CAM software: hyperMILL Version 2014

Version
What’s new 2014?
Contents
hyperMILL® ShopViewer
More transparency, fewer errors.
6
CAM – 3D strategies
13
3D arbitrary stock roughing:
Slot boundary
13
Highlight
General information
8
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hyperMILL quick-start
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Start-up button
8
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hyperMILL settings:
Lock/unlock model
Highlight
8
Linking toolpath and associated job
Highlight
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view manager for hyperMILL browser
8
9
The tool database has been revised
9
Tool status
10
Tool comparison
10
Displaying the calculated tool length
10
Highlight new tool types
11
Context menu for toolpaths
11
Copying technology data sets
11
CAM – 2D strategies
12
Adaptive pocket ‘circular pocket’
12
2
13
Highlight automatic 3D rest machining:
Secure and improved complete machining
for roughing
14
Soft bounding concept for profile finishing
14
Additional guiding mechanism
for equidistant finishing
14
9
Unfolding of compound and linking jobs
Highlight
3D point measurement
HPC toolpaths with hyperMAXX
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15
CAM – 5axis machining
16
5axis tangential machining
16
5axis shape offset roughing
16
New return macro
for the 5axis shape offset finishing
16
Highlight New features
in the 5axis rework
16
System requirements: Windows 7 (64 bit), DVD capable drive
CAD integrations: hyperCAD , hyperCAD -S, Autodesk Inventor , SOLIDWORKS
Software languages: de, en, es, fr, it, nl, cs, pl, ru, sl, pt-br, ja, ko, zh-cn, zh-tw
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Special applications
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Single blade machining
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17
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Feature and macro technology
18
New functionality in the macro database
18
Selection by filter or selction scripts
18
User-defined variables
18
Fit hole to stock model
18
Feature recognition
18
Additional basic types
for ‘generic hole’ feature
18
CAD integrations
20
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Integration with Autodesk Inventor
and SOLIDWORKS
20
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21
hyperCAD -S module deformation
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22
Placing text labels
24
Chamfer generation
24
Search function in the model tree
24
Restore selection
24
Structuring group elements
25
3D dimensions
25
Copying attributes
25
Picking up visibility filters
25
hyperCAD -S:
CAD Innovation for CAM programmers
Post-processors and simulation
19
Rapid display of group elements
26
Machine simulation
19
Changing line/arc/circle
26
Intro and final text
19
Export views
26
Elements in the toolpath
26
Parallel line tangentially to arc/circle
26
Interfaces
19
Floating widgets
27
Zoller integration
19
Tool tip
27
Coordinates
27
Restricted surface
27
Drilling cycles
20
Drilling in workplanes
20
Optimised deep hole drilling
20
Highlight
3
What’s new?
20 years OPEN MIND - that is 20 years of innovation
and customer orientation. The latest version
®
of hyperMILL demonstrates this once again: with
basic functions that are even more powerful.
With NC programming that has become much easier
and safer. With extended feature technology that
automates programming tasks more efficiently.
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hyperMILL 2014 means technology leadership
with real added value!
Dr Josef Koch,
CTO at OPEN MIND Technologies AG
Puzzle-ball
on YouTube
5
Kapitel
hyper
MILL® ShopViewer
Highlight
More transparency, fewer errors:
Review CAM/CAD data prior to production
Until now, for setup preparation only the NC programs were available to machine operators. With the
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new hyperMILL ShopViewer, the visualization solution for the workshop, the hyperCAD -S and hyperMILL
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data can be visualised directly next to the machine. Now every manufacturing operation can be checked in
detail on the monitor even before the setup begins.
The clearly structured world of CAM programming has a far better connection to the workshop with the
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hyperMILL ShopViewer. In this way, the machine operators with their vast knowledge about production
practices can independently view and simulate CAM/CAD processes. This allows a far better understanding
of the actual manufacturing process than before.
Benefit: Improves communication between departments. Feedback is improved. Safety is significantly
increased.
Simple and fast display, analysing
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Usage area: The hyperMILL
ShopViewer is designed for
quick access in the manufacturing environment in the postCAM programming phase.
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Familiar operating concept: Thanks
to the hyperMILL operating concept,
the user can work in his usual interface. The operation is intuitive, and
the hyperMILL ShopViewer is thus
quick to use.
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Target group: Machine operators
can apply their in-depth manufacturing know-how with the hyperMILL
ShopViewer. Serious mistakes, such
as wrong tool choice or unproductive
processes, can be avoided.
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6
NOTE: The ShopViewer is currently available for hyperCAD -S.
hyperMILL® ShopViewer
Kapitel
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Improved communication:
Detailed information about
hyperMILL jobs are immediately and consistently available for all parties involved in
the manufacturing process.
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Faster access: The hyperMILL
ShopViewer allows quick
access to the complete
manufacturing data, as
well as geometry and
component structure.
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Verifying details: Display of
all elements and parameters
(geometry, features and toolpaths) as in hyperMILL . With
a few clicks, the operator can
measure and check the toolpaths
on the machine for example.
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Simulating manufacturing processes:
The traceability of NC programs is
noticeably improved through the
toolpath simulation, the material
removal simulation and the internal
machine simulation. The manufacturing processes with the corresponding
clamping status can be safely simulated starting with the stockmodel.
Increased process reliability:
Experienced machine operators
can detect possible errors in time
before the start of manufacturing
using virtual process analyses.
and documenting of the prepared CAM/CAD data
7
General information
hyperMILL® quick-start
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Only for hyperCAD -S
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With the ‘Automatic hyperMILL Start’ option in hyperCAD -S,
hyperMILL can now be started from a preset value in the preferences menus.
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Benefit: Start programming even faster and more efficiently.
Start-up button
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Users can start even faster with hyperMILL 2014 as there is a new
start-up button in the ‘Add-Ins’ menu. This menu window allows
the quick and easy setting of all necessary start-up settings, such
as NCS, frame and raw material definitions. When programming a
new model, these are then automatically executed.
Benefit: Start programming even faster and in a more userfriendly way.
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hyperMILL® settings: Lock/unlock model
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Only for hyperCAD -S
This function can lock CAM/CAD elements (geometry and attributes) to protect them from deleting or editing. The elements can no
longer be accidentally changed during programming.
Benefit: More safety.
Linking toolpath and associated job
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Only for hyperCAD -S
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The hyperMILL integration in hyperCAD -S offers a very close
link between the toolpath and the hyperMILL job. By hovering
over the toolpath the following toolpath information can be
seen: hyperMILL toolpath -job: [job name]. By double-clicking
on the toolpath the assigned job can now be opened directly.
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Benefit: Faster with increased user friendliness
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General information
Highlight
View manager for hyperMILL® browser
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The hyperMILL browser now has a view manager to control/
move the browser window (for sample frame, job list, etc.). The
windows can be detached from the browser tabs and individually arranged or hidden and displayed via the context menu. The
window elements can be simply moved between the hyperMILL
browser windows via drag and drop.
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Benefit: Individual arranging of browser windows (even on
second monitors).
Unfolding of compound and linking jobs
There are four new options for faster unfolding of the job structure tree.
Benefit: Increased user friendliness.
The tool database has been revised
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In hyperMILL 2014, the user interface has closer alignment
between the tool list in hyperMILL and the external tool database. In addition, a new tool management concept has been
introduced. Secure, intuitive work and improved clarity of tool
management thanks to synchronisation between document
database and external database. A fixed connection of imported tools with the external database ensures that tool data is
always up to date. In the hyperMILL browser ‘tools’ tab there
are separate groupings for milling cutters, drills, and turning
tools. Thanks to this, the tool types are more easily managed.
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Benefit: Easier, more transparent and user-friendly
tool management.
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General information
Tool status
Now milling, drilling or turning tools can be linked to the tool
database. The tool database is a central location to safely store
and quickly access tool information.
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In the hyperMILL browser tab ‘tools’ a new column to display
the tool status has been added. In this way, the tools can be
compared quickly and easily with tools in the database.
Benefit: More safety. Increased user friendliness.
Tool comparison
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Tools that are used in hyperMILL can be compared with the
associated tool from the tool database.
Benefit: Better overview and easier assembly of tools.
Displaying the calculated tool length
If the reduce or extend options are selected in the ‘settings’ tab,
a tool length is suggested to override the provisional cutter dimension. If the tool is used in multiple jobs, hyperMILL shows
the recommended minimum or maximum length for the tool
over each job.
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Benefit: More safety. More efficient.
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General information
Highlight
New tool types
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The following new types of tools can be used in hyperMILL :
– Reamer
– Lens cutter
– Measuring probe
(only applies for the cycle 3D point measuring).
– Barrel cutters in diverse design forms:
- General barrel cutter
- Tapered barrel cutter
- Tangential barrel cutter
Benefit: More flexibility. Better mapping of existing tools.
Context menu for toolpaths
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Only for hyperCAD -S
Display and settings of toolpaths can be controlled centrally in
the hyperCAD -S graphics window. To this end, the toolpath is
marked per right-click with the mouse. Using the context menu,
you can open the job dialogue, and now show only G0 motions
or only G1 motions, in addition to all previously available options. Also, both the internal simulation as well as the internal
machine simulation can be started for the toolpath.
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Benefit: Increased user friendliness.
Copying technology data sets
Already created, complete data sets for technology tools and
inserts can now be very easily copied to a new tool or to already
existing, selected tools. If technology data is being inserted that
already exists, a confirmation prompt is shown.
Benefit: Time saving. Reuse of know-how.
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CAM – 2D strategies
Adaptive pocket ‘circular pocket’
When applying the pocket milling cycle, the option ‘adaptive
pocket’ is now available also for circular pockets. There are
processing strategies for open and closed circular pockets with
and without islands.
Benefit: More flexibility. More efficient.
12
CAM – 3D strategies
3D arbitrary stock roughing
Slot boundary
In this cycle, the processing can now be limited to corners and
slots with individually defined groove depth. Unnecessary toolpaths for roughing are avoided.
Benefit: Optimised toolpaths and reduced calculation times.
Highlight
3D point measuring
The in-process quality control on the CNC machine tool is
becoming increasingly important. Therefore, with the new 3D
point measuring cycle any 3D points can be easily defined on
component surfaces that are to be measured later with a probe.
The cycle ensures that an NC program is generated with controlspecific subroutine calls for measuring. In addition, all movements are checked for collisions. By starting the NC measuring
program, the machine records the measurement results that can
be evaluated later with a separate program.
Note: The 3D point measuring cycle requires an adapted postprocessor.
Benefit: Accelerated quality assurance process to detect the
surface accuracy of the machined surface.
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CAM – 3D strategies
Highlight
Automatic 3D rest machining
Safe and improved complete machining
when roughing
This improvement allows the automatic detection of rest material areas where additional roughing is necessary. Additional
roughing passes are then calculated for these areas.
Through the clip function, only the collision-free areas are considered on the machining model. Any existing collision-prone
areas are always clearly indicated and can be processed in a
further machining job using a different tool, a different strategy
or a different tool orientation.
Benefit: Reliable, flexible and optimised milling path calculation. Lower machine run time.
Soft bounding concept for profile finishing
When using ball mills, the machining of milling surfaces can be
controlled with the help of adjacent geometries and by defining
an overlap factor (soft bounding), so that the milling surfaces
are machined completely, i.e. without interruptions.
Benefit: Greater process safety. Optimised surface quality.
Additional guiding mechanism
for equidistant finishing
For precise machining of steep areas, drive surfaces can also be
selected in the ‘flow’ infeed strategy, in addition to the profile
curves. The defined profile curves must lie on the selected drive
surfaces.
Benefit: More flexibility. Simplifies handling of rounded surfaces
that cannot be machined with the ISO strategy.
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Info: hyperMAXX®
HPC toolpaths with hyperMAXX® –
maxximal results
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hyperMAXX is the High Performance Cutting Strategy (HPC) for hyperMILL . The strategy is
based on VoluMill™, a proven best-in-class HPC technology from Celeritive Technologies, and
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on highly efficient special developments from OPEN MIND. The result: hyperMAXX is one of the
most extensive and most powerful HPC packages for generating trochoidal-like toolpaths.
Using this strategy, it is very easy to generate ideally distributed 2D, 3D and 5axis HPC paths.
This way, CAM programmers can always maximise machine performance.
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‘Learning to work in hyperMAXX did not take long, less than
an hour in fact. Our tool life has improved by 500 per cent
with respect to our components. This is why we believe in doing
everything with hyperMAXX . It‘s the best way forward!’
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Roland Mascke, CNC programmer
at Werkzeugbau Gebr. Kemmerich GmbH & Co. KG
15
CAM – 5axis machining
5axis tangential machining
For the 5axis tangential machining there are new types of tools:
the tapered and the tangential barrel cutters.
Benefit: More flexibility when finishing surfaces that cannot be
manufactured with swarf cutting.
5axis shape offset roughing
The calculated toolpath can be trimmed against a stock model.
A resulting stock model can also be calculated and used with
further machining.
Benefit: Reduces the number of air cuts. Optimised offset for
finishing.
New return macro
for the 5axis shape offset finishing
The new macro type ensures minimal linking movements
between the infeed planes for machining in zigzag mode.
Benefit: Time saving
Highlight
New features in the 5axis rework
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Can also be used for hyperMAXX
When converting from 3axis toolpaths to 5axis toolpaths,
different types of tool types - barrel and woodruff cutters can
be used. With new strategies, the tool can be adjusted to the
machining model. For this purpose, axial or lateral projections
can be selected. For the conversion of the reference data for the
new machining tool, the original and the new technology data is
always available.
Benefit: Can be used for all supported tool types and in all
operations. Undercut machining is possible. More options when
projecting reference toolpaths.
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Special applications
Highlight
Single-blade milling
Feature for automatic single-blade milling
The user interface of the ‘single blade’ application has been
improved and simplified. The proven method for the selection
of the geometry and to automate the machining of impellers
and blisks is now also available for the machining of blades.
In hyperMILL 2014, the geometry selection is carried out
centrally via a specially designed feature.
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Thanks to the full feature support for the turbine blade cycles,
new possibilities open up for the automation of the CAM process: Improved user guidance in defining the machining strategy in the platform machining cycle allows targeted machining
of hub or shroud surfaces through simple switching in the user
interface. These are available at all times without re-selection
thanks to the central management of all geometry data in one
feature. The blade point milling cycle has been extended by
the ‘complete machining’ function that offers an easy way of
finishing the entire blade surface by means of a ball mill.
The new option ‘optimised tolerances’ calculates toolpaths with
greater accuracy. This ensures increased accuracy without the
need to generate an excessive number of points, as would be
the case with a simple reduction of the machining tolerance.
This results in smoother running of the machine and consequently, improved surface quality.
New tool types
Barrel and lens cutters can now also be used.
Benefit: Faster and more user-friendly. Improved
surface quality.
17
Feature and macro technology
New functionality in the macro database
With the new option ‘DB + auto+’ further options for the tool use
open up: When using a macro, the tool diameter required is read
automatically from the feature and the required tool is searched
from the database. User variables and formulas can now be used
for the rule definition. With these formulas user variables can be
assigned to a rule.
Benefit: Reduced number of macros. Flexible applications.
Easier to maintain. Clearer.
Selection by filter or selection scripts
Easy choice of geometries by layer and/or colour selection.
Benefit: Increased user friendliness.
User-defined variables
User-defined variables can now be loaded and saved
in hyperMILL .
Benefit: Creating environment variables in a more efficient way.
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Fit hole to stock model
The value defined for the model tolerance can now be saved as
a default value.
Benefit: Increased user friendliness.
Feature recognition
Faster creation of hole features by selecting a reference feature
and the associated parameters.
Benefit: More flexibility.
New basic types for ‘generic hole’ feature
Two new options ‘Torus’ and ‘Undercut’ have been added to the
feature ‘generic hole’.
Benefit: New applications of generic holes when applying
feature mapping.
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Post-processors and simulation
Machine simulation
Machine models for machines with parallel axes can be built in
hyperMILL 2014. The parallel axes can be simulated.
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Benefit: Secure simulation of complex machines.
Intro and final text
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In hyperMILL 2014, the creation of intro and final text with
additional information on NC programs that are available after
the PP-run is possible.
Benefit: More flexibility.
Interfaces
Zoller integration
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The Zoller integration in hyperMILL enables fast data exchange
with the Zoller tool management system. To enable the interface, the user must select the ‘Zoller TMS hyperMILL ’ function.
Subsequently tools from hyperMILL can be exported to the
Zoller system, or tools can be imported from the Zoller system
into hyperMILL .
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Benefit: Increased user friendliness. Error prevention.
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Drilling cycles
Highlight
Drilling in work planes
With this extension of the 5axis drilling, extremely efficient drilling on highly dynamic and non-highly dynamic 5axis machines
is possible. The new drilling mode allows the definition of the
direction of drilling using workplanes. For different workplanes,
relative clearance planes are used according to user specifications and global clearance planes are no longer used.
The retraction movements are always calculated so that a safe
move in the Z-direction is possible. Infeed movements in XY
direction are performed on a relative clearance plane, automatically calculated for each frame. All holes of a clearance plane
form a work step. The work steps can then be processed either
in an entire NC program or in several individual NC programs.
Benefit: Easier. Safer. Can be used for all machines.
Optimised deep hole drilling
When performing optimised deep hole drilling, the spindle
speed can now be set to 0 or assigned negative values to allow
counter-clockwise rotation. The dwell time parameter can be
used to define the time during which the drill dwells on the drill
floor for free cutting of material. A new feedrate ramp has been
defined for certain sections.
Benefit: Allows merging with stationary spindle and retraction
of the drill with reverse spindle orientation.
CAD integrations
Integration with Autodesk® Inventor®
and SOLIDWORKS
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hyperMILL 2014 supports Autodesk Inventor and
SOLIDWORKS in the current version.
Benefit: Perfect data associativity and CAM integration at the
user interface of your chosen CAD solution.
20
Info: hyperCAD®-S
CAD Innovation for CAM programmers
Every CAM programmer is familiar with the standard CAD tasks such as: Selecting, inserting, deleting, modifying,
showing and hiding points, curves and faces. Users expect top-quality results from the ruled, filling and
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offset faces. hyperCAD -S is able to meet these standards. OPEN MIND took extra care when developing the
CAD innovation to adapt the CAD functions to meet the specific needs of CAM programmers.
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The powerful hyperCAD -S delivers everything a CAM programmer wants and needs today. OPEN MIND,
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known as a pioneer in 5axis CAM machining, has also taken a new approach with hyperCAD -S as it seeks
to deliver the best possible product to its customers.
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64-bit multi-application
■ Top
performance
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Optimal ergonomics
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Highly intuitive
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Optimal hardware utilisation
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CAD integrations
Highlight
hyperCAD -S module ‘Deformation’:
Targeted deforming of geometries
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Targeted deformation of geometries is an important requirement that designers and CAM
programmers pose to CAD systems. Designers want to deform geometries, to produce variants
and complex geometries very quickly. Experienced CAM programmers change geometries in order to
accommodate for tool or part deflections and increase the precision of the actual part.
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In hyperCAD -S, the user has the possibility to deform all geometries according to his concepts with
the new ‘deformation’ module. Through this powerful modification tool, global and local component
areas can be altered in a way which would be very costly with traditional modelling techniques.
Benefit: More flexibility and greater time savings.
Fast and simple
Deforming elements
Faster to the desired end geometry!
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Volumetric deforming
Volumetric deforming
Application areas
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Volumetric deforming: Starting
from an initial surface, the selected
elements (surfaces, curves, points,
point cloud and network) are deformed
volumetrically to a target surface.
Compensating for manufacturing variations:
Application of manufacturing variations to produce precision parts.
Before
After
Creating complex
geometries: Projectinging a 2D logo to a 3D
geometry by volumetric
deformation.
Volumetric deforming
of a tire mould
Deforming elements:
Starting from start
contours or points, the
selected elements such as
surfaces, curves, points,
point cloud and network
(green) are deformed
to target contours or
points (red). Sections
can also be fixed here.
CAD integrations
Placing text labels
®
In hyperCAD -S, single or multi-line text can now be inserted at
a specific position. The text is formatted in a bounding box (for
example in bold, italic, underlined, justified, left/right aligned,
centred, text at the top/middle/bottom).
A link between a text and an element can be established with
the text label. The element variables present in the text are thus
used automatically.
Benefit: Time saving. Error prevention.
Chamfer generation
Fast creation of chamfers between two surfaces.
Benefit: More flexibility.
Search function in the model tree
In the model tree, users can find the items much faster with the
new and extensive search function. The search also evaluates
regular expressions.
Benefit: Increased user friendliness.
Restore selection
Each command saves the selection of elements and options
when leaving or applying the command. Thus, the previous situation can be restored quickly if you rerun the command.
Benefit: Increased user friendliness.
24
CAD integrations
Structuring group elements
Elements can be combined in a freely definable group, assigned
to a group or moved to an existing group.
Benefit: Increased user friendliness.
3D dimensions
3D dimensions of distance, angle, diameter, radius and length
can be inserted into hyperCAD -S. Various properties are
available for the dimensioning, which can be clearly arranged
and freely defined via the ‘dimension properties’ dialogue. The
dimensions can be edited and moved later.
®
Benefit: Immediate detection of dimensions. Reader-friendly,
aligned text.
Copy attributes
The layer and material properties of selected (reference) elements can be transferred very easily with this functionality to
other (target) elements.
Benefit: Increased user friendliness.
Before
Picking up visibility filters
Using a pipette in the visibility filter, the layer and material can
be picked up directly from several elements in the graphics area
in order to hide or display them.
Benefit: Increased user friendliness.
After
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CAD integrations
Rapid display of group elements
Group elements can now be displayed more effectively. In the
model tree, all hidden parents or children of an element or
group can be displayed.
Benefit: Increased user friendliness.
Changing line/arc/circle
With a simple double-click on an element, values such as
length, angle and radius of the elements line, arc and circle can
be easily edited using the new floating widgets.
Benefit: Increased user friendliness.
Export views
The current view can now be easily and quickly exported via the
‘print file’ and ‘image export’ functions.
Benefit: Increased user friendliness.
Elements in the toolpath
Besides splines, also lines, arcs and spirals are now represented as toolpath elements, in order to obtain an exact representation.
Benefit: Increased user friendliness and more performance.
Parallel line tangential to arc/circle
With the new option ‘tangential snap closed’, a line can now be
constructed using the ‘parallel line’ function that runs tangentially to the capture of an element.
Benefit: Increased user friendliness.
26
CAD integrations
Floating widgets
A double-click on editable CAD elements shows the so-called
mini dialog boxes. These allow a more convenient editing of the
element properties.
Benefit: Increased user friendliness.
Tool tip
The tooltip displays properties of an element at the current
cursor position. Now also RGB values, job used, locked item,
command-specific information and custom properties are
displayed.
Benefit: Increased user friendliness.
Coordinates
With the new coordinate dimensioning, labels with XYZ values
can be attached to a 3D text, based on a selected workplane
and its zero point.
Benefit: Immediate detection of dimensions. Reader-friendly,
aligned text.
Restricted surface
The ‘limited surface’ function supports inner curves (islands) in
the perimeter boundaries and trims these areas automatically
from the surfaces.
Benefit: Time saving.
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OPEN MIND Technologies AG
Argelsrieder Feld 5 • 82234 Wessling • Germany
Phone: +49 8153 933-500
E-mail: Info.Europe@openmind-tech.com
Support.Europe@openmind-tech.com
UK
OPEN MIND Technologies UK Ltd.
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Phone: +44 1869 290003
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USA
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Phone: +1 888 516-1232
E-mail: Info.Americas@openmind-tech.com
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Phone: +55 11 2424 8580
E-mail: Info.Brazil@openmind-tech.com
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E-mail: Info.Asia@openmind-tech.com
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No. 1088 South Pudong Road
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Phone: +86 21 588765-72
E-mail: Info.China@openmind-tech.com
India
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Bangalore 560 043 • Karnataka • India
Phone: +91 80 3232 4647
E-mail: Info.India@openmind-tech.com
Japan
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Phone: +81 422 23-5305
E-mail: info.jp@openmind-tech.co.jp
Taiwan
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Taiwan, R.O.C.
Phone: +886 3 46131-25
E-mail: Info.Taiwan@openmind-tech.com
OPEN MIND Technologies AG is represented
worldwide with own subsidiaries and through
competent partners and is a member of the
Mensch und Maschine technology group,
www.mum.de
www.openmind-tech.com
© All rights reserved, OPEN MIND Technologies AG, Wessling, Germany. Last updated July 2014. Subject to modifications. No reproduction allowed without the consent of the publisher.
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