutting edge machining strategy is one of the highlights for 3D milling jobs. This strategy enables efficient machining, particularly for cutting blades, which are frequently used in tool engineering. Roughing and finishing operations can easily be generated via a 3D curve selection. The rest material machining is generated via the ‘Reference job’ option. Here, the rest material areas of the previous machining operation are also included in each case. Toolpath smoothing ensures a better milling result if the contours are of poor quality.

hyperMILL MAXX Machining
The new version also expands the scope of the hyperMILL MAXX Machining performance package. hyperMILL 2017.1 allows the spindle speed to be adjusted in the plunge macro for roughing. Modifying the spindle speed and specifying a dwell time for the speed change ensure more tool-friendly machining. This option also increases process reliability.

5-axis swarf cutting with a curve
Users can now benefit from two new functions for 5-axis swarf cutting with a curve. The perfect surface and equally perfect curve are created automatically for SWARF cutting based on a simple face selection. This feature automatically fillets interior corners, so the programmer can eliminate the input of additional geometries when pocket and fillet machining.

hyperCAD-S
Three basic improvements make the newest version of the hyperCAD-S CAD solution stand out. This is the draft, curvature and selection function analyses. The new selection functions make selecting CAD elements particularly convenient. The new draft and curvature analyses help users quickly view and examine milling areas or radii sizes.

With its mountain bike frame milled from solid stock, North Bucks Machining Ltd, based in Milton Keynes, UK, has created a new reference workpiece that demonstrates the many possibilities offered by the hyperMILL® CAM suite from OPEN MIND Technologies.

Engineer Steward Palmer introduced the hyperMILL® CAM system to his parents’ family business to make more efficient use of the company’s 5-axis machining centre. The extremely powerful machining strategies of the CAM software allowed him to realise his personal dream of developing his own weld-free and weight-optimised downhill mountain bike frame.

The main frame, seat post and swing arm are each milled from solid aluminium blocks. Here, Palmer took advantage of the roughing module in the hyperMILL® MAXX Machining performance package. The high-performance cutting (HPC) strategies allowed North Bucks Machining to achieve large stock removal volumes in the shortest time possible. Palmer explains: “Using hyperMILL®, we were able to machine the main frame in one hour and 30 minutes. In the past, this took two hours and 20 minutes. This is equivalent to a reduction of around 40 percent.”

An aluminium frame weighing less than 7kg was machined from raw material with a starting weight of 165kg. But this isn’t enough for Palmer: He now seeks to further enhance the design of the frame to reduce the overall weight to 5kg.

Perfect Surface

The finishing strategies offered by hyperMILL® were also very important as the bike frames produced by North Bucks Machining do not undergo secondary finishing operations. It’s only since calculating the toolpaths with the CAM software from OPEN MIND that the company has been able to achieve the desired surface finish.

hyperMILL, the CAM/CAD solution from OPEN MIND Technologies AG has now been certified by Autodesk Inc. This means that an integrated and fully autonomous workflow is ensured when converting files from Inventor 2017 software to hyperMILL.This makes transition from Inventor through the hyperMILL CAM system and on to the CNC machine tool completely seamless. 

The necessary data association was confirmed following a rigorous test procedure for the latest edition of hyperMILL, version 2016.2. This was fully affirmed on the same database to increase the common access, speed and efficiency. This new authentication ensures that errors are avoided and the workload for the end users is reduced overall. The big advantage for customers is the changes in the CAD data that leads to an automatic update of the CAM operation. This is particularly convenient for Inventor users as it allows them to invoke the entire CAM functionality of hyperMILL^® within this familiar CAD interface.

OPEN MIND Technologies AG, a leading manufacturer of CAD/CAM solutions now introduces hyperMILL 2016.2 with a host of optimisations in 2D, 3D, 5-axis and HPC machining that will boost performance and ease of use. Highlights of the new version include 5-axis tangent machining from the hyperMILL MAXX Machining performance package and also the 5-axis optimised rest material roughing module that ensures extremely short calculation and processing times. In addition, hyperCAD-S the CAD for CAM system has also been significantly improved.

The hyperMILL MAXX Machining performance package has once again been expanded to incorporate 5-axis tangent machining of any arbitrary faces with conical barrel cutters. Delivering results with speed, the use of conical barrel cutters enable performance increases of up to 90 percent compared to conventional production methods. The special feature of the OPEN MIND development is application of cutting tools that have radii of up to 1000mm. This unique tool feature allows the tool to conduct greater step-over distances that reduce tool paths whilst improving the theoretical roughness. The result is extremely fast production times with optimum surface quality. In addition to this module, the hyperMILL MAXX Machining package includes powerful solutions for roughing and drilling. 

Tool Saving 5-axis Strategies
New strategies for 5-axis machining can undoubtedly speed up production and save tool life and machine service life. The conical interpolation results with the “Fast movement optimised” tool positions on conical way around the pole. So simultaneous 5-axis movement is generated with less acceleration of machine axes.

The 5-axis Optimized Rest Roughing creates high-speed cutting (HSC) optimised tool paths for the rest machining – from a previous roughing. The definition of the tilt angles for the B- and C-axes is very simple. The user can choose whether to automatically create the tilt angle in the ‘3D mode’ within a specified angular range or generate it from the plane normals. All connecting paths between the tilt angles are optimised and fully checked for collisions. This indexed machining strategy offers many advantages. Firstly, shorter tools improve stability and performance. In particular, deep cavities and hard-to-reach areas can be processed economically with this cycle.

More performance for 3D machining
OPEN MIND has given hyperMILL 2016.2 numerous extensions for 3D operations. One new feature is the impressive 3D plane level machining. Toolpaths for finishing levels can be quickly and easily generated. Three new functions are available for 3D optimised rest material roughing: the ‘avoid areas’ option can exclude specific areas from processing, the ‘undercut optimisation’ feature avoids unnecessary redundant movements in undercut areas when performing multi-axis machining on stock; and the ‘plane level detection’ is used when plane level needs to be machined using a different stepdown, an intermediate step is added automatically.

CAD for CAM
In hyperCAD-S, plane curves or texts can now be created without distorting the geometry angle on a cylindrical surface or rotational faces. The direction, scaling and mirroring can also be modified.

With the function ‘Compare and merge’ users can compare various versions of CAD models and select the geometry elements to insert them into an existing document. All not-modified geometries remain in hyperMILL. So, only the updated fields have to be reprogrammed. For the user, the work will be accelerated considerably.

The performance package hyperMILL MAXX Machining offers three modules for finishing, roughing and drilling that make it possible to achieve impressive boosts in productivity. HEGGEMANN AG, headquartered in Büren, Germany, is a development and manufacturing partner of the aerospace and automotive industry. The company uses hyperMILL to reduce machining times by up to one third on a range of workpieces.

HEGGEMANN AG owner Robert Heggemann manages his company according to the motto ‘360° from Engineering to Production’. He explains what lies behind this approach: “We’re a service provider in the metalworking sector, and we’re in a position to cover the entire process chain from development right through to series production. Our customers are well aware of this. Most of them are in the aerospace and automotive industry and they also value our expertise, reliability, flexibility and quality.”

To ensure it is possible to meet the high requirements of a customer industry known for being challenging, HEGGEMANN employs highly qualified staff, both in its engineering and manufacturing operations. Employees define the most efficient manufacturing concept at an early stage during component development and construction. The engineering specialists have broad expertise covering a wide range of materials and production methods, and this is where their skills come into play. What’s more, the company is well equipped with machinery for working with sheet metal and solids. There is a total of 18 milling, turning and hybrid machines available for machining, with most coming from DMG Mori and Hermle. This puts HEGGEMANN in a position to be able to respond to all requirements in terms of complexity and volumes.

Modern software in all areas
HEGGEMANN AG is also state of the art in terms of the software the company uses. The manufacturing management department makes use of a manufacturing execution system (MES) that complies with the latest Industry 4.0 standards. A product data management (PDM) system manages customer data as well as proprietary 2D and 3D CAD data. Once final approval is given by the customer, programmers can access the final data record and generate the required NC programs via CAM.

HEGGEMANN has used the hyperMILL CAM system from OPEN MIND since 2009. It particularly stands out thanks to the innovative hyperMILL MAXX Machining performance package. The ‘5axis tangent plane machining’ strategy in particular has left a lasting impression at HEGGEMANN, as it offers enormous potential for savings, confirms René Reiffer, Head of Production at HEGGEMANN AG.

It was Dirk Lehmann, Technical Sales Consultant at OPEN MIND, that originally sparked the interest for the new finishing strategy among Reiffer’s milling team in early 2015 and asked the team to test the 5axis tangent plane machining strategy. The metal removal team got the chance to do just that at the Hermle AG technology centre in Kassel. This is because Hermle, a leading manufacturer of 5axis machining centres, is among HEGGEMANN’s preferred suppliers. “The result immediately won us over,” explains Reiffer. “We now use the 5axis tangent plane machining strategy as often as possible, as we can achieve a significant reduction in machining times.”

A major component of the innovative finishing strategy is the tool it employs – a conical barrel cutter specially developed by OPEN MIND for this purpose. Its geometry has a large radius of 1,000 millimetres or more, allowing enormous line increments during finishing. “We regularly achieve time reductions of 70 to 90 per cent in test workpieces compared with the use of traditional ball mills,” adds Dirk Lehmann.

Finishing time cut from 90 to 15 minutes
Reiffer provides an example of the savings achieved at HEGGEMANN: “We just manufactured a component with deep pockets measuring 155 mm and vertical walls. Until recently, we would have milled it with a 12 mm ball mill, which would have taken about 90 minutes of machining time. Using the new method and a barrel cutter with a lateral radius of 500 mm and a tool radius of 4 mm at the tip, the finishing process only takes 15 minutes. The surface quality was R_z = 3.2 µm in both cases.”

The time saving is primarily due to the barrel cutter’s enormous line increments measuring 4 mm during the final finishing pass. With a ball mill, it would be more than ten times the number of lines at a distance of 0.35 mm.

Reiffer’s team saves additional time when it comes to programming. It takes about 20 minutes to create a finishing programme for a pocket like this with a ball mill. It is possible to program machining jobs for the 5axis tangent plane machining in five minutes.

Optimised roughing for 2D, 3D or 5axis operations
The new OPEN MIND performance package also offers other interesting high-performance cutting (HPC) strategies for roughing. For example, the hyperMILL MAXX Machining roughing module allows the user to achieve a maximum stock removal rate by intelligently separating spiral and trochoidal-like tool paths and dynamically adjusting the feed rate to suit the prevailing cutting conditions.

What makes this special is that it can be used for any type of machining operation, be it 2D, 3D or 5axis. HEGGEMANN AG takes full advantage of this possibility. “We mostly use it for 2D components, as we can often machine these components with the entire shank length of the tool,” reports Reiffer, delighted with the time savings. “In cases like this, we are two to three times faster and we also benefit from less tool wear.”

HEGGEMANN also places great value on its excellent cooperation with OPEN MIND. “We receive a top quality service. When we have a question, we get a prompt response by e-mail or by phone. And if it’s really urgent, they’ll send over an application engineer to solve problems directly on site,” says Rene Reiffer.