Increasing CAM Functionality and Virtual Machining Simulation

Advanced, comprehensive hyperMILL® 2018.1 CAM software from OPEN MIND Technologies USA, Inc. (Needham, MA) includes greater blending capabilities, 3D-optimized roughing, global fitting, rotational abilities for CAD electrode applications and – totally new to the industry – virtual machining simulation. New hyperMILL 2018.1 functionality includes an enhancement to the “soft overlap” feature for blending machining marks found between steep and flat areas, or located at the boundaries of rest machining regions. Using this enhanced feature, the milling tool is briefly lifted to blend milling paths into another, preventing visible transitions from being generated, resulting in better surface quality. The 3D-optimized roughing cycle has been enhanced for applications with high feed cutters. The step-over distance can be calculated from the scallop height measured against the high feed cutter geometry. A special tool path movement removes rest material from corners when there is a very large step-over. Intelligent cut division and optimized toolpaths provide greater process safety for the remaining thin ridges.

A “global fitting” feature can simplify the definition of complex surfaces or patches of surfaces. Many hyperMILL CAM strategies will recognize and follow the ISO u-v orientation of the surface patch. hyperMILL MAXX Machining finishing is one technique that benefits from having a simplified surface definition. hyperCAD®-S Electrode automates the construction and manufacturing of electrodes for die-sinking. Users can simply choose their electrodes from the face to be die-sunk within the component geometry, with no special expertise required. To save users time during milling and eroding, hyperCAD-S in hyperMILL 2018.1 includes an easy-to-use “rotational electrode” feature that facilitates the circular placement of multiple electrode geometries with different spark gaps on a holder.

Developed with Industry 4.0 in mind, an early release of hyperMILL VIRTUAL Machining simulation is available in version 2018.1 that enables constant real time bi-directional communication between the machine tool controller and a remote VIRTUAL Machining simulation, significantly improving manufacturing workflow. Machining operations can be reliably evaluated, checked and optimized before running a job by using process networking and virtual mapping found in VIRTUAL Machining. The NC Optimizer can enhance computed NC instructions to optimize available workspace, manage limited axes and select the best approach for asymmetric machine heads. Safety, reliability, speed and process control optimization from CAD/CAM to machine are all improved with VIRTUAL Machining.

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To meet the needs of the evolving digital manufacturing initiative, OPEN MIND Technologies has partnered with TNC controls from Heidenhain Corporation (Schaumburg, IL) to provide exclusive first use of this new NC code-based VIRTUAL Machining in hyperMILL 2018.1. The CONNECTED Machining module allows networked TNC controls to be run from remote locations, a key component for digital production systems. “We are thrilled to begin roll-out of this unique new virtual machining feature in conjunction with the powerful TNC 640 control,” said Alan Levine, the managing director of OPEN MIND North America. “Our bi-directional virtual software allows the user to start or stop the machine tool, review or override some settings, run simulations, synchronize the machine simulation to the actual machine position and modify the Heidenhain control from anywhere our software is networked. This promises to increase machining efficiency by optimizing machining productions, and reduces the chance of errors while connecting a CAM programming environment with the shop floor machining world.”

The workshop-oriented TNC 640 mill-turn contouring control is well known for HSC and 5-axis machining on machines with up to 18 axes. Guiding basic to advanced machining, the TNC 640 pairs well with this virtual software by connecting with DNC software and TNC Remo SDK options. “They have a well-engineered control and its programming interface was a perfect match with our system,” added Levine. “We are excited to begin implementation at some end users and help expand their virtual manufacturing networks.” Three new system modules of hyperMILL VIRTUAL Machining – the Center, Optimizer and CONNECTED Machining – help to decisively step up communication between the hyperMILL CAM suite and the machine tools. “Our partnership with them is a good fit,” noted Gisbert Ledvon, the TNC business development manager at Heidenhain. “We are happy to continue meeting users’ needs with this advanced machining technology. This new functionality shows how our flexible TNC control is helping shops take the next step in digital manufacturing utilizing 5-Axis technology.”

OPEN MIND Technologies USA, Inc., 1492 Highland Avenue, Unit 3, Needham MA 02492, 339-225-4557, Fax: 270-912-5822, alan.levine@openmind-tech.com, www.openmind-tech.com.

Heidenhain Corporation, 333 East State Parkway, Schaumburg, IL 60173, 847-884-4761, jrenz@heidenhain.com, www.heidenhain.us.