New Functionality for NC Programming Efficiency

OPEN MIND Technologies, a developer of CAD/CAM software will be highlighting the latest iteration of its programming suite – hyperMILL® 2024 CAD/CAM software suite at IMTS 2024, Booth 133351. The recently introduced version of the program includes a range of enhancements to its core toolpath capabilities, as well as new functionality for increased NC programming efficiency in applications ranging from 2.5D machining to five-axis milling.

New / enhanced CAM

Among the many new capabilities in hyperMILL® 2024 is an Optimized Deep Hole Drilling CAM strategy that improves machining reliability by providing a user-friendly interface with process-relevant parameters clearly defined on a new process tab. The new capabilities allow coolant and dwell time stages to be identified, allow a chip break to be integrated into a drilling process, and more. A single-tip gun drill tool simulation function provides precise collision checking and a detailed visualization of the stock removal.

A new algorithm for three-axis and five-axis Rest Machining ensures automatic, complete detection of all rest material areas, in addition to optimized toolpath calculations for faster, reliable machining. Toolpaths are now optimally divided to ensure more efficient machining, and detection of intersection areas where paths meet has been optimized for collision avoidance.

A further toolpath improvement is an enhanced path layout for the 3D Plane Machining cycle, with a smoother path and fewer pick-ups. While the toolpath length (distance) may be longer in some cases, the machining time, as tested on a variety of NC controllers, has been reduced.

OPEN MIND is introducing a novel generation of programming assistance and analysis called “CAM Plan” in hyperMILL® 2024, simplifying various programming tasks and identifying possible sources of error. Predefined workflow steps safely guide users through the preparation and programming process, while the geometries and features required are automatically created. Also, potential errors are flagged for removal such as double surfaces or gaps between model patches.

Once the data is organized, the CAM workflow can be processed with more intelligence and higher efficiency. The first benefit from hyperMILL® CAM Plan is that component topology is analyzed to produce a precise toolpath that has command locations aligned with key geometric features and with optimized point distribution for milling. The result is improved surface finishes, easier processing by NC controllers, and reduced machining times.

Optimizing virtual machining

For easy generation of three-axis and five-axis NC programs with axis change and an optimized use of the workspace, the NC Optimizer feature in the hyperMILL® VIRTUAL Machining strategy offers the option to transform X- and Y-axis movements into a movement that uses the rotation axis in the table. By swapping axes, an XY movement is transformed into a simultaneous CX movement that eliminates rewind movements during machining.  This is especially impactful on machines that have a limited linear axis range.

Reading back of measuring points when using hyperMILL® VIRTUAL Machining is a new feature that allows graphical representation of measured points on the part model, rather than comparing a list of measurement results. Also, users can quickly identify measuring points that are out of tolerance on a 3D part model and compare trends over sequential measurements. As a result, it is easier to analyze and compensate for inaccuracies and tool wear after milling.

In addition to the CAD/CAM developments to be demonstrated at IMTS 2024, OPEN MIND’s additive manufacturing product manager David Bourdages, together with Oak Ridge National Laboratory researcher, will make a presentation – HEAL-IT: Hybrid-Manufacturing Enabled Agility and Longevity of Industrial Tools – focusing on a recent collaboration to repair a bottle mold using hybrid manufacturing, i.e., additive manufacturing in coordination with subtractive machining. That presentation will take place on Wednesday, September 11, at 11:00 a.m.

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