Contourparallel clearing movements using the 39standard pocket39 machining mode

“Adaptive Pockets” and Five-Axis Timesavers

Aug. 15, 2012
Time-saving five-axis programming Optimized 3D roughing Collision avoidance

The highlighted detail for OPEN Mind Technologies AG’s updated hyperMILL CAM software is the “adaptive pocket” machining mode for rectangular shapes, but users also will benefit from improvements to standard functions, calculation times, and programming times, as well as new strategies for machining high-value parts. The new release will debut at IMTS.

In a machining job, classification occurs automatically in closed and open pockets and rectangular levels. “Adaptive pocket” machining is hyperMILL’s new mode for automatic programming of rectangular pockets.

According to the various accessibility conditions for the tool and relative sizes of the tool and pocket, hyperMILL automatically selects the most suitable machining method: spiral, contour-parallel or peeling. The optimized clearing movements take place in long, straight paths with constant cutting conditions. Critical, full-cutting areas are parameterized separately, so operators can control over feedrate values and reduce production times.

To shorten production time during five-axis shape offset machining, hyperMILL, users can avoid redundant movements thanks to the new axial sorting option that makes it possible to divide machining by area. This allows corners or pockets, for example, to be machined individually and in sequence. Users can decide whether to create toolpaths with offset level sorting or axial sorting.

For roughing specific high-value components there are several new five-axis programming features. For machining of impellers, for example, it is possible to divide the machining region into a left and right pocket between the main blade and the splitter. This option means that these areas can now be machined with different tools in a targeted manner.

The flank mode during roughing allows swarf cutting near blade surfaces. The user can decide whether to use the swarf mode for every step or just for the last step. This extension results in a consistent stock allowance for finishing. Production time can also be reduced here as preliminary finishing can be skipped.

Tapered tools for 3D ISO machining, including automatic collision avoidance, are supported by hyperMILL 2012. In the process, the entire tool is checked for collisions against the model, thereby ensuring process reliability. Tapered tools offer more stability, reduce tool vibrations, and improve surfaces simultaneously.

For turning operations, hyperMILL functionality has been extended to include inclined grooving, so offset tools now can be used, and the tool database has been expanded to include these recessing tools.

Finally, pocket milling has been improved in the 3D roughing area. As a result, for the machining of pockets, the ramp is moved continuously in one direction. Then, the pocket is cleared from the outside in, and thanks to this continuous inward movement of the ramp, the tool path is optimized and zig-zag movements are avoided.

About the Author

Robert Brooks | Content Director

Robert Brooks has been a business-to-business reporter, writer, editor, and columnist for more than 20 years, specializing in the primary metal and basic manufacturing industries. His work has covered a wide range of topics, including process technology, resource development, material selection, product design, workforce development, and industrial market strategies, among others. Currently, he specializes in subjects related to metal component and product design, development, and manufacturing — including castings, forgings, machined parts, and fabrications.

Brooks is a graduate of Kenyon College (B.A. English, Political Science) and Emory University (M.A. English.)

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