Eleven years ago in San Diego, California two experienced and motivated entrepreneurs, Steve Grangetto and Chris Taylor co-founded 5th Axis, Inc. As the company’s name implies, they recognized that 5-axis machining would give their new company a competitive advantage and entry into demanding niche markets like Aerospace, Medical, and other challenging high-tech industries.

Now, not only do they offer complex precision machining to meet a broad range of custom requirements but have evolved to manufacture their own line of 5-axis work holding products. The line encompasses a wide range of vises, fixtures and adapters that complement a broad spectrum of CNC machines. “There weren’t many good 5-axis work holding fixtures available when we started.” Chris Taylor said, “Out of necessity our team started designing and building their own fixtures. Those fixtures and work holding products matured, and we began selling them around five years ago, and now this product line is a substantial part of our business.”

Chris Taylor boils down their company’s philosophy into one sentence: “From day one, 5th Axis’ strategy has been to take advantage of the most technologically advanced software, equipment and technologies available.”

Today, a walk through their bustling shop floor is lined with the best of the best 3- and 5-axis high-speed machining centers from Germany, Switzerland and Japan. All of the machines are programmed with hyperMILL, the CAM solution from OPEN MIND and clearly demonstrates their commitment to the company’s philosophy. But it wasn’t always this way.

Business grew dramatically over their first three years. Their first machine was a HAAS, but in order to meet the growing demand for complex 5-axis machining, 5th Axis began purchasing new high-speed 5-axis equipment including superfast 42,000 rpm Mikron HSM 400U’s, followed by Hermle C 30 U’s, and Grob G350 mills, and a couple Okuma MB-5000H horizontal machining centers. Once they began to dig into programming the machines, they were dismayed to find that their existing CAM software had huge shortcomings. They were faced with unexpected machining collisions and couldn’t fully utilize the speed, capabilities and potential of their new high-end machines.

Chris and Steve assembled some of their best talent to look for new CAM software for their high-end equipment, and at trade shows one of the questions they asked machine manufacturers presenting 5-axis machining demos was, ‘What software did you program that demo with?’ “And, without exception every single 5-axis demo, hands down, was programmed in hyperMILL.” Encouraged by this feedback, they decided to experience hyperMILL first hand. Chris recounts that, “We demoedhyperMILL on a complicated 5-axis part that was giving us fits, and were very impressed by the efficient tool paths, reliable collision avoidance, and how seamlessly the software integrated into SolidWorks. The demo clinched the deal and we’ve been successful using hyperMILL ever since.”

Steve Grangetto adds: “Our company goal was to find a CAM software solution that allowed us to take advantage of the high-speed machining that today’s machine tools have to offer. The results have been faster run times, better surface finishes and overall better part quality. Over the years we found that hyperMILL has fit our company’s strategy perfectly.

5th Axis, Inc. takes advantage of its high speed 5-axis machining centers programmed with hyperMILL to manufacture a wide range of precision parts including turbine impellers, that cannot be made efficiently any other way and, this machine-software pairing delivers part-precision and time-savings benefits.

• 5-axis machining greatly improves part precision by eliminating alignment errors that are introduced in standard machining when a part is removed and re-fixtured in another orientation.
• 5-axis machining is extremely time efficient because most or all of the work is performed in a single setup with no delays while waiting for an operator to unload, reload, and reposition the part.

Jesse Norton, Director of Manufacturing and Senior Programmer has been programming with hyperMILL^® for seven years and in addition to echoing Chris Taylor’s praise for the hyperMILL for Solidworks integration he pointed out that with hyperMILL, he is able to simulate not only the part in his fixture, but the tool, the tool holder, the spindle and the entire machine envelope itself. “I can step through the tool path and watch it remove material and verify that it clears the machine and that there aren’t going to be any collisions. This is an invaluable time saver since I don’t have to walk out to the shop floor and manually look inside a machine with coolant flowing to check clearances.”

hyperMILL MAXX Machining – Super Fast and Efficient Tool Paths

“hyperMILL MAXX Machining creates extremely efficient roughing tool paths due to careful control of material removal and use of smooth trochoidal tool path motion where possible The hyperMILL MAXX Machining roughing module extends tool life by maintaining a constant chip load, never overloading the cutter or wearing out tools prematurely. It allows feedrates to be set for the best cutting conditions, rather than the typical process of setting feedrates for the most challenging cut, such as a corner condition. And, we can use hyperMILL MAXX Machining on materials from aluminum right up to hard materials like Inconel because our high-speed machines are fast enough to keep up with the rapid tool path motion that is generated. Bottom-line, using hyperMILL MAXX Machining results in super-efficient and fast tool paths.”

OPEN MIND Support – The Big Differentiator

Chris Taylor said that, “hyperMILL support is one of the things that really separates OPEN MIND from other CAM software vendors on the market.” Furthermore he adds: “OPEN MIND takes complete ownership of post processor development, and that’s a really big deal, especially with 5-axis machining where an accurate post becomes extremely critical in avoiding crashes. The machine does exactly what we simulate on the computer screen.” OPEN MIND postprocessors are developed as a core technology of the company, using internal experts. Postprocessors are customized and have configurable parameters to give the customer needed control for their particular environment.

“The combination of high quality tool paths and the advanced capabilities of the CAM software along with the post processor support, plus having a team of extremely skilled technical support people on hand when we program very complex parts give us the confidence to take on ever more challenging jobs. With OPEN MIND’s help we never burn money getting stuck on a job and their contribution has been a really big part of the growth of our business.

For Chris Taylor and Steve Grangetto, it is clear that hyperMILL is the right choice for their business. “hyperMILL, and our excellent working relationship with the OPEN MIND team has allowed us to make aggressive decisions that have helped us grow to where we are today!”

The latest version of OPEN MIND’s CAM/CAD suite hyperMILL^® will include a host of new optimisations, machining strategies and intuitive features that can further exploit the possibilities of modern CNC machines whilst enhancing ease of use. There are five outstanding highlights in the latest package that include new functions for 2D and 5axis machining. These features can considerably reduce programming times and enable efficient machining whilst numerous powerful extensions in hyperCAD^®-S, the CAD system for CAM users will deliver real added value.

The most important expansion in hyperMILL^® 2015.1 is a 5axis helical drilling strategy. This helical drilling cycle generates helical tool paths with the tool plunging into the material quickly. This eliminates the need for pre-drilling operations. By setting the milling tool inclination based on 5-axes, the user can benefit from efficient and tool-friendly machining with rapid swarf removal. Particularly suited to difficult to cut materials, this strategy improves cycle times and tool life considerably.

Internal process measuring

With internal process quality control becoming increasingly important, there are three new probing cycles featured in hyperMILL^® 2015.1. These include the measurement of rectangle and circle elements as well as measuring parallel to the axis. The touch probe is easy to program in all cycles, just like a tool in hyperMILL^®. Enabling users to choose between three measuring functions, the Informative Process Control, Active Process Control and Zero-Point Definition, OPEN MIND will drastically improve process reliability for customers. With the ‘Informative Process Control’ feature, it is possible to create measuring data for the individual component geometries and access it from the controller, a major plus for any machine shop.

The ‘Active Process Control’ feature allows probing cycles to be integrated into the machining process in order to actively control parameters. Deviations in dimensional accuracy can be processed in the controller for actual machining based on the off-set value. The new ‘Zero-Point Definition’ tool complements this exceptional benefit. This new addition makes it possible to quickly and reliably define the component zero-point, providing more precise and efficient machining. In addition to this, all movements are checked for collisions on both 3 and 5-axis machine tools.

CAD for CAM users

hyperCAD^®-S, the CAD element within the hyperMILL^® suite is also unveiling new innovations. Toolbars can be individually customised and the desired commands can be pasted into or deleted from the toolbars via a drag and drop facility. This enables the programmer to personalise the system for streamlined operation and programming times. Another new feature is the improved clipping plane. The clipping plane function is used to generate a planar section through a component. The selected clipping plane remains active within other functions, but does not affect the existing geometry of the component. This function makes it easier to analyse components whilst tool and tool paths remain unaffected

OPEN MIND Technologies AG has released hyperMILL® ShopViewer, a proprietary visualisation solution for the workshop. It provides machine operators with a complete overview of the upcoming NC program right through to simulation and ensures that only safe, checked NC programs run on the machine.

Although the digital process chain from design through NC programming already exists in many companies, there is often a break in the chain when it comes to the production environment. The actual programs are forwarded to the controller via the network, but the associated information is not normally transferred. The machine operator can usually only take advantage of static aids like drawings, tool reports, screenshots, PDFs etc. It is a different picture with a viewing system. Here, the system provides the specialist operating the machine with all of the information related to manufacturing data, as well as geometry and component structure. hyperMILL® ShopViewer makes it possible to view and examine data from hyperMILL® and hyperCAD®-S in more detail directly next to the machine. “The viewer typically allows the machine operator to view everything but not modify anything,” explains Wolfgang Weiss, product manager for CAD at OPEN MIND.

hyperMILL® ShopViewer was developed specifically to the requirements of hyperMILL® users. The information visible on the hyperMILL® ShopViewer workspace includes:

• 3D model with the ability to measure features
• CAM program
• 3D clamping plans
• Tool data

This way, the machine operator can simulate the actual manufacturing process and gain a better understanding of the milling process in the machine. The hyperMILL® operating concept allows users to work in their usual interface, which enables them to reach their goals quickly. “hyperMILL® ShopViewer features an uncluttered interface, where the user can only see what he or she needs at any given time,” says Wolfgang Weiss.

OPEN MIND, one of the world’s five leading manufacturers of CAM/CAD software, is set to present at IMTEX 2015. The trade fair for metal-cutting machine tools is the largest of its kind in South and Southeast Asia and will take place from 22 to 28 January 2015. OPEN MIND will use the event in Bangalore to showcase the 2014.2 version of its hyperMILL® suite. In addition to a key extension for solid modelling in hyperCAD®-S, the CAD part of the system, the software features efficient and tool-friendly machining strategies and improvements for CAM programmers.

When it comes to Z-level finishing, CAD systems usually simply follow the X and Y coordinates. If the bottom plane is curved, the milling result is not optimal and it is necessary to perform a number of rework machining steps. A new function for 3D shape Z-level finishing makes it possible to use hyperMILL® to reference curved bottom surfaces, after which the milling paths are aligned. As a result, the milling tool nestles optimally along the boundary edge between the bottom and the wall. All intermediate levels are offsets of the bottom plane.

3D rest material machining
The open and deep and steep and flat areas of cavities can be machined in one job with collision avoidance. hyperMILL® now automatically transfers the rest material areas that are recognised during the collision avoidance to the subsequent job. To this end, optimal tool selection and positioning once again take place. For example, a longer tool or a modified position.

CAD for CAM users
OPEN MIND specifically addresses the requirements of CAM users with hyperCAD®-S, the CAD part of the hyperMILL® suite. The highly intuitive and time-saving direct modelling process is a perfect example. It enables users to easily create and modify solid models. The hyperCAD®-S Solids module allows all solid models to be reliably imported, created, converted, modified and combined. New standard features in hyperCAD®-S, such as the possibility to create basic structures, linear extrusions, rotational solids, linear and rotation slots, pockets or holes, round out the new features in the CAD suite.

With the AMB show being the European launch platform for new products and innovations in September, the DMG Mori ‘Innovation Week’ was an opportunity for UK manufacturers to see first-hand, what the company and its technology partners had to offer.

Whilst DMG Mori introduced a number of new machine tools to a hungry audience, its technology partners such as Sandvik, Hexagon, Micron Workholding and OPEN MIND Technologies all had new developments of their own. For OPEN MIND, the focus was on the new hyperCAD-S platform and new 5-axis machining strategies incorporated into the latest version of hyperMILL 2014.2.

With the event having a specific industry focus on each of the five days, OPEN MIND used the ‘Innovation in Aerospace’ day to introduce the new features built into hyperMILL and hyperCAD-S. From a practical standpoint, this took shape in a live on-machine demo of an aircraft undercarriage component being machined on a DMG NTX2000 mill/turn centre. The demo part highlighted OPEN MIND’s new features that further improve HSM, 5-axis strategies and power-cutting to maximise stock removal.

This on-machine demo was accompanied by a technical presentation by OPEN MIND UK’s Sales Director, Mr Ken Baldwin. The 30 minute presentation to a packed seminar theatre of enthusiastic engineers encompassed an overview of OPEN MIND’s new Direct Modelling feature that sits within hyperCAD-S. This exciting new innovation provides programmers a ‘just do it’ approach to design with a modelling strategy that gives end users the power to quickly define and capture a geometry.

In real terms, it allows a programmer/designer to focus on creating a geometry rather than building features, constraints and design intent into models, which is the historical working method with the widely used Parametric Modelling strategy used by alternate CAD vendors. By adopting hyperCAD-S and its Direct Modelling strategy as opposed to the industry accepted Parametric Modelling, end users can eliminate the time-old process of anticipating and defining feature constraints, relations and dependencies to ensure that any design modification will update all related downstream geometries in a predefined way. With engineers keenly nodding in acceptance of this new methodology, Mr Baldwin highlighted the benefits by showing a Parametric model that was created in 7minutes 31seconds then being created in 4minutes and 46seconds with hyperCAD-S – a time saving of 36%.

As well as demonstrating the practical and theoretical benefits of hyperCAD-S, the technical presentation also highlighted how a new geometric kernel, new database, graphics and user interface with touch support plus a new API for internal and external developers within hyperCAD-S can benefit the end user.

On top of presenting the benefits of hyperCAD-S, another prominent aspect was the utilisation of 5-axis machining strategies within 2D & 3-axis applications to improve productivity on the shop floor. One example of this was the new 5-axis pocket strategy in hyperMILL. The unique 5X immersion method has been proven to reduce axial forces and loads on the cutting tool and spindle whilst permitting increased step-overs for significant gains in productivity.

With DMG Mori’s prestigious aerospace customer base in attendance, OPEN MIND hit a key chord with many of its new developments. Focusing upon delivering shorter programming times, faster processing time, longer tool life and better surface quality, the OPEN MIND presentation and on-machine demos combined to impress the attendees of this event.