New hyperMILL Modules for Tool and Mould Making

1 March 2012

The new integrated hyperCAD®/hyperMILL® system now supports tool- and mould-makers every step of the way, from importing item data to NC program post-processing. The current version of hyperMILL® 2011 now includes several useful and high-performance functions for this industry sector.

OPEN MIND Technologies has developed machining strategies for its hyperMILL® CAM system that are now ideal for the tool and mould making industry. 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 the company's 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 of hyperMILL 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 and workholding fixtures. 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 the new 5-axis 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 & steep walls, hyperMILL® provides 5-axis strategies that enable reliable machining with short tool lengths in these areas. Proven 3D strategies such as Z-level finishing, profile finishing, equi-distant finishing or rest machining have been updated with 5-axis 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 the tool and mould making sector. 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 definition, 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 that is defined for specific milling areas and this is now also available for rest machining.

Last but not least, hyperMILL® 2011 has enhanced its automatic 5-axis approach and retract macros. Within the 5-axis cycles, the approach and retract paths use 5-axis simultaneous motion. This allows all of the axes of the machine to already be moving when the cutter approaches the part. It also 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 5-axis approach and retract strategies ensure greater quality and less programming time.